AMM20

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AIRCRAFT MAINTENANCE MANUAL

AIRFRAME STANDARD PRACTICES
LIST OF EFFECTIVE PAGES
Chapter Chapter
Section Section
Subject Config Page Date Subject Config Page Date
20 − Effective 1 * Aug 10/2007 206 Apr 20/2004
Pages 207 Apr 20/2004
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AIRFRAME STANDARD PRACTICES
TABLE OF CONTENTS
Chapter
Section
Subject Subject Page
AIRFRAME STANDARD PRACTICES 20−00−00

Description and Operation 1
Effectivity: ON A/C ALL
General
Description
Torquing Procedures
Fittings and Connections
Wire Cables
Bushings and Bearings
ELECTRICAL/ELECTRONIC EQUIPMENT 20−10−00

Maintenance Practices 201
General
Safety Procedures for Use of Heat Guns,
Soldering Guns and/or Soldering Irons
Connector Integrity After a Disconnect and Re− 204
connection
Removal/Installation 401
1. General
Removal of Electrostatic Discharge Sensitive
Components
Installation of Electrostatic Discharge Sensitive 406
Components
DEMAGNETIZATION 20−10−01
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Chapter
Section
General
Demagnetization of the Aircraft Components
and/or Structures
TORQUING 20−21−00
General
Torque Procedures for Threaded Fasteners
Torque Procedures for Plumbing Lines 212
Torque Procedures for Electrical Fittings 222
FITTINGS AND CONNECTIONS 20−22−00

General
Inspection Requirements for Damaged Tubing 202
Repairs of Hydraulic Tubing − Cryofit Couplings 208
and Compatible Fittings
Repairs of Hydraulic Tubing − Cryolive Flareless 229
Sleeve Assemblies and Compatible Fittings
Repairs of Hydraulic and Pneumatic Tubing − 242
Deutsch Permaswage Fittings
Repairs of Hydraulic and Pneumatic Tubing − 254
Harrison "H" Fittings
Repair of Plumbing Lines − Flareless Fittings (MS 266
21922 Sleeves and MS 21921 Nuts)
Repair of Plumbing Lines − Sierracin/Harrison 276
HMS Flareless Sleeves and Unions
Repair of Hydraulic Tubing − Rynglok Fittings 292
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Chapter
Section
PLUMBING LINES 20−22−01

General
Bend Radii, Clearances and Tolerances of
Plumbing Lines
Application of Thread Compounds and Tape to 210
Threaded Fittings on Plumbing Lines
Temporary Repairs to Hydraulic Tubing Using 213
Flexible Hoses
WIRE−ROPE CONTROL CABLES 20−23−00

Inspection/Check 601
General
Inspection of Wire−Rope Control Cables and
Related Components
SAFETYING DEVICES 20−24−00

General
Cotter Pins − Maintenance Practices
Lockwire − Maintenance Practices 204
Safety Cable − Maintenance Practices 211
Tab Lock Washers − Maintenance Practices 218
Turnbuckle Safety Devices − Maintenance 220
Practices
Rod−End Assembly Safety Devices − 224
Maintenance Practices
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Chapter
Section
BUSHINGS AND BEARINGS 20−26−00

General
Bushed Joint Assemblies − Assembly Data
Removal of Interference Fit Bushings 205
Thermal Installation of Interference Fit Bushings 208
Mechanical Installation of Interference Fit 219
Bushings
Removal of Staked Bearings 221
Installation of Staked Bearings 224
Removal of Swaged Bearings 227
Installation of Swaged Bearings 229
Removal of Swaged Aileron Bearings 238
Installation of Press−Swaged or Roller−Swaged 242
Aileron Bearings
Removal of Swaged Bearings in the Inboard and 250
Outboard Flap Hinge Arm Assemblies
Installation of Swaged Bearings in the Inboard and 254
Outboard Flap Hinge Arm Assemblies
V−BAND COUPLINGS 20−30−00

General
V−Band Couplings − Maintenance Practices
Wiggins Couplings − Maintenance Practices 205
PLUG−IN RELAY − REMOVAL/INSTALLATION 20−42−00

Removal/Installation 401
General
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Chapter
Section
Replacement of the Plug−in Relay

Replacement of the Relay Module 404
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**ON A/C ALL
AIRFRAME STANDARD PRACTICES − DESCRIPTION AND OPERATION
1. General
A. This chapter contains information and instructions for the standard practices that are
applicable to the airframe. The standard practices are the usual maintenance tasks that
are specified regularly in the different maintenance procedures in the manual. To keep
space to a minimum, standard practices tasks are not written every time they are part of
a maintenance procedure. When a standard practice is part of a maintenance procedure,
a reference is made to the applicable task in this chapter.
B. The airframe standard practices include the sections that follow:
– Torquing procedures (20−21−00)
– Fittings and connections (20−22−00)
– Wire cables (20−23−00)
– Bushings and bearings (20−26−00).
2. Description
A. Torquing Procedures
(1) This section includes the torquing procedures and the torque values necessary to
tighten the threaded fasteners and the plumbing lines that are installed in the
aircraft.
B. Fittings and Connections
(1) This section includes information and procedures to examine and repair the tubing,
and to install and remove the pipe fittings, unions, clamps, and couplings that are
installed in the aircraft.
C. Wire Cables
(1) This section includes information and procedures to examine, replace and clean the
wire−rope control cables used in the aircraft.
D. Bushings and Bearings
(1) This section includes information and procedures to find and install the bushings
and the bearings used in the different mechanical components on the aircraft.
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See Effective TR

**ON A/C ALL
ELECTRICAL/ELECTRONIC EQUIPMENT − MAINTENANCE PRACTICES
1. General
A. The maintenance procedures that follow give the minimum recommended safety
procedures to operate heat guns, soldering guns/irons on aircraft. The maintenance
procedures also give the information to prevent injuries to persons or damage to the
equipment. Follow the regulations and the procedures made by local agencies and
airlines, if they are more applicable.
B. The maintenance procedure that follows, gives the recommended procedure to test the
electrical system(s). Do an operational test of the system(s), if there is any doubt as to
the integrity of the connection after a connector has been re−connected.
TASK 20−10−00−910−801
Safety Procedures for Use of Heat Guns, Soldering Guns and/or Soldering Irons
1. Job Set−Up Information

Subtask 20−10−00−910−002
A. Tools and Equipment
REFERENCE DESIGNATION
None specified Heat Gun, Blower Type − Thermogun 500A (or
equivalent)
None specified Soldering Gun or Soldering Iron
None specified Mine Safety Appliances − Model 2A (or equivalent)
None specified Mine Safety Appliances − Davis, Model D−16 (or
equivalent)
Subtask 20−10−00−910−003
B. Reference Information
AMM24−00−00−910−801 Electrical/Electronic Safety Precautions
2. Procedure
Subtask 20−10−00−910−001
A. General
WARNING: OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO
MAINTENANCE ON OR NEAR ELECTRICAL/ELECTRONIC
EQUIPMENT. IF YOU DO NOT DO THIS, YOU CAN CAUSE INJURIES
TO PERSONS AND/OR DAMAGE TO THE EQUIPMENT.
(1) Obey all electrical/electronic safety precautions (Ref. TASK 24−00−00−910−801).
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WARNING: DO NOT TOUCH THE HEAT GUN REFLECTOR OR THE SOLDERING
GUN TIP. THE REFLECTOR OR THE TIP OF THE DEVICE WILL BE
HOT WHEN THE DEVICE IS OPERATED. IF YOU TOUCH THE
REFLECTOR OR TIP OF THE DEVICE YOU CAN GET BURNED.
(2) Carefully follow the operating manuals provided by the vendor of the heat gun,
soldering gun/iron. These manuals properly describe the safety conditions and
precautions related to the specific heat device.
(3) You must examine the conditions of operation and be careful when you use heat
guns, soldering guns/irons. It is the responsibility of the aircraft technician to know
where heat guns, soldering guns/irons are to be used.
WARNING: USE A THERMOGUN THAT IS RESISTANT TO EXPLOSION WHEN
YOU HEATSHRINK MATERIAL NEAR AN AIRCRAFT THAT IS FILLED
WITH FUEL. THE HEAT FROM OTHER DEVICES CAN IGNITE FUEL.
IF YOU DO NOT USE A DEVICE THAT IS RESISTANT TO EXPLOSION
YOU CAN CAUSE AN EXPLOSION AND FIRE.
(4) It is not recommended that you use devices that supply heat when you do repairs to
any wiring harness on or around the fuel tanks. If you do use such a device, use a
thermogun or similar device that will not cause an explosion.
WARNING: DO NOT OPERATE HEAT GUNS, SOLDERING GUNS AND/OR
SOLDERING IRONS ON OR AROUND AIRCRAFT WHERE THE FUEL
FUME LEVEL IS NOT ZERO. THESE DEVICES CAN OPERATE AT
TEMPERATURES HIGHER THAN THE IGNITION TEMPERATURE OF
FUEL (450° F (232° C)). THESE DEVICES CAN ALSO CONTAIN
ELECTRICAL SWITCHES WHICH CAN CAUSE SPARKS AND THE
IGNITION OF FUEL. IF YOU OPERATE THESE DEVICES WHERE
FUEL FUME LEVEL IS NOT ZERO, YOU CAN CAUSE AN EXPLOSION
AND FIRE.
(5) Do not use heat guns or soldering guns/irons within a radius of 100 feet (30.5 m)
from an aircraft during the following operations.
– When you fuel
– When you defuel
– When the fuel tanks are open
– When a fuel fume level condition is greater than zero.
(6) To make sure that the fuel fume level is safe, measure the fuel fume level with a
combustible gas indicator that reads in "Percent Lower Explosive Limit" or "Percent
Explosive". For example , you can use Mine Safety Appliances, Model 2A or Davis,
Model D−16. If you can read a fuel fume level with this equipment, then a liquid fuel
or fume source is near, or the area is not properly ventilated.
(7) Make sure that the correct amount of emergency/fire fighting equipment is at the
repair area. Make sure that persons authorized to use the emergency/fire fighting
equipment are at the repair area.
(8) You must make maintenance and safety persons aware that you will be operating a
device that can cause ignition of fuel fumes when operating.
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CAUTION: DO NOT OPERATE HEAT GUNS NEAR HEAT SENSITIVE MATERIALS
FOR LONG PERIODS OF TIME. THIS COULD CAUSE CHANGES IN
THE PROPERTIES OF THESE MATERIALS. DAMAGE TO THESE
MATERIALS COULD OCCUR IF THEIR PROPERTIES ARE CHANGED.
(9) You must take special precautions when working around heat sensitive materials,
these materials will not resume their normal state after being damaged.
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TASK 20−10−00−910−803
Connector Integrity After a Disconnect and Re−connection
1. General
A. The maintenance procedures that follow provide retest procedures to allow an aircraft to
be returned to service following disconnection of electrical connectors, after rework
and/or repair requirement.
NOTE: It is the operator’s discretion to apply the method to be used for the test
requirements and procedures based on the work performed on the aircraft to
implement the rework or repair.
NOTE: These procedures do not alter the requirements to perform the regular AMM
tasks for any equipment (other than connectors) removed, reworked or
repaired.
NOTE: These procedures are not applicable to aircraft system that have been
installed through a Supplementary Type Certificate (STC) or other method not
supported by AMM tasks and/or Service Bulletin activities.
NOTE: When a Service Bulletin was used to modify the aircraft, the retest
requirements of the SB shall also be performed.
NOTE: Normal procedures for continuity and/or insulation testing shall be performed
when wires are replaced or repaired, before doing the AMM tasks.
NOTE: It is not necessary to perform any testing where a connector has been
disconnected only for access to a work area. The operator may perform retest
requirements based on Method one (1) or two (2).
NOTE: Make sure that there is no abnormal, miscompare, or failure indications
displayed in the cockpit.
NOTE: Throughout the testing, monitor for abnormal indication and/or messages on
the Engine Indication Crew Alert System (EICAS) displays.

