FORM TC-20

PRACTICAL EXERCISE SHEET

PHIẾU BÀI TẬP THỰC HÀNH
Title Pipes and Hoses - Exercise 01 - Rev 00

Code AMB-M7.9-01 Applicable for: Cat A,B1,B1+B2

Compliance with Pipes and Hoses, code: AMB-M7.9

Description This exercise is designed for new technical engineer/technician in accordance

with the course curriculum “VAR Part 7 – Aircraft Maintenance Basic” at Module
7.

Duration  Training hours: 5 hours  Level: 1

Materials  Document handout: Aircraft Maintenance Basic Training Manual Module 7.

 Tool/equipment: I.A.W the following “1. JOB SET-UP INFORMATION”

Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

WARNING: PRESSURE TESTING IS NORMALLY THE RESPONSIBILITY OF SPECIALISTS. A
HOSE THAT BURSTS UNDER PRESSURE CAN CAUSE SERIOUS OR EVEN
FATAL INJURIES.
WARNING: WHEN INSTALLING A BONDED CLAMP, ENSURE ANY PAINT OR ANODIZING IS
REMOVED FROM THE LINE WHERE THE CLAMP IS FITTED FOR ELECTRICAL
CONTINUITY.
CAUTION:
TUBE LINE MUST NOT BE BENT BACK FOR CORRECTION!

CAUTION: A STRESS FREE INSTALLATION IS A MAIN FACTOR FOR A GOOD FUNCTION

AND LIFETIME OF TUBE LINES!

1. JOB SET-UP INFORMATION

A. Fixtures, Tools, Test and Support Equipment

REFERENCE QTY UNIT DESIGNATION

As required 1 EA The Pipe Cutter

As required 1 EA The tube bender

As required 1 EA The Flaring tool

B. Comsumable Material

REFERENCE QTY UNIT DESIGNATION

N/A 8 EA Fabric Gloves

N/A 8 EA Face Mask

N/A 8 EA Industrial glasses

N/A 0.5 KG Industrial rags

C. Expendable Parts

REFERENCE QTY UNIT DESIGNATION

N/A N/A N/A N/A

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

D. Referenced Information

REFERENCE DESIGNATION

N/A N/A

2. JOB SET-UP
A.The Pipe Cutter
The pipe cutter normally has to guiding pulleys and a cutting wheel. The cutting pressure can be
adjusted by a screw in the handle. The tube is cut with a constant and low cutting pressure in order to
prevent deformation of the tube end. After 2−3 revolutions the cutting pressure is adjusted. Periodical
lubrication of pulleys and cutting wheel are necessary to prevent early wear. Of course the tube ends
have to be burred after cutting.

Pipe Cutter

B.Tube Bender
The tube bender mainly consists out of the form wheel handle with form wheel, the swivel handle with a
guide and the tube clamp
The form wheel handle is formed in such a way that it can easily be put into a vice. There are markings
from 0° to 180° on the form wheel in order to achieve the desired angle exactly. The tube clamp can be
used for fixing the tube. A guide is installed at the swivel handle. On it the markings 0°, 45°, R (RIGHT)
und 90° (= LEFT) can be found. These markings are used for the correct orientation of the tube in the
tube bender and therefore have influence on the accuracy of the bending.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

Tube Bender
C.Flaring Tool
A Flaring tool mainly consists out of two parts, a clamping device for the tube and the actual flaring tool.
With the help of the clamping device tubes from 3/16“ to 5/8“ diameter can be clamped. The main
flaring tool consists out of a aluminium casted mounter which is clamped in a vice and holds a cone
with three tapered rolls for forming the flare. With the help of a pivoting calliper the tube can be adjusted
in its height in order to achieve the right flare diameter depending on the tube size.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

Flaring Tool
Flexible hoses
are used extensively on aircraft to connect stationary to moving parts and in areas of high vibration.
There are essentially three types of hose ratings:
_ Low pressure . . . . . . . . . . . . . . up to 600 pounds per square inch (psi)
_ Medium pressure . . . . . . . . . . . up to 3000 psi
_ high pressure . . . . . . . . . . . . . . 3000 psi +
Hoses are built up from layers.
_ The inner layer carries the fluid and therefore must be compatible (chemically) with the fluid
being transported and have the minimum amount of porosity.
The four main compounds used to construct inner liners are
− Neoprene (for petroleum-based fluids)
− Buna-N (better suited for petroleum-based fluids)
− Butyl (phosphate ester-base hydraulic fluid (Skydrol))
− Teflon (compatible with almost every fluid carried).
_ Reinforcement layers cover the inner liner and determine the hose’s strength.
Common materials used for reinforcement layers are
− cotton
− rayon
− polyester fabric
− carbon-steel wire
− stainless steel wire braid.
Diligent design of reinforcement layers can minimise the dimensional changes of hoses under pressure.
_ The protective outer cover is usually made of rubber-impregnated fabric or stainless steel
braid. It is put over the reinforcement to protect from physical damage or heat.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

