tube is small (under 1⁄4") and can be hand formed,

Dent Cable casual bends may be made to allow for this. It the
tube must be machine formed, definite bends must
be made to avoid a straight assembly. Start all bends
a reasonable distance from the fittings because the
Bullet
sleeves and nuts must be slipped back during the
Figure 9-13. Dent removal using a bullet. fabrication of flares and during inspections. In all
cases, the new tube assembly should be so formed
Aluminum 6061-T6, corrosion resistant steel prior to installation that it will not be necessary to
304-1/8h and Titanium 3AL-2.5V tubing can be pull or deflect the assembly into alignment by means
repaired by swaged fittings. If the damaged portion of the coupling nuts.
is short enough, omit the insert tube and repair
by using one repair union. (Figure 9-14) When FLEXIBLE HOSE
repairing a damaged line, be very careful to remove FLEXIBLE HOSE INSPECTION
all chips and burrs. Any open line that is to be left Check the flexible hose and hose assemblies for
unattended for some time should be sealed, using deterioration at each inspection period. Leakage,
metal, wood, rubber, or plastic plugs or caps. separation of the cover or braid from the inner tube,
cracks, hardening, lack of flexibility, or excessive
When repairing a low-pressure line using a flexible “cold flow” are apparent signs of deterioration
fluid connection assembly, position the hose clamps and reason for replacement. The term “cold flow”
carefully to prevent overhang of the clamp bands or describes the deep, permanent impressions in the
chafing of the tightening screws on adjacent parts. hose produced by the pressure of hose clamps or
If chafing can occur, the hose clamps should be supports.
repositioned on the hose. Figure 9-15 illustrates
the design of a flexible fluid connection assembly When failure occurs in a flexible hose equipped
and gives the maximum allowable angular and with swaged end fittings, the entire assembly must
dimensional offset. be replaced. Install a new hose of correct size and
length, complete with factory installed end fittings.
When replacing rigid tubing, ensure that the layout When failure occurs in hose equipped with reusable
of the new line is the same as that of the line being end fittings, a replacement line can be fabricated
replaced. Remove the damaged or worn assembly, with the use of such tooling as may be necessary
taking care not to further damage or distort it, and to comply with the assembly instructions of the
use it as a forming template for the new part. If the manufacturer.
old length of tubing cannot be used as a pattern,
make a wire template, bending the pattern by hand FABRICATION AND REPLACEMENT
as required for the new assembly. Then bend the OF FLEXIBLE HOSE
tubing to match the wire pattern. Never select a path To make a hose assembly, select the proper size hose
that does not require bends in the tubing. A tube and end fitting. MS-type end fittings for flexible
cannot be cut or flared accurately enough so that it hose are detachable and may be reused if determined
can be installed without bending and still be free to be serviceable. The inside diameter of the fitting
from mechanical strain. Bends are also necessary is the same as the inside diameter of the hose to
to permit the tubing to expand or contract under which it is attached. (Figure 9-16 and 9-17)
temperature changes and to absorb vibration. If the

9.10 Module 07 - Maintenance Practices

 Type of Failure Repair Method

1. Pin hole leak or circumferential crack in tubing.t 1. a. Make 1 or 2 cuts as necessary, to remove damaged
section. If 2 cuts are required, the distance between
them shall not exceed 0. 30". If distance is more than
0.30 inch, go to repair method 2.

b. Swage 1 tube-to-tube union in tube section

under repair.
Not to exceed 0.30 inch

2. Longitudinal crack in tubing (crack length in excess 2. a. Make 2 cuts to enable removal of damaged section.
of 0.30").
b. Remove damaged section and duplicate.

c. Swage replacement section into tubing under repair

New Section
using 2 tube-to-tube unions.

Original Tubing

3. Leaking tee or elbow (permanent tube connection type). 3. a. Cut out defective tee or elbow.

b. Duplicate tubing sections for each branch.

c. Swage splice sections to tee or elbow.

d. Connect each splice section to tubing under repair

using a tube to tube union.

4. Leaking flared, flareless, or lipseal end fittings. 4. a. Cut tubing to remove defective fitting.

b. Swage appropriate end fitting to tube end.

c. Connect new end fitting to mating connection,

torquing nut as required.

PIPES AND HOSES

Figure 9-14. Permaswage™ repair.

FLEXIBLE HOSE TESTING dry, oil-free air or nitrogen. When testing with a
All flexible hose must be proof-tested after assembly liquid, all trapped air is bled from the assembly prior
and applying pressure to the inside of the hose to tightening the cap or plug. Hose tests, using a
assembly. The proof-test medium may be a liquid gas, are conducted underwater. In all cases, follow
or gas. For example, hydraulic, fuel, and oil lines the hose manufacturer’s instructions for proof-test
are generally tested using hydraulic oil or water, pressure and fluid to be used when testing a specific
whereas air or instrument lines are tested with hose assembly. (Figure 9-18)

Module 07 - Maintenance Practices 9.11

 Clamps
¼" Min.

G. Ref
Lo
e
to wire braid
.

Tw
cover with
plier
s
Fitting Hose Tubing
1. Place hose in vise and cut 2. Locate length of hose to be
3° Max. angular deviation to desired length using cut off and slit cover with
fine tooth hacksaw or cut knife to wire braid. After
off wheel. slitting cover, twist off with
pair of pliers. (See note below)
1/16" Max. offset

Figure 9-15. Flexible fluid connection assembly.

3. Place hose in vise and 4. *Lubricate inside of hose

screw socket on hose and nipple threads liberally.
counterclockwise.

NOTE: Hose assemblies

fabricated per MIL-H-8790
must have the exposed wire
braid coated with a special
sealant.

NOTE: Step 2 applies to high

pressure hose only.

*CAUTION: Do not use any

petroleum product with hose
designed for synthetic fluids,
(SKYDROL and/or HYJET
5. Screw nipple into socket
product). For a lubricant
using wrench on hex of during assembly, use a
nipple and leave .005" to vegetable soap liquid.
.031" clearance between
nipple hex and socket. Disassemble in reverse order.

Figure 9-17. Assembly of MS fitting to flexible hose.

FLEXIBLE HOSE SIZE DESIGNATIONS

Hose is designated by a dash number, according to
Figure 9-16. Hose identification markings. its size. The dash number is stenciled on the side of
the hose and indicates the size tubing with which
When a flexible hose has been repaired or overhauled the hose is compatible. It does not denote inside
using existing hardware and new hose material, or outside diameter. When the dash number of
and before the hose is installed on the aircraft, it is the hose corresponds with the dash number of the
recommended that the hose be tested to at least 1.5 tubing, the proper size hose is being used. Dash
system pressure. A hydraulic hose burst test stand is numbers are shown in Figure 9-17.
used for testing flexible hose. (Figure 9-19) A new
hose can be operationally checked after it is installed
in the aircraft using system pressure.

9.12 Module 07 - Maintenance Practices