Subtask 20−10−00−910−017
A. Reference Information
AMM24−00−00−910−801 Electrical/Electronic Safety Precautions
3. Job Set−Up
Subtask 20−10−00−910−018
WARNING: OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO MAINTENANCE
ON OR NEAR ELECTRICAL/ELECTRONIC EQUIPMENT. IF YOU DO NOT
DO THIS, YOU CAN CAUSE INJURIES TO PERSONS AND/OR DAMAGE
TO THE EQUIPMENT.
A. Obey all electrical/electronic safety precautions (Ref. TASK 24−00−00−910−801).
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4. Test Procedure
Subtask 20−10−00−700−001
A. Testing Methods.
NOTE: Three (3) methods may be used to retest aircraft electrical connectors
following rework or repair activities.
1. Method 1, is applicable for activities that affect a single connector directly related
to one system only.
2. Method 2, is applicable for activities to one or a few connectors related to multiple
aircraft systems.
3. Method 3, is applicable for activities affecting connectors related to multiple aircraft
system(s)
(1) Method 1, is applicable for activities that affect a single connector directly related to
one system only.
(a) You have to determine the system applicable to the connector.
(b) Locate the main unit applicable to the connector/system.
(c) Perform the Operational Test of the unit.
(2) Method 2, is applicable for activities to one or a few connectors related to multiple
aircraft systems.
(a) You have to determine the systems affected applicable to the connector(s)
(b) Locate the main unit(s) applicable to the connector(s) system(s).
(c) Perform the Operational Test of the unit(s).
NOTE: If there is no Operational Test, perform the Functional Test as
applicable.
(3) Method 3, is applicable for activities affecting connectors related to multiple aircraft
systems
NOTE: An operator may elect not to do some of the AMM tasks, if it is
determined that the referred AMM tasks have no relation with the affected
connector(s).
NOTE: The order of testing is not specified in the table. The operator needs to
define the order of testing based on the connector(s) rework or repair
requirement.
(a) Do the method 3 test procedure using the following tables;
TABLE 201
Power Checks
AMM task reference Task Title
AMM24−00−00−861−801 Connect Electrical Power to the Aircraft
AMM24−00−00−910−801 Electrical / Electronic Safety Precautions
AMM24−11−01−710−801 Operational Test of the Left IDG
AMM24−11−01−710−802 Operational Test of the Right IDG
AMM24−22−01−710−801 Operational Test of the APU Generator System
AMM24−23−15−710−801 Operational Test of the ADG Auto Deploy Control Unit
AMM24−31−01−710−801 Operational Test of the TRU
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TABLE 201
Power Checks
AMM24−31−01−710−804 Operational Test of the Essential TRU’s and the Power
Transfer Circuits
AMM24−32−01−710−801 Operational Test of the Main Battery
AMM24−32−02−710−801 Operational Test of the APU Battery
TABLE 202
Environmental Control System
AMM21−24−10−710−801 Operational Test of the Avionics Cooling Panel
AMM21−24−19−710−801 Operational Test of the Display Supply Fans and the Standby
Supply Fan
AMM21−24−28−710−801 Operational Test of the Avionics Exhaust Fan
AMM21−24−31−710−801 Operational Test of the Inboard Exhaust Valve
AMM21−24−34−710−801 Operational Test of the Overboard Exhaust Valve
AMM21−31−00−710−801 Operational Test of the Pressurization Control
AMM21−60−00−710−801 Operational Test of the Temperature Control System
TABLE 203
Autoflight
AMM22−11−00−710−801 Operational Test of the Go−Around Mode
AMM22−11−00−710−802 Operational Test of the Flight Control Computer
TABLE 204
Communication
AMM23−11−00−710−801 Operational Test of the VHF System
AMM23−12−00−710−801 Operational Test of the HF System
AMM23−31−01−710−801 Operational Test of the Passenger Address Amplifier
AMM23−51−00−710−802 Operational Test of the Audio Integrating System
AMM23−71−00−710−801 Operational Test of the Voice Recording System
AMM23−81−00−710−801 Operational Test of the Radio Tuning System
AMM23−82−00−710−801 Operational Test of the Standby Tuning System
NOTE: A: Installation option − select test per aircraft configuration.

NOTE: B: As per aircraft effectivity.
TABLE 205
Fire Protection
AMM26−11−00−710−802 Operational Test of the Engine Fire / Overheat−Detection
System
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TABLE 205
Fire Protection
AMM26−12−00−710−802 Operational Test of the APU Fire Detection System
AMM26−14−00−710−801 Operational Test of the MLG Fire Overheat Detection and
Warning System
AMM26−15−00−710−801 Operational Test of the Cargo Smoke−Detection System
AMM26−16−00−710−803 Operational Test of the Lavatory Smoke−Detection System
TABLE 206
Flight Control
AMM27−11−00−710−803 Operational Test of the Aileron Control System
AMM27−11−00−710−804 Operational Test of the Aileron Trim System
AMM27−13−00−710−802 Operational Test of the Aileron Disconnect System
AMM27−21−00−710−804 Operational Test of the Rudder Trim System
AMM27−32−00−710−802 Operational Test of the Elevator Disconnect System
AMM27−35−01−710−801 Operational Test of the Stall Protection System (Pre−Flight
Test)
AMM27−35−01−750−806 Operational Test of the Stall Protection System (Autopilot
interface)
AMM27−40−00−710−802 Operational Test of the Horizontal Stabilizer Trim System
AMM27−41−15−710−801 Operational Test of the Stab Trim Channel Engage Switch
AMM27−51−15−710−803 Operational Test of the Skew Detection System (IBIT)
AMM27−54−00−710−801 Operational Test of the Flaps
AMM27−63−01−710−802 Operational Test of the Ground Spoiler Actuator
AMM27−64−00−710−801 Operational Test of the Flight Spoilers / Spoileron
TABLE 207
Fuel System
AMM28−00−00−710−801 Operational Test of the Fuel System
AMM28−25−00−710−801 Operational Test of the Pressure Refuel/Defuel System
TABLE 208
Hydraulic Power
AMM task reference AMM task reference
AMM29−10−00−720−801 Operational Test of the Systems No. 1 and No. 2
AMM29−10−00−720−802 Operational Test of the Systems No. 3
TABLE 209
Anti−Ice Protection
AMM30−12−00−710−803 Functional Test of the Wing Anti−Ice Control and Indicating
System
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TABLE 209
Anti−Ice Protection
AMM30−41−01−710−801 Functional Test of the Windshield Temperature Controllers
AMM30−81−01−710−801 Operational Test of the Ice Detectors
TABLE 210
Indicating and Recording
AMM31−21−01−710−801 Operational Test of the Digital Clock
AMM31−31−01−710−801 Operational Test of the Digital Flight Data Recorder (FDR)
See: NOTE A
AMM31−31−01−710−802 Operational Test of the Expanded Digital Flight Data Recorder
(EFDR)
See: NOTE A
AMM31−32−00−710−801 Operational Test of the QAR
See: NOTE A
AMM31−41−01−710−801 Operational Test of the EICAS Control Panel

TABLE 211
Landing Gear
AMM32−43−00−710−801 Operational Test of the Brake System
AMM32−44−00−710−801 Operational Test of the Anti−Skid System
AMM32−46−00−710−801 Operational Test of the Brake Temperature Monitoring System
AMM32−51−00−710−801 Operational Test of the Nosewheel Steering
TABLE 212
Lighting
AMM33−11−00−710−801 Operational Test of the Panel Floodlight System
AMM33−12−00−710−801 Operational Test of the Panel Integral Lighting
AMM33−12−19−710−801 Operational Test of the Center−Pedestal Lighting Panel
AMM33−13−00−710−801 Operational Test of the Miscellaneous Lighting System
AMM33−13−16−710−801 Operational Test of the Miscellaneous Lights Panel
AMM33−21−00−710−801 Operational Test of the Passenger Compartment Lights
AMM33−22−00−710−801 Operational Test of the Reading Lights
AMM33−41−00−710−801 Operational Test of the Landing and Taxi/Recognition Lights
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TABLE 212
Lighting
AMM33−51−00−710−801 Operational Test of the Emergency Lights
See − NOTE: B.