3. PROCEDURE
A. Tube Cutting
In order to produce a tube with an accurate size the right cutting is very important. It is advisable to cut
the tube to the desired length after bending.
This means that the tube’s pre-cut is a little bit longer than the desired length.
Normally a pipe cutter is used for cutting tubes.
B. Tube Bending 90°
Alignment of the Tube
The first step to manufacture an accurate tube is to mark the distance between the both 90°
bends on the unfinished tube. The bending tool is firmly clamped in a vice and the form wheel and
guide is lightly greased. After that the tube is inserted. The tube clamp is fixed and the tube is
aligned in such a way that the marking on the tube is identical to the 90° marking on the guide.
During this it has also be controlled that the 0° marking on the guide and form wheel match.
Bending of the first 90° Bend
If the tube is aligned, the tube is pulled with a constant force by the swivel handle around the
form wheel until the 0° marking of the guide matches with the 90° marking of the form wheel.
Inspection/Correction
After removal of the tube and the inspection of the angle often another bending turn is needed
since the tube does spring back, which results in a larger angle.
Alignment/Bending the second 90° Bend
The tube is aligned in the bending tool in such a way that the second marking on the tube
matches the „R“ marking of the guide. Also here the two 0° markings of the guide and the form
wheel have to be aligned. After checking the horizontal angle, the tube can be pulled with the
swivel handle until reaching the 90° marking.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

C. Tube Flaring
Flare-type fittings (in aircraft production 37°) are often used in the engine area.
The main reason is the good vibration resistance of this fitting type. In a flare-type fitting the flared tube
is pressed against the fitting’s cone by tightening a union nut and the conical sleeve.
Single Flare
Single 37° flares are used for aluminium and steel tubes. They are manufacturered with the
help of a rolling tool. By rolling a constant deformation of the tube’s end without a heavy force can
be achieved. To fulfill the high quality standards, the sealing surface of the flare has to have a
surface quality of minimum 32 microinches and has to be free from scratches and dents
(BACD2046). During the flare’s manufacturing a decreasing of the wall thickness at the tube’s end
does occur. This must not exceed 15% of the tube’s wall thickness.

D.Installation of Tubes
A basic requirement for leak tightness and the lifetime of a hydraulic tube is a vibration-free
and stress-free installation. This is achieved by a periodical clamping of the line with the structure.
Tube lines are installed with a predetermined distance to each other to prevent contact
between the lines which could result in wear.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

Correct Tube Alignment

TUBE INSTALLATION

E. Installation of Hoses
There are a number of checks to carry out prior to installing a flexible hose.
Inspect the hose for:
_ applicability
_ length
_ cleanliness
_ damage.
Check the hose identification tag for:
_ part number
_ cure date (within limits)
_ manufacturing date (within limits)
It is possible to replace a short bend radius with an elbow fitting, but the largest possible bend
radius is still preferred.
The minimum permissible bend radius is determined by the operating pressure, the type of
hose and the nominal size. The bend radius required increases when the hose has to carry out
movements in the operating condition.
If they can move and become twisted, they are to be fixed with clamps to prevent this.
Clamps are also necessary where there is a danger to the hoses due to vibration, long lengths
or sharp edges.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

HOSE INSTALLATION

4. PRODUCTION REQUIREMENTS/ ASSESSMENT

A. Question: How to perform a tube-cutting practice ?(4pts)
Answer:
 Determine the desired length to be cuted. (1pts)
 Adjust the pipe-cutter to hold the tube by handle (1 pts)
 Perform the cutting practice with constant pressure (1 pts)
 Inspect and burr the tube-end (1 pts)
B. Question: How to install hydraulic tubes in position? (3 pts)
Answer:
 Check the tube is no damage, no sign of leak, no deformation (1 pts)
 Align/ position the tube-ends to the connection fittings with finger pressure and
assure the correct distance from other tubes, bulkhead, wall... (1 pts)
 Tighten the connection with required torque. In case of necessary use clamps to fix
the tubes. (1 pts)
C. Question: How to install flexible hoses in position? (3 pts)
Answer:
 Check the hose is no damage, no sign of leak, no deformation, no twisted (1 pts)
 Align/ position the hose-ends to the connection fittings with finger pressure and
assure the correct distance from other tubes, bulkhead, wall… Largest possible
bend radius is preferred. (1 pts)
 Tighten the connection with required torque. In case of necessary use clamps to fix
the hose. (1 pts)
5. CLOSE-UP
A. Make sure that the work area is clean and clear of tools and other items.

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Pipes and Hoses - Exercise 01 Code: AMB-M7.9-01

B. Clean Workshop
C. Put Workshop to Its usual condition

Prepared by: Nguyễn Minh Châu Date: 01/01/2022

Evaluated by: Nguyễn Thế Khôi Date: 01/01/2022

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