TABLE 213
Navigation
AMM34−21−00−720−801 Functional Test of the Attitude and Heading Reference System
See − NOTE: A.
AMM34−21−01−710−801 Operational Test of the Attitude Heading Computer
AMM34−23−01−710−801 Operational Test of the Standby Attitude Indicator
See − NOTE: B.
AMM34−41−00−730−801 System Test of the Weather Radar System
AMM34−42−01−710−801 Operational Test of the Enhanced Ground Proximity Warning
Computer (P/N # 965−0976−003−210−210)
AMM34−42−01−710−806 Operational Test of the Enhanced Ground Proximity Warning
Computer (P/N # 965−0976−003−212−212)
AMM34−42−01−740−801 Built−in Test of the Ground Proximity Warning Computer
AMM34−43−00−710−801 Operational Test of the TCAS
AMM34−44−01−740−801 Built−in Test of the Radio Altimeter
AMM34−45−00−710−801 Operational Test of the IRS
See − NOTE: A.
AMM34−51−00−710−801 Operational Test of the VHF Navigation Receiver
AMM34−58−00−710−801 Operational Test of the Global Positioning System
(Single GPS, Single FMS)
(Single GPS, Dual FMS)
(Dual GPS, Dual FMS)
(Dual GPS, Single FMS)

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TABLE 214
Oxygen System
AMM35−10−00−710−802 Operational Test of the Crew Oxygen System
AMM35−20−00−710−801 Operational Test of the Passenger Oxygen System
See − NOTE: B.
AMM35−20−00−710−803 Operational Test of the Passenger Oxygen System
See − NOTE: B.

TABLE 215
Bleed System
AMM36−21−00−710−802 Operational Test of the Bleed−Air Leak−Detection and Warning
System
TABLE 216
Auxiliary Power
AMM49−10−00−710−801 Operational Test of the APU
TABLE 217
Powerplant
Powerplant Ground Run Manual Do an engine run with both engines
(PPGRM)
AMM71−00−00−710−801 Power On Built−In Test
AMM71−00−00−710−806 Thrust Reverser Operational Check
AMM77−30−00−710−801 Operational Test of the Engine Vibration−Monitoring System
5. Close Out
Subtask 20−10−00−941−004
A. Remove all tools, equipment, and unwanted materials from the work area.
Subtask 20−10−00−861−002
B. Remove the external AC power (Ref. TASK 12−00−07−861−802).
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**ON A/C ALL
ELECTROSTATIC DISCHARGE SENSITIVE COMPONENTS − REMOVAL/INSTALLATION
1. 1. General
A. The maintenance procedures that follow are for the removal and installation of
Electrostatic Discharge Sensitive (ESDS) components. These components have a
typical ESDS label (refer to (refer to Figure 401). If the ESDS component is a printed
circuit board it will have a STATIC SENSITIVE label.
TASK 20−10−00−000−802
Removal of Electrostatic Discharge Sensitive Components

Subtask 20−10−00−943−004
None specified Conductive work surface
None specified Static wrist strap with ground cord − 470 ohm
series resistor
None specified Static ground cord with clip
Subtask 20−10−00−944−003
B. Consumable Materials
None specified Cotton cord
None specified Conductive bags
None specified Conductive dust caps
Subtask 20−10−00−946−002
C. Reference Information
TASK 24−00−00−910−802 Electrostatic Discharge Safety Precautions
2. Job Set−Up
Subtask 20−10−00−910−011
A. Obey the electrostatic discharge safety precautions (Ref. TASK 24−00−00−910−802).
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Subtask 20−10−00−861−001
B. Remove the electrical system power from the component.
Subtask 20−10−00−010−002
C. Remove the necessary panels to get access to the component.
3. Procedure
Subtask 20−10−00−910−012
Refer to Figure 201 and Figure 202.
A. If the ESDS component has a metal case, do the steps that follow:
(1) If applicable, disconnect the electrical wire connectors on the front face of the
ESDS component.
NOTE: Make sure that you correctly identify the connectors for the installation
procedure.
(2) Loosen the clamps that attach the ESDS component to the mounting tray.
(3) Remove the ESDS component from the mounting tray.
(4) If applicable, disconnect the electrical wire connectors on the rear face of the ESDS
component.
NOTE: Make sure that you correctly identify the connectors for the installation
procedure.
(5) Make sure that you do not touch the pins in the electrical connectors on the ESDS
component.
(6) Install the conductive dust caps on the electrical connectors.
NOTE: Conductive dust caps are the color black or gray.
B. If the ESDS component is a printed circuit board, do the steps that follow:
(1) Put the conductive work surface adjacent to the area where you will remove the
printed−circuit board.
(2) Attach the grounding cord to the conductive work surface and a good grounding
point on the aircraft structure.
(3) Attach the wrist strap to your wrist. Attach the grounding cord of the wrist strap to a
good grounding point on the aircraft structure.
(4) Find the location of the printed−circuit board that you will remove.
(5) Use extractors at the edges of the printed−circuit board to remove the
(6) Immediately put the printed−circuit board in the conductive bag.
(7) Seal the conductive bag with a cotton cord or an ESDS label.
(8) Make sure there is an ESDS label on the bag.
(9) Put the printed−circuit board and the bag in a rigid container before you send it to
the shop. The rigid container will prevent damage to the conductive bag.
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(10) Disconnect the wrist strap and conductive work surface from the grounding points.
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ATTENTION
Static Sensitive
Devices
Handle Only at
Static Safe Work
Stations
Reusable Container
Do not Destroy
ram2010002_001.dg, om, 22/09/03
Typical ESDS Component Symbols and Label

Figure 401
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CONNECT THE GROUND CORD

TO THE WORK SURFACE AND
THE ALLIGATOR CLIP TO A GOOD
WRIST STRAP − CONNECT
GROUND.
THE ALLIGATOR CLIP TO
ANY GOOD GROUND
CONDUCTIVE
WORK SURFACE ram2010002_002.dg, yf, 24/09/03
Typical Static−Safe Work Area

Figure 402
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TASK 20−10−00−400−802
Installation of Electrostatic Discharge Sensitive Components

Subtask 20−10−00−943−006
None specified Conductive work surface
None specified Static wrist strap with ground cord − 470 ohm
series resistor
None specified Static ground cord with clip
TASK 24−00−00−910−802 Electrostatic Discharge Safety Precautions
2. Job Set−Up
Subtask 20−10−00−910−015
A. Make sure that the aircraft is in the same configuration as in the removal task.
B. Make sure that the electrical power to the ESDS component is removed.
C. Obey the electrostatic discharge safety precautions (Ref. TASK 24−00−00−910−802).
3. Procedure
Subtask 20−10−00−420−002
A. If the ESDS component has a metal case, do the steps that follow:
(1) Remove the conductive dust caps from the electrical connectors.
(2) Make sure that you do not touch the pins in the electrical connectors on the ESDS
component.
(3) If applicable, connect the electrical wire connectors to the electrical connectors on
the rear face of the ESDS component.
(4) Put the ESDS component on the mounting tray.
(5) Tighten the clamps that attach the ESDS component to the mounting tray.
(6) If applicable, connect the electrical wire connectors to the electrical connectors on
the front face of the ESDS component.
B. If the ESDS component is a printed−circuit board, do the steps that follow:
(1) Put the conductive work surface adjacent to the area where you will install the
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(2) Attach the grounding cord to the conductive work surface and a good grounding
point on the aircraft structure.
(3) Attach the wrist strap to your wrist. Attach the grounding cord of the wrist strap to a
good grounding point on the aircraft structure.
(4) Remove the printed−circuit board from the conductive bag.
(5) Use the extractors to hold the printed−circuit board at the edges. Install the
printed−circuit board into the correct slot.
(6) Use the extractors to lock the printed−circuit board in position.
(7) Disconnect the wrist strap and the conductive work surface from the grounding
points.
4. Close Out
Subtask 20−10−00−410−003
A. Install the panels that you removed to get access to the equipment.
Subtask 20−10−00−710−002
B. Do an operational test of the related system.
Subtask 20−10−00−941−003
C. Remove all tools, equipment, and unwanted materials from the work area.
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**ON A/C ALL
DEMAGNETIZATION − MAINTENANCE PRACTICES
1. General
A. The maintenance practices that follow supply the standard procedure for the
demagnetization (also known as degaussing) procedure of the aircraft’s components
and/or structures.
TASK 20−10−01−910−801
Demagnetization of the Aircraft Components and/or Structures

Subtask 20−10−01−943−001
None specified R.B. Annis Company, Industrial Probe
Demagnetizer, Model B
None specified Magnaflux Unit, Y−6 or Y−7 Yoke (Magnetic
Particle Inspection Yoke)
None specified R.B. Annis Company, Pocket Magnetometer
Model 25 (10 Gauss range)
NOTE: The above tools or their equivalent can be otained locally. The recommended
specifications for the demagnetization tool shown in the table above, are as
follows:
– Normal Operating Voltage − 120V/220V, 50–60 Hz
– Operating Current − 22 Amperes
– Probe Field Strength − 1100 Oersteds
– Flush Pole Field − 1700 Oersteds.
NOTE: If a dedicated de−magnetizer is not available, use of the Magnetic Particle
Inspection Yoke is permitted.
2. Job Set−Up
Subtask 20−10−01−910−002
A. Verify the level of residual magnetism as follows:
(1) Approach the area to be tested with a degauss meter (pocket magnetometer)
preferably with a 10 Gauss range, and determine the level of residual magnetism.
NOTE: Record this level for comparison later.
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Subtask 20−10−01−010−001
B. Remove all the components that can be damaged by the demagnetization procedure.
3. Procedure
Subtask 20−10−01−910−001
CAUTION: THE MAGNETIC PULL CAUSED BY THE DEMAGNETIZATION OF THE
COMPONENT AND/OR STRUCTURE CAN CAUSE THE DEMAGNETIZER TOOL
TO HIT THE COMPONENT AND /OR STRUCTURE. HOLD THE DEMAGNETIZER
TOOL TIGHTLY AGAINST THE MAGNETIC PULL.
CAUTION: THE DEMAGNETIZER TOOL MUST STAY IN AN ENERGIZED CONDITION
WHEN IT IS CLOSE TO OR IN TOUCH WITH THE COMPONENT AND/OR
STRUCTURE. THIS WILL PREVENT UNWANTED MAGNETIZATION OF THE
COMPONENT OR STRUCTURE BY THE LAST HALF CYCLE OF POWER.
A. Demagnetize the components and/or structures as follows:
(1) Energize the demagnetizer before you put it closer than 12 inches (305 mm) to the
component/structure.
NOTE: There will be a strong attraction between the demagnetizer and the
component/structure. Hold the demagnetizer tool firmly with two hands
(2) Slowly apply the demagnetizer to the component and/or structure.
(3) Touch the work surface then proceed to move or scan the whole area to be
demagnetized, move slowly 3 inches (76 mm) to 4 inches (102 mm) per second in a
track pattern, slightly overlap the tracks.
(4) After the scan is complete, carefully and slowly break contact with the work surface
and move the demagnetizer, while still energized, to a minimum distance of 12
inches (305 mm).
NOTE: The quality of the final demagnetization is good if the demagnetizer’s
release and withdrawal is slow. The demagnetizer tool must stay in an
energized condition during this procedure.
4. Close Out
Subtask 20−10−01−910−003
A. Verify that there is a reduction in magnetic residual as follows:
(1) Approach the area to be tested with a degauss meter (pocket magnetometer)
preferably with a 10 Gauss range, and record the level of residual magnetism.
NOTE: Compare the measurement to the initial one, a drop in residual
magnetism should be noted. If necessary, repeat the procedure.
Subtask 20−10−01−410−001
B. Install all the removed components.
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Subtask 20−10−01−941−001
C. Remove all the tools, equipment, and unwanted material from the work area.
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**ON A/C ALL
TORQUING − MAINTENANCE PRACTICES
1. General
A. The maintenance practices that follow supply the standard and specified torque
procedures for all threaded fasteners and plumbing line fittings. Standard torque values
are given in these procedures.
B. The torque values in the maintenance practices that follow are given in pound−inches.
NOTE: If it is necessary to use a torque wrench calibrated in pound−feet, use the
specified torque value (in this maintenance practice) given in pound−inches
and divide by 12.
TASK 20−21−00−910−801
Torque Procedures for Threaded Fasteners

Subtask 20−21−00−944−001
A. Consumable Materials
16−002 Lacquer, cellulose nitrate, gloss for aircraft, white
2. Job Set−Up
Subtask 20−21−00−910−001
A. Definition of Torque Terms
(1) Standard Torque
(a) Standard torques are applicable for standard threaded fasteners. Use the
standard torque procedures when the torque is not specified by the applicable
maintenance procedure.
(2) Specified Torque
(a) Specified torque values are used for special design functions. If the applicable
maintenance procedure shows a specified torque, use that value, not the
standard value.
Subtask 20−21−00−910−002
B. Torque Wrenches
(1) For specified torques, use hand−operated torque wrenches (dial or clip type),
torque screwdrivers, or power−operated torque tools.
(2) If it is necessary to use a torque wrench adapter, calculate the correct dial
indication. Use the instructions shown in Figure 201.
(3) Hand−operated torque wrenches are generally less accurate in the lower 20% of
their torque range. Whenever possible choose a hand−operated torque wrench to
match the specified torque value. The torque value should lie within 20% to 100%
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of the torque wrench capacity.
NOTE: For example, if the specified torque value for a fastener is 20
Pound−inches, choose a hand−operated torque wrench with a range of 0
to 50 Pound−inches.
(4) The set value for non indicating power torque tools shall be +10% above the lower
specification limit to −10% below the upper specification limit. Use the mid range
value for cases where these values overlap.
NOTE: For example, if the specified torque for a fastener is 60−80 Pound−inches
the set value shall be 66−72 Pound−inches.
(5) Do not use a torque wrench if the calibration date is expired.
3. Procedure
Subtask 20−21−00−910−003
A. General
(1) Do not put lubricating or antiseize compounds on the threaded fasteners unless
specified.
(2) Do not remove lubricant or corrosion−preventive compound that is applied by the
manufacturer.
(3) Remove unwanted materials such as paint or corrosion from the threads before you
tighten the fastener.
(4) Turn the torque wrench with a slow and stable movement when you torque.
(5) When it is possible, turn the nut when you tighten the fastener assemblies.
CAUTION: DO NOT TIGHTEN THE BOLT OR SCREW TO 10 PERCENT MORE
THAN THE MAXIMUM RANGE FOR THE TORQUE. TOO MUCH
TORQUE CAN CAUSE DAMAGE TO THE FASTENER.
(6) When it is not possible to turn the nut, turn the bolt or screw to tighten the fastener
assembly. Torque the bolt or screw to the maximum specified torque.
(7) When nuts are safetied to bolts, screws, or studs with cotter pins or lockwire:
(a) Tighten the nut to the minimum specified torque range.
(b) If necessary, continue to tighten the nut until the slot (in the nut) aligns with the
hole (in the bolt). Do not loosen the nut to align the slot with the hole.
Subtask 20−21−00−910−004
B. Standard Torque
CAUTION: DO NOT USE STANDARD TORQUE VALUES WHEN THE
APPLICABLE MAINTENANCE PROCEDURE SHOWS SPECIFIED
TORQUE VALUES. IF YOU DO THIS, YOU CAN CAUSE DAMAGE TO
THE FASTENER.
(1) When the maintenance procedure does not show a specified torque, use the
standard torque values in Table 201 and Table 202.
(2) Standard torque values for tension−type nuts and inserts on high−strength bolts,
screws, and studs are shown in Table 201.
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(3) Standard torque values for shear−type nuts and inserts on standard−strength bolts,
screws, and studs are shown in Table 202.
BOLTS, SCREWS, AND STUDS − 160 ksi (1103 MPa) UTS AND MORE * ** ***
Tension−Type Nuts and Inserts
Thread Dimension 200−220 ksi (1379−1517 MPa) UTS and 180−200 ksi (1103−1379 MPa) UTS
more † and more ††
Coarse Fine Pound−inches Newton meters Pound−inches Newton meters
8 − 32 — — — 15 − 18 1.7 − 2.0
— 8 − 36 — — 15 − 18 1.7 − 2.0
10 − 24 — — — 25 − 35 2.8 − 4.0
— 10 − 32 — — 25 − 35 2.8 − 4.0
1/4 − 20 — — — 50 − 70 5.7 − 7.9
— 1/4 − 28 90 − 125 10.2 − 14.1 70 − 90 7.9 − 10.2
5/16 − 18 — 135 − 185 15.3 − 20.9 90 − 145 10.2 − 16.4
— 5/16 − 24 180 − 250 20.3 − 28.2 140 − 205 15.8 − 23.2
3/8 − 16 — 240 − 375 27.1 − 42.4 185 − 250 20.9 − 28.2
— 3/8 − 24 300 − 500 33.9 − 56.5 190 − 350 21.5 − 39.5
7/16 − 14 — 405 − 670 45.8 − 75.7 255 − 430 28..8 − 48.6
— 7/16 − 20 510 − 840 57.6 − 94.9 500 − 755 56.5 − 85.3
1/2 − 13 — 690 − 1070 78.0 − 120.9 480 − 790 54.2 − 89.3
— 1/2 − 20 870 − 1300 98.3 − 146.9 690 − 990 78.0 − 111.9
9/16 − 12 — 1085 − 1550 122.6 − 175.1 700 − 990 79.1 − 111.9
— 9/16 − 18 1300 − 1800 146.9 − 203.4 1000 − 1400 113.0 − 158.2
5/8 − 11 — 1600 − 2050 180.8 − 231.6 900 − 1350 101.7 − 152.5
— 5/8 − 18 1900 − 2300 214.7 − 259.9 1300 − 2160 146.9 − 244.0
3/4 − 10 — 2600 − 3300 293.8 − 372.8 1600 − 2250 180.8 − 254.2
— 3/4 − 16 3300 − 4300 372.8 − 485.8 2500 − 3195 282.5 − 361.0
7/8 − 9 — 4200 − 5500 474.5 − 621.4 3000 − 4140 339.0 − 467.8
— 7/8 − 14 5100 − 6700 576.2 − 757.0 3000 − 6300 339.0 − 711.8
1−8 — 6050 − 8800 683.6 − 994.3 5000 − 6840 564.9 − 772.8
— 1 − 12 7000 − 10900 790.9 − 1231.5 5250 − 7920 593.2 − 894.8
— 1 − 14 7000 − 10900 790.9 − 1231.5 5500 − 9000 621.4 − 1016.9
1 1/8 − 7 — 8250 − 11950 932.1 − 1350.2 6500 − 10800 734.4 − 1220.2
— 1 1/8 − 12 9500 − 13000 1073.4 − 1468.8 7000 − 12400 790.9 − 1401.0
1 1/4 − 7 — 12650 − 16100 1429.3 − 1819.1 8000 − 14000 903.9 − 1581.8
— 1 1/4 − 12 15800 − 19200 1785.1 − 2169.3 11000 − 17000 2142.8 − 1920.7
1 3/8 − 6 — 17900 − 21600 2022.4 − 2440.4 — —
— 1 3/8 − 12 20000 − 24000 2259.7 − 2711.6 — —
These values are applicable only to nuts and externally−threaded fasteners that are not
* lubricated or not dry−film lubricated. For lubricated nuts and/or externally threaded fastener
combinations (includes dry−film lubricants), decrease the torque values by 20%.
Standard Torque Values for Tension−Type Nuts and Inserts on High−Strength Bolts, Screws, and Studs
Table 201
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BOLTS, SCREWS, AND STUDS − 160 ksi (1103 MPa) UTS AND MORE * ** ***
Tension−Type Nuts and Inserts
Thread Dimension 200−220 ksi (1379−1517 MPa) UTS and 180−200 ksi (1103−1379 MPa) UTS
more † and more ††
Coarse Fine Pound−inches Newton meters Pound−inches Newton meters
If you use shear−type nuts on high−strength externally−threaded fasteners, use the torque
**
values given for shear−type nuts (refer to Table 202).
For self−locking nuts and self−locking nutplates, find the end torque value as follows: − find
***
the average friction−torque − add this to the torque value given in this table.
† Nuts MS14182, MS21084 and NAS1804
†† Nuts ESNA ZEB1845, KFN673, MS14145, NAS577, NAS578 and Voishan VN465
Standard Torque Values for Tension−Type Nuts and Inserts on High−Strength Bolts, Screws, and Studs
Table 201
BOLTS, SCREWS, AND STUDS − 125−145 ksi (873−1000 MPa) UTS AND MORE * ***
Shear−Type Nuts and Inserts **
Regular Height Smaller Height
Thread Dimension
70 ksi (482.6 MPa) 70 ksi (482.6 MPa) All Strength Levels
UTS and more † UTS and less †† †††
Pound−inches
Coarse Fine
(Newton meters)
3.4 − 4.5 3−4 2−3
2 − 56 —
(0.38 − 0.51) (0.34 − 0.45) (0.23 − 0.34)
3.4 − 4.5 3−4 2−3
— 2 − 64
(0.38 − 0.51) (0.34 − 0.45) (0.23 − 0.34)
6−8 5−7 3−5
4 − 40 —
(0.68 − 0.90) (0.57 − 0.79) (0.34 − 0.57)
6−8 5−7 3−5
— 4 − 48
(0.68 − 0.90) (0.57 − 0.79) (0.34 − 0.57)
8 − 10 6−8 5−7
5 − 40 —
(0.90 − 1.13) (0.68 − 0.90) (0.57 − 0.79)
8 − 10 6−8 5−7
— 5 − 44
(0.90 − 1.13) (0.68 − 0.90) (0.57 − 0.79)
10 − 13 8 − 10 6−8
6 − 32 —
(1.13 − 1.47) (0.90 − 1.13) (0.68 − 0.90)
10 − 13 8 − 10 6−8
— 6 − 40
(1.13 − 1.47) (0.90 − 113) (0.68 − 0.90)
13 − 16 10 − 12 8 − 10
8 − 32 —
(1.47 − 1.80) (1.13 − 1.35) (0.90 − 1.13)
Standard Torque Values for Shear−Type Nuts and Inserts on Standard−Strength Bolts, Screws and Studs
Table 202
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Thread Dimension
Pound−inches
Coarse Fine
(Newton meters)
13 − 16 10 − 12 8 − 10
— 8 − 36
(1.47 − 1.80) (1.13 − 1.35) (0.90 − 1.13)
20 − 25 12 − 15 10 − 12
10 − 24 —
(2.26 − 2.82) (1.35 − 1.95) (1.13 − 1.35)
20 − 25 12 − 15 10 − 12
— 10 − 32
(2.26 − 2.82) (1.35 − 1.95) (1.13 − 1.35)
40 − 50 25 − 30 20 − 25
1/4 − 20 —
(4.52 − 5.65) (2.82 − 3.39) (2.26 − 2.82)
50 − 70 30 − 40 25 − 30
— 1/4 − 28
(5.65 − 7.91) (3.39 − 4.52) (2.82 − 3.39)
80 − 90 50 − 55 35 − 40
5/16 − 18 —
(9.04 − 10.17) (5.65 − 6.21) (3.96 − 4.52)
100 − 140 60 − 85 45 − 55
— 5/16 − 24
(11.3 − 15.8) (6.78 − 9.60) (5.08 − 6.21)
160 − 185 95 − 110 55 − 65
3/8 − 16 —
(18.08 − 20.9) (10.7 − 12.4) (6.21 − 7.34)
160 − 190 95 − 110 65 − 80
— 3/8 − 24
(18.08 − 21.4) (10.7 − 12.4) (7.34 − 10.4)
235 − 255 140 − 155 85 − 100
7/16 − 14 —
(26.5 − 28.8) (15.8 − 17.5) (9.6 − 11.3)
450 − 500 270 − 300 110 − 140
— 7/16 − 20
(50.8 − 56.5) (30.5 − 33.9) (12.4 − 15.8)
400 − 480 240 − 290 130 − 160
1/2 − 13 —
(45.2 − 54.2) (27.1 − 32.7) (14.7 − 18.0)
480 − 690 290 − 410 150 − 170
— 1/2 − 20
(54.2 − 77.9) (32.7 − 46.3) (16.9 − 19.2)
500 −700 300 − 420 175 − 195
9/16 − 12 —
(56.5 − 79.1) (33.9 − 47.4) (19.7 − 22.0)
800 −1000 480 − 600 200 − 240
— 9/16 − 18
(90.4 − 113.0) (54.2 − 67.8) (22.6 − 27.1)
700 − 900 420 − 540 250 − 290
5/8 − 11 —
(79.1 − 101.7) (47.4 − 61.0) (28.2 − 32.7)
Table 202
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Thread Dimension
Pound−inches
Coarse Fine
(Newton meters)
1100 − 1300 660 − 780 300 − 360
— 5/8 − 18
(124.3 − 146.9) (74.6 − 88.1) (33.9 − 40.6)
1150 − 1600 700 − 950 425 − 510
3/4 − 10 —
(129.9 − 180.8) (79.1 − 107.3) (48.0 − 57.6)
2300 − 2500 1300 − 1500 550 − 660
— 3/4 − 16
(259.9 − 282.5) (146.9 − 169.5) (62.1 − 74.6)
2200 − 3000 1300 − 1800 750 − 900
7/8 − 9 —
(248.6 − 339.0) (146.9 − 203.4) (84.7 − 101.7)
2500 − 3000 1500 − 1800 950 − 1140
— 7/8 − 14
(282.5 − 339.0) (169.5 − 203.4) (107.3 − 128.8)
3700 − 5000 2200 − 3000 1175 − 1470
1−8 —
(418.0 − 564.9) (248.6 − 339.0) (132.7 − 166.1)
3700 − 5250 2200 − 3150 1500 − 1800
— 1 − 12
(418.0 − 593.2) (248.6 − 355.9) (169.5 − 203.4)
3700 − 5500 2200 − 3300 1700 − 2040
— 1 − 14
(418.0 − 621.4) (248.6 − 372.9) (192.1 − 230.5)
5500 − 6500 3300 − 4000 2100 − 2520
1 1/8 − 7 —
(621.4 − 734.4) (372.9 − 451.9) (237.3 − 284.7)
5000 − 7000 3000 − 4200 2500 − 3000
— 1 1/8 − 12
(564.9 − 790.9) (339.0 − 474.5) (282.5 − 339.0)
6500 − 8000 4000 − 5000 3000 − 3600
1 1/4 − 7 —
(734.4 − 903.9) (451.9 − 564.9) (339.0 − 406.7)
9000 − 11000 5400 − 6600 3500 − 4200
— 1 1/4 − 12
(1016.9 − 1242.8) (610.1 − 745.7) (395.4 − 474.5)
* These values are applicable only to nuts and externally−threaded fasteners that are
not lubricated or not dry−film lubricated. For lubricated nut and/or externally threaded
fastener combinations (includes dry−film lubricants), decrease the torque values by
20%.
If you use shear−type nuts on high−strength externally−threaded fasteners, use the
**
torque values given in this table.
For self−locking nuts and self−locking nutplates, find the end torque value as follows: −
***
find the average friction torque − add this to the torque value given in this table.
Table 202
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Thread Dimension
Pound−inches
Coarse Fine
(Newton meters)
NAS509, NAS1033, NAS1067, NAS1330, NAS1473 and NAS1474; MS9201, MS9358,
MS9363, MS17825, MS20500, MS21025, MS21044, MS21045, MS21047, MS27512
(steel), MS35649, MS35650 and MS35651; AN310 (steel), AN316 (steel) and AN320
†
(steel); ESNA nuts 52LHA3006, 52LHA3006M, 52LHA3207 and F52LHA3575;
Hi−Shear BN360; Kaynar F51643 thru 51648, HW14, HW19373, MF19058 and
MF51594; TA Mfg Corp TA2507.
MS9200, MS17825 (non−steel), MS27130 (non−steel) and MS27512 (non−steel);
††
AN310 (non−steel), AN316 (non−steel) and AN320 (non−steel); Kaynar KFN600.
NAS679, NAS680, NAS684, NAS696, NAS697, NAS698, NAS1068, NAS1423,
NAS1832, NAS1834 and NAS1835; MS14145, MS17826, MS21042, MS21043,
MS21048, MS21049, MS21051, MS21052, MS21053, MS21055, MS21059 thru
†††
MS21063, MS21065,MS21069 thru MS21076, MS21083, MS21086, MS21087,
MS21209, MS21245;Delron Co. 40( )CA( )−( ), 40( )HA( )−( ), 604D( )−( )−( ) and
604F( )−( )−( ).
Table 202
(4) For joints sealed with synthetic rubber sheet or gaskets. Use the torque values
shown in the table that follows:
TORQUE VALUE
FASTENER DIMENSION
Pound−inches Newton meters
No. 10 20 − 25 2.26 − 2.82
1/4 25 − 50 2.82 − 5.65
5/16 35 − 60 3.95 − 6.78
Torque Values for Joints Sealed with Synthetic Rubber Sheet or Gaskets
Specification MIL−C−6183
(5) After you torque the fastener, make a mark on the torqued fasteners with white
lacquer.
Subtask 20−21−00−910−005
C. Specified Torque
(1) If the applicable maintenance procedure shows a specified torque value, use the
torque value given in the procedure. Make a mark on the torqued fasteners with
white lacquer.
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Subtask 20−21−00−910−006
D. Torque Again
(1) When it is necessary to tighten the fastener assembly again, loosen the fastener
assembly and tighten it again to the specified torque value. Do not let the fastener
turn.
Subtask 20−21−00−910−007
E. Over−Torque
(1) When a threaded fastener is tightened to more than the maximum specified torque
value, replace the assembly. Do not loosen the fastener and tighten again.
Subtask 20−21−00−910−019
F. Running Torque (Locking Torque)
(1) The average torque developed after the fastener is at least one full thread through
the nut, but prior to the tightening of the joint.
Subtask 20−21−00−910−020
G. Seating Torque
(1) The torque required to bring the bearing faces into contact, at the point where
further torquing will create an axial load on the fastener.
Subtask 20−21−00−910−021
H. Assembly Torque (Installation Torque)
(1) The torque required (per the Engineering documents) in order to create the desired
axial load on the bolt/nut assembly. The assembly torque is divided into either
Class I or Class II installation in accordance with Design Engineering.
(a) Class I Torque
1 The torque required to overcome the friction between the bolt and the part
(the running torque is included).
2 When the maintenance procedure does not show a specified Class, the
Class I torque requirements apply and the fasteners shall be torqued to the
values shown in Table 201 and Table 202.
(b) Class II Torque
1 The running torque for each individual nut and fastener must be added to
the assembly torque values specified by the engineering drawing or
document.
2 When the maintenance procedure specifies a Class II torque value, the
running torque prior to tightening, shall be observed for each individual
fastener. The torque value for tightening each individual nut and fastener in
the joint shall consist of the value shown in Table 201 and Table 202
added to the running torque, observed for the individual nut and fastener.
3 Use only dial type hand operated torque wrenches and torque screwdrivers
for torquing Class II fasteners.
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Subtask 20−21−00−910−008
I. Torque Identification
Refer to Figure 202.
(1) Make a mark to identify all torqued threaded fasteners as follows:
(a) Apply a white stripe or mark of white lacquer. Put the mark on the nut when
possible. If this is not possible, put the mark on the head of the bolt or screw.
(b) Make sure that the edges of the mark are easy to see.
(c) Examine the parts of the white stripe or spot if the torqued fastener moves. If
the parts of the white stripe or spot are not aligned, torque the fastener again.
Make a mark after you torque the fastener.
(d) Do not mark torque fasteners for the conditions that follow:
1 On the heads of the countersink bolts or screws that are installed on the
external surfaces of the aircraft.
2 When the fastener is internal to systems (such as fuel, hydraulic, or
pneumatic systems).
3 When the fastener is internal to tanks that are part of the wing or fuselage.
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ADAPTER
CL
AXIS OF TORQUE
ROTATION WRENCH
A A
QUADRANT 4
QUADRANT 1 L1
CL
QUADRANT 2
QUADRANT 3
A A
HANDGRIP
CENTER
L
AXIS OF TORQUE
WRENCH DRIVE
NOTE CORRECTION FACTORS

Use the formulas that follow to Correction
Angle A
calculate the necessary corrections Factor C
to the dial indication on the 0 1.000
torque wrench
5 0.996
10 0.985
When adapter is in quadrant 1 or 2; 15 0.966
Dial Indication = Specified torque X L 20 0.940
L + (L 1 X C) 25 0.906
When adapter is in quadrant 3 or 4; 30 0.866
35 0.819
Dial Indication = Specified torque X L 40 0.766
L − (L1 X C)
45 0.707
50 0.643
55 0.574
LEGEND
60 0.500
L = Length of the torque wrench
rsr5141040_001(1).dc, gg , 12/06/95
L1= Length of the adapter 65 0.423

70 0.342
C = Correction factor
A = Angle between the centerline of the 75 0.259
torque wrench and the centerline of 80 0.174
the adapter in the plane of rotation to 0.087
85
the nearest five degrees
90 0.000
Dial Correction Indication for Torque Wrench Adapters

Figure 201
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Apply a continuous Apply a continuous

straight stripe across Apply a continuous
straight stripe across straight stripe across
the head of the bolt. the head of the nut and
Continue the stripe the head of the screw
and on the adjacent the mating external
down the two sides of threads. Continue the
the head and on the surfaces.
stripe down the two
adjacent surfaces. sides of the nut.
BOLT SCREW NUT
STRIPE METHOD
Apply the blob on Apply the blob on

a part of the head a part of the nut
and on the adjacent and the mating
surface. external threads.
ram2021000_002.dg, SW ,06/03/91
BOLT SCREW NUT
BLOB METHOD
Identification Marks on Torqued Fasteners

Figure 202
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TASK 20−21−00−910−802
Torque Procedures for Plumbing Lines

Subtask 20−21−00−944−002
16−002 Lacquer, cellulose nitrate, gloss for aircraft, white
2. Job Set−Up
Subtask 20−21−00−910−009
A. Torque Wrenches
(1) For specified torques, use hand−operated torque wrenches (dial or clip type), or
power−operated torque tools.
(2) If it is necessary to use a torque wrench adapter, calculate the correct dial
indication. Use the instructions shown in Figure 201.
(3) Hand−operated torque wrenches are generally less accurate in the lower 20% of
their torque range. Whenever possible choose a hand−operated torque wrench to
match the specified torque value. The torque value should lie within 20% to 100%
of the torque wrench capacity.
NOTE: For example, if the specified torque value for a fitting is 20−25
Pound−inches, choose a hand−operated torque wrench with a range of 0
to 50 Pound−inches.
(4) The set value for non indicating power torque tools shall be +10% above the lower
specification limit to −10% below upper specification limit. Use the mid range value
for cases where these values overlap.
NOTE: For example, if the specified torque for a fastener is 60−80 Pound−inches
the set value shall be 66−72 Pound−inches.
(5) Do not use a torque wrench if the calibration date is expired.
3. Procedure
Subtask 20−21−00−910−010
A. General
(1) Turn the torque wrench with a slow and continuous movement.
(2) Be very careful when it is necessary to torque fittings where one end was torqued
before. When you torque these fittings at the opposite end, hold the other end with
a wrench to prevent movement.
(3) Torque plumbing line fittings to the specified values in the applicable tables that
follow.
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Subtask 20−21−00−910−011
B. Flared Fittings
(1) For fittings on aluminum alloy lines, use the torque values shown in Table 203.
(2) For fittings on corrosion−resistant steel lines, use the torque values shown in
Table 204.
Torque Value − Pound−inches (Newton meters)
Hose Thread 5052−0 6061−T6
Outer Diameter
Assembly Dimension of Aluminum Alloy Aluminum Alloy
of Tube − Flexible Hose
Dimension Fittings − Tubing with Tubing with
Inches Assemblies
Dash No. Inches Fittings of All Fittings of All
Material Material
1/8 −2 5/16−24 20−25
− −
(2.26−2.82)
3/16 −3 3/8−24 25−35 30−70 70−100
(2.82−3.95) (3.39−7.91) (7.91−11.30)
1/4 −4 7/16−20 40−65 70−120 70−120
(4.51−7.34) (7.91−13.55) (7.91−13.55)
5/16 −5 1/2−20 60−80 120−130 85−180
(6.77−9.03) (13.55−14.69) (9.59−20.3)
3/8 −6 9/16−18 [1] 75−125 [2] 130−180 100−250
(8.46−14.12) (14.69−20.34) (11.30−28.25)
1/2 −8 3/4−16 150−250 300−400 210−420
(16.95−28.25) (33.90−45.19) (23.73−47.45)
5/8 −10 7/8−14 200−350 430−550 300−480
(22.60−39.54) (48.58−62.14) (33.90−54.23)
3/4 −12 11/16−12 300−500 650−800 500−850
(33.90−56.49) (73.44−90.39) (56.49−96.04)
1 −16 15/16−12 500−700 900−1100 700−1150
(56.49−79.09) (101.69 − (79.09−129.93)
124.28)
1 1/4 −20 15/8−12 600−900 [2] 1200−1450 1200−1450
(67.79−101.69) (135.58 − (135.58 −
163.83) 163.83)
1 1/2 −24 17/8−12 600−900 1550−1850 1550−1850
(67.79−101.69) (175.13 − (175.13 −
209.02) 209.02)
Torque Values for Flared Fittings on Aluminum Alloy Tubing and Hose Assemblies
Table 203
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Hose Thread 5052−0 6061−T6
Outer Diameter
Assembly Dimension of Aluminum Alloy Aluminum Alloy
of Tube − Flexible Hose
Dimension Fittings − Tubing with Tubing with
Inches Assemblies
Dash No. Inches Fittings of All Fittings of All
Material Material
1 3/4 −28 21/4−12 700−1000 2000−2350 2000−2350
(79.09−112.98) (225.97 − (225.97 −
265.51) 265.51)
NOTE: [1] For 3/8−inch outer−diameter (−6 dimension) tubing of 5052−0 and 6061−T6
materials, use a torque value of 120−140 Pound−inches (13.56−15.81 Newton Meters)
on drain, vent, and return lines, for all materials used for the lines. For pressure lines,
use the torque values shown in this table
NOTE: [2] For 1 1/4−in. outer diameter magnesium alloy tubing, Specification WW−T−825
composition AZ31, use the torque value shown for 1 1/4−in. outer−diameter
aluminum−alloy tubing.
Torque Values for Flared Fittings on Aluminum Alloy Tubing and Hose Assemblies
Table 203

Outer Diameter of Tube − MIL−T−6845 and AMS5566 All Flared Corrosion−Resistant
Inches Corrosion−Resistant Steel Steel Tubing with Aluminum
Tubing with Steel Fittings Alloy Fittings
3/16 90−100 −
(10.17−11.30)
1/4 135−150 40−65
(15.25−16.95) (4.52−7.34)
5/16 180−200 60−80
(20.34−22.60) (6.78−9.04)
3/8 270−300 75−125
(30.51−33.90) (8.47−14.12)
1/2 450−500 200−300
(50.84−56.49) (22.60−33.90)
5/8 650−700 350−450
(73.44−79.09) (39.54−50.84)
3/4 900−1000 500−600
(101.69−112.98) (56.49−67.79)
1 1200−1400 700−800
(135.58−158.18) (79.09−90.39)
Torque Values for Flared Fittings on Corrosion−Resistant Steel Tubing

Table 204
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Outer Diameter of Tube − MIL−T−6845 and AMS5566 All Flared Corrosion−Resistant
Inches Corrosion−Resistant Steel Steel Tubing with Aluminum
Tubing with Steel Fittings Alloy Fittings
1 1/4 1500−1800 900−1000
(169.48−203.37) (101.69−112.98)
1 1/2 2000−2300 900−1000
(225.97−259.87) (101.69−112.98)
1 3/4 2600−2900 −
(293.76−327.66)
2 3200−3600 −
(361.55−406.75)
Torque Values for Flared Fittings on Corrosion−Resistant Steel Tubing

Table 204
(3) For fittings in oxygen systems, use the table that follows.
(4) If you cannot use a torque wrench, tighten the coupling nut a half turn more than
hand tightness (for new lines). For used lines, tighten the coupling nut a third turn
more than hand tightness.
TORQUE VALUE − Pound−inches (Newton
OUTER DIAMETER OF TUBE − INCHES
meters)
5/16 100−125 (11.30−14.12)
Use the torque value shown in Table 203 or
All dimensions other than 5/16
Table 204 for the applicable material
Subtask 20−21−00−910−012
C. Brazed Fittings in Oxygen Systems
(1) For brazed fittings in oxygen systems, use the torque values in the table that
follows:
OUTER DIAMETER OF TUBE − Inches TORQUE VALUE − Pound−inches (Newton meters)
3/16 40−50 (4.52−5.65)
(2) If you find leakage, torque again to 70 pound−inches (7.9 N·m).
Subtask 20−21−00−910−013
D. Tapered (Pipe) Fittings
(1) For tapered fittings in systems other than the oxygen system, use the torque values
shown in the table that follows:
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TORQUE VALUE
GIVEN PIPE DIMENSION − Inches
Pound−Inches (Newton Meters)
1/8 40 − 300 (4.52 − 33.90)
1/4 60 − 600 (6.78 − 67.79)
3/8 75 − 700 (8.47 − 79.09)
1/2 100 − 900 (11.30 − 101.69)
3/4 300 − 1600 (33.90 − 180.78)
1 400 − 2200 (45.19 − 248.57)
1 1/4 500 − 2500 (56.49 − 282.46)
(2) For tapered fittings in oxygen systems, use the torque values shown in the table
that follows:
TORQUE VALUE − Pound−inches (Newton
GIVEN PIPE DIMENSION − Inches
meters)
1/8 50 − 100 (5.64 − 11.30)
1/4 100 − 200 (11.30 − 22.60)
(3) Torque tapered fittings to the minimum specified value. Then continue to slowly
tighten until the fitting is in the correct position. Do not torque more than the
maximum specified value.
(4) If leakage starts, tighten the fitting one turn more. Do not torque more than the
maximum specified value.
(5) If leakage continues, replace the parts.
Subtask 20−21−00−910−014
E. Straight Fittings (Installed on Bosses and Through Bulkheads)
(1) For straight threaded fittings installed in bosses, jamnuts on universal fittings, and
bulkhead fittings, use the table that follows.
(2) Install the fittings correctly (as specified in AND 10064 or MS33566) before you
torque these fittings.
(3) Use the torque values in the Table 205 that follows:
INSTALLATION TORQUE − [1] & [2]
Pound−inches (Newton meters)
FITTING or NUT DASH ALUMINUM or STEEL, CRES or STEEL, CRES or
NO. ANNEALED CRES TITANIUM TITANIUM BULKHEAD
FITTINGS WITHOUT
SEALS
76−84 95−105 250−275
−3
(8.59−9.49) (10.73−11.86) (28.25−31.07)
Torque Values for Tightening Jam Nuts Against Bulkheads and Fittings Against Bosses
Table 205
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INSTALLATION TORQUE − [1] & [2]

Pound−inches (Newton meters)
FITTING or NUT DASH ALUMINUM or STEEL, CRES or STEEL, CRES or
NO. ANNEALED CRES TITANIUM TITANIUM BULKHEAD
FITTINGS WITHOUT
SEALS
−4 104−115 133−147 340−375
(11.75−12.99) (15.03−16.61) (38.41−42.37)
−5 133−147 180−199 430−475
(15.03−16.61) (20.34−22.48) (48.58−53.67)
−6 161−178 256−284 750−825
(18.19−20.11) (28.92−32.09) (84.74−93.21)
−8 266−294 475−525 1000−1100
(30.05−33.22) (53.67−59.32) (112.98−124.28)
−10 342−378 665−735
−
(38.64−42.71) (75.13−83.04)
−12 427−472 855−945
−
(48.24−53.32) (96.60−106.77)
−16 712−787 1140−1260
−
(80.45−88.92) (128.80−142.36)
−20 855−945 1520−1680
−
(96.60−106.77) (171.74−189.81)
−24 855−945 1900−2100
−
(96.60−106.77) (214.67−237.27)
NOTE: [1] − Fittings with boss connection ends which agree with style "E" of MS33514 and
MS33566 (installed in MS33649 boss, jamnuts AN924 and AN6289).
NOTE: [2] − For aluminum, steel or titanium fittings installed in aluminum bosses, aluminum
torque values shall be used.
For steel or titanium fittings installed in steel or titanium bosses, steel torque values
shall be used.
Torque Values for Tightening Jam Nuts Against Bulkheads and Fittings Against Bosses
Table 205
Subtask 20−21−00−910−015
F. Flareless Fittings, Harrison/Sierracin internally swaged and Deutsch Permaswage
(1) Use the torque values shown in Table 206 that follows:
NOTE: The flareless fittings are rated for 3000 psi maximum operating pressure
except as noted.
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Tube Outer [4] Torque − Pound−inches (Newton meters)

Fitting
Dimension,
Dimension Aluminum Fittings Steel and CRES Fittings
Inches
1/8 −02 50−80 (5.6−9.0) 75−120 (8.5−13.6)
3/16 −03 70−105 (7.9−11.9) 95−140 (10.7−15.8)
1/4 −04 100−140 (11.3−15.8) 135−190 (15.3−21.5)
5/16 −05 130−180 (14.7−20.3) 170−240 (19.2−27.1)
3/8 −06 150−195 (16.9−22.0) 215−280 (24.3−31.6)
1/2 −08 270−350 (30.5−39.5) 470−550 (53.1−62.1)
5/8 −10 360−430 (40.7−48.6) 620−745 (70.0−84.2)
3/4 −12 460−550 (52.0−62.1) 855−1055 (96.6−119.2)
1 −16 700−840 (79.0−94.9) 1140−1370 (128.4−154.8)
1 1/4 −20 [1] 850−1020 (96.0−115.2) [1] 1520−1825 (171.7−206.2)
1 1/2 −24 [2] 900−1080 (101.7−122.0) [1] 1900−2280 (214.7−257.6)
2 −32 [3] 1800−2000 (203.4−226.0) [1] 2660−2940 (300.5−332.2)
NOTE: Restrictions as follows:
[1] − This size is limited to 1500 psi maximum operating pressure.
[4] − Where either the nut or the fitting is of aluminum alloy, the values for aluminum fittings shall
be used.
Torque Values for Flareless Fittings at 3000 psi Maximum Operating Pressure (except as noted)
Table 206
Subtask 20−21−00−910−016
G. Flareless Fittings, MS21922 Sleeves and MS21921 Nuts
(1) Install the fittings correctly (as specified in SAE AS5148) before you torque these
fittings.
(2) Use the torque values shown in the Table 207 that follows:
Tube Aluminum Fitting − Steel Fitting − CRES Steel Fitting − CRES 1/8
Tube
Outer Aluminum Tube Tube Hard Tube
Wall
Dimension
Thickness Pound−inches (Newton meters)
Inches
55
1/8 .012 − −
(6.2)
100
3/16 .016 − −
(11.3)
Torque Values for Flareless Fittings, MS21922 Sleeves and MS21921 Nuts
Table 207
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Tube
Wall
Dimension
Inches
100
3/16 .020 − −
(11.3)
80
3/16 .028 − −
(9.0)
1/4 .020 140 140
−
(15.8) (15.8)
110 140
1/4 .028 −
(12.4) (15.8)
5/16 .020 190 190
−
(21.5) (21.5)
140 190
5/16 .028 −
(15.8) (21.5)
3/8 .028 170 270
−
(19.2) (30.5)
270
3/8 .035 − −
(30.5)
280
1/2 .028 − −
(31.6)
1/2 .035 360 500
−
(40.7) (56.5)
500
1/2 .042 − −
(56.5)
5/8 .028 360
− −
(40.7)
415
5/8 .035 − −
(46.9)
700
5/8 .042 − −
(79.1)
700
5/8 .058 − −
(79.1)
3/4 .028 450
− −
(50.8)
Table 207
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Tube
Wall
Dimension
Inches
450
3/4 .049 − −
(50.8)
900
3/4 .058 − −
(101.7)
900
3/4 .065 − −
(101.7)
1 .035 750
− −
(84.7)
1 .049 800
− −
(90.4)
1200
1 .065 − −
(135.6)
1 .083 1200
− −
(135.6)
Table 207
(3) If leakage starts at the fitting joint do the following:
NOTE: Do not attempt to prevent the leakage by overtorquing.
— Loosen the coupling nut and remove the tube end from the fitting
— Inspect the seal areas of the sleeve and mating fitting for scratches, nicks,
dents, foreign material, etc
— Reassemble the joint with new parts if necessary.
Subtask 20−21−00−910−017
H. Torque Identification
CAUTION: DO NOT MAKE TORQUE STRIPES ON THE PLUMBING LINE
FITTINGS IN FUEL OR EQUIVALENT SYSTEMS. THE LACQUER CAN
CAUSE CONTAMINATION IN THE SYSTEM IF IT MIXES WITH FUEL
OR OTHER FLUIDS.
(1) After you torque a plumbing line fitting, make a mark to identify the fitting. Apply a
stripe of white lacquer. The position of the stripe shows if the torqued fitting moves.
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STRIPE OF WHITE LACQUER ACROSS

EACH SET OF TORQUED FITTINGS
STRIPE OF WHITE LACQUER ACROSS

EACH SET OF TORQUED FITTINGS
ram2021000_003.dc AB 8/01/91.
Identification Marks on Plumbing Lines

Figure 203
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TASK 20−21−00−910−803
Torque Procedures for Electrical Fittings

Subtask 20−21−00−943−001
None Specified Special Pliers No. AT508K − Aircraft Tools Inc.,
Los Angeles, California
None Specified TG70 Mini−strap wrench − Glenair, Glendale,
California (or equivalent)
2. Procedure
Subtask 20−21−00−910−022
A. Tightening of Connectors
(1) Connectors with knurled type nuts shall be tightened with special pliers No.
AT508K. Nuts having flat faces shall be tightened with a spanner. An MS connector
is not properly tightened if there is any play left in the insert barrel.
NOTE: Care should be taken not to overtighten nuts to avoid gripping of the
connector.
(2) Connector strain relief clamps having a strain relief arm (eg. MA27670) shall be
tightened by hand, then tightened slightly beyond hand tight (max. 1/8 turn) with the
TG70 mini−strap wrench tool or equivalent. To prevent the rotation of the connector
shell (barrel), it should be coupled to a mating connector either on the aircraft or on
the cable board as applicable.
Subtask 20−21−00−910−023
B. Tightening of Bulkhead Feedthrough Fittings
(1) The assembly pn 601A53218−1 fitting, pn MS9068−030 packing, pn 600−53219−1
backshell, and pn MS27512−18A shall be tightened as follows:
(a) Hexagonal nut MS27512−18A shall be torqued sufficiently (approximately 60
pound−inches) to assure a leak proof seal, and safe−tie by lock wire.
(b) Tighten the backshell, first by hand and then tighten slightly beyond hand tight
(max. 1/8 turn) with the TG70 mini−strap wrench tool or equivalent and
safe−tie with lock wire.
Master
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STRAP
WRENCH
STRAP
PLUG FEEDTHROUGH
LOOSEN
STRAP
WRENCH
TIGHTEN
3/8 SQUARE
DRIVE
PLUG
STRAP
ANGLED
FACE
ram2021000_004.dg, rm, 06/05/02
Use of the TG70 Mini−Strap Wrench to Torque Electrical Fittings

Figure 204
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**ON A/C ALL
FITTINGS AND CONNECTIONS − MAINTENANCE PRACTICES
1. General
A. The maintenance procedures that follow give:
– The limits of damage to tubing (straight and curved sections)
– The permitted maximum bend radius for damaged tubing
– The minimum length of tube (from the bend radius to the end of the tube) that is
required for a repair
– The procedures and requirements for the permanent repair of damaged or defective
tubing.
B. The procedures are also given that will allow you to do the types of repairs that follow:
(1) Cryofit/Cryolive Repairs of Tubing
(a) Aerofit Products Inc. Cryofit coupling/Cryolive assembly (flareless sleeves and
nuts) are made from a shape−memory alloy which can be used on aluminum,
corrosion resistant steel (CRES), stainless steel or titanium high pressure
(3000 psi) tubing. The Cryofit couplings/Cryolive assemblies are shipped and
stored in liquid nitrogen before installation.
NOTE: The tube materials used on the CRJ−100 and CRJ−200 hydraulic
systems are as follows:
– 6061−T6 aluminum alloy, size −04 to −12, used on hydraulic
return tubing and drains
– 21−6−9 CRES, size −04 to −10, used on hydraulic pressure
tubing and most −04 tubing
– 304 1/8H CRES, size −04 to −08, used on some of the hydraulic
piping on the landing gear and in the wheel wells.
(b) For installation, the Cryofit coupling/Cryolive assembly is removed from the
liquid nitrogen and is put on the prepared tube ends. When it becomes warm
(room temperature), it shrinks to an inside diameter which is smaller than the
outside diameter of the tubes. This causes the tubes to be compressed and a
permanent connection to be made.
(2) Deutsch Permaswage Repairs of Tubing
(a) Deutsch Permaswage fittings can be used on aluminum, corrosion resistant
steel (CRES), stainless steel or titanium high pressure (3000 psi) tubing. The
fittings are shipped and stored in protective packages before installation. A
Permaswage power swage head is used to compress the fitting onto the tubes
to make a permanent connection.
NOTE: The tube materials used on the CRJ−100 and CRJ−200 hydraulic
systems are as follows:
– 6061−T6 aluminum alloy, size −04 to −12, used on hydraulic
return tubing and drains
– 21−6−9 CRES, size −04 to −10, used on hydraulic pressure
tubing and most −04 tubing
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(3) Harrison "H" Fitting Repairs of Tubing
(a) Harrison "H" fittings can be used on aluminum, corrosion resistant steel
(CRES), stainless steel or titanium high pressure (3000 psi) tubing. The fittings
are shipped and stored in protective packages or in Harrison "H" Fitting Repair
Kits. Harrison "H" fittings are installed with standard hand wrenches.
(4) Bite Type Flareless Fittings, MS 21922 Sleeves and MS 21921 Nuts − Repairs of
Tubing
(a) Bite type flareless fittings can be used on aluminum, corrosion resistant steel
(CRES), stainless steel (3000 psi) tubing. The fittings are shipped and stored
in protective packages. Flareless fittings are installed with standard torque
wrenches or open end wrenches.
(5) Sierracin/Harrison HMS 35211/35235 Sleeves, HMS 35066/35312 Unions and
HMS 35230 Bulkhead Union − Repairs of Tubing
(a) Sierracin/Harrison HMS sleeves and unions can be used on aluminum,
corrosion resistant steel (CRES), stainless steel (3000 psi) tubing. The sleeves
and unions are shipped and stored in protective packages. The equipment and
tools for the installation of Sierracin/Harrison coupling assemblies including
swaging tools, swage block holders, retainers, jaws, expander tools and
mandrels shall be as specified by the manufacturer of the fittings (unless
otherwise specified).
(6) Rynglok Fittings− Repair of Tubing
(a) The Rynglok fitting is made of titanium and can be used on tubing of any
material. There is only one fitting for all wall thicknesses. Only requires one
fitting for all pressures. The procedure that follows for the Rynglok fitting is
applicable to hydraulic tubes between two adjacent clamp locations except if
they are located outboard of the engines firewall, in the engine cowls or on the
landing gears.
TASK 20−22−00−220−802
Inspection Requirements for Damaged Tubing
1. Limits of Damage to Tube Assemblies

Subtask 20−22−00−220−002
Refer to Figure 201, Table 201, and Table 202.
A. The tables that follow give the limits to determine if a tube assembly is serviceable, is
damaged but repairable, or if the tube assembly must be replaced. Damage to the tubing
is described as to the surface defects that follow:
– Dents
– Burnish Marks
– Scratches, scores, gouges and evidence of chafing
– Kinks
– Wrinkles
– Cracks, pit marks, burs and sharp edges
– Superficial marks
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– Finning.
NOTE: Finning is described as a raised metal ridge with a sharp crest, pushed up on
the exterior of flared and beaded tubing. Finning is caused by the split lines
between the segments of two and four piece flaring and beading tools.
NOTE: When a surface defect is present in combination with a dent, each defect must
be evaluated separately.
NOTE: If the damage is more than the allowable limits that are given in this procedure,
a permanent repair of the tube assembly is required.
B. Refer to the table that follows for damage limits for straight or bent tube sections:
STRAIGHT OR BENT SECTIONS OF TUBE
DAMAGE DEFINITION MAXIMUM PERMITTED DAMAGE
(MAXIMUM DEPTH)
Dent Depression with rounded 10% of tube O.D. − system working pressure
edges that have no sharp <1000 psi
bends or edges 5% of tube O.D. − system working pressure ≥1000
psi
Burnish marks Polished surface with no 10% of tube O.D. − system working pressure
sharp edges <1000 psi
5% of tube O.D. − system working pressure ≥1000
psi
Scratches, Depression having sharp 10% of tube wall thickness − system working
scores, chafing, bends or edges pressure <500 psi
and gouges 5% of tube wall thickness − system working
pressure ≥500 psi
None permitted at bends− Reject
Kinks Sharp upward edge or None permitted − Reject
bump
Wrinkles Furrows and ridges Permitted on the inside radius of a bent tube if the
damage is within the limits
(Refer to Figure 201)
Tool marks [1] Bumps, depressions, or 10% of tube O.D. − system working pressure
burnish marks that are <1000 psi
caused by the tube forming 5% of tube O.D. − system working pressure ≥1000
tool psi
NOTE: [1] Damage limits from tool marks are based on the outer tube diameter. The limits for
all other permitted types of damage are based on the tube wall thickness
Tube Damage Limits in Straight or Bent Sections

Table 201
C. Refer to the table that follows for damage limits for flared or beaded tube sections:
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FLARED OR BEADED SECTIONS OF TUBE

DAMAGE LOCATION MAXIMUM PERMITTED DAMAGE
Grooves, tool Inside surface None permitted − Reject
marks, and
other defects
Cracks, pit Outside surface None permitted − Reject
marks, burs,
and sharp
edges
Superficial Outside surface Permitted
marks
Finning [1] Outside diameter None permitted − remove finning to the
surface of the tube or reject. Apply a
chemical conversion coating to the areas
where the surface finish is removed.
NOTE: [1] Finning is the raised metal ridge with a sharp crest on the exterior of both flared and
beaded tubing. Finning is caused by the joints in the two and four part flaring or beading
tools.
Tube Damage Limits in Flared or Beaded Sections Table 202

Table 202
2. Permitted Bend Radius for Damaged Tubing (Relative to the Centerline of the Tube)
Subtask 20−22−00−220−003
Refer to Figure 202 and Table 203.
A. Make sure that the bend radius in the damaged tubing is not smaller than the permitted
limit for that tube, as given in the table that follows:
Outer Diameter of Maximum Bend Radius (in inches) Measured at the Centerline of the Tube
Tube (inches) (DIMENSION Z)
Aluminum Alloy Tubing CRES
5052−O/6061−0 6061−T6 304, MIL−T−6845, 321
AMS5561 − CL2
0.125 0.500 N/A 0.500 0.500
0.187 0.625 0.750 0.750 0.625
0.250 0.750 0.750 0.750 0.750
0.312 1.000 1.000 1.000 1.000
0.375 1.125 1.125 1.125 1.125
0.500 1.500 1.500 1.500 1.500
0.625 1.875 1.875 1.875 1.875
Permitted Repair Limits for Damaged Tubing (Maximum Bend Radius)

Table 203
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Outer Diameter ofMaximum Bend Radius (in inches) Measured at the Centerline of the Tube
Tube (inches) (DIMENSION Z)
Aluminum Alloy Tubing CRES
5052−O/6061−0 6061−T6 304, MIL−T−6845, 321
AMS5561 − CL2
0.750 1.125 [1] 2.250 2.250 1.125 [1]
1.000 1.500 [1] 3.000 3.000 1.500 [1]
1.250 1.875 [1] 3.750 3.750 1.875 [1]
1.500 2.250 [1] 7.500 7.500 2.250 [1]
1.750 2.625 [1] 8.750 8.750 2.625 [1]
2.000 3.000 [1] 10.000 10.000 3.000 [1]
NOTE: [1] The maximum system pressure that is permitted is 500 psi.
Permitted Repair Limits for Damaged Tubing (Maximum Bend Radius)

Table 203
3. Permitted Bend Radius for Damaged Tubing (Relative to the End of the Tube)
Subtask 20−22−00−220−004
Refer to Figure 202 and Table 204.
A. Make sure that the length of the tube between the bend radius and the end of the tube is
not less than the permitted dimension for that tube, as given in the table that follows:
Outer Diameter of Maximum Dimension (in inches) From the End of the Tube to the Start of the
Tube (inches) Bend of the Tube
(DIMENSION Y)
Single and Double Deutsch End Harrison End MS21922
Flared Fitting Fitting Fitting Flareless Fitting
0.125 1.375 N/A N/A 0.750
0.187 1.500 0.750 N/A 0.750
0.250 1.500 0.937 1.000 0.750
0.312 1.500 0.937 1.000 0.937
0.375 1.500 1.000 1.000 1.000
0.500 1.625 1.500 1.062 1.125
0.625 1.625 1.562 1.187 1.187
0.750 1.625 1.625 1.625 1.187
1.000 1.750 1.750 1.625 1.250
1.250 2.000 1.875 1.625 1.250
1.500 2.250 2.000 1.750 1.250
Permitted Repair Limits for Damaged Tubing (Minimum Dimension)

Table 204
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PERMITTED ON THE INSIDE RADIUS OF LIMITS OF WRINKLES

A BENT TUBE IF THE DAMAGE IS WITHIN
A B
THE LIMITS
OUTSIDE DIAMETER MAXIMUM
OF TUBE DEPTH
NOTES
Up to 0.500 in. 0.005 in.
1 10% of tube wall thickness−system (0.13 mm)
(12.70 mm)
working pressure less than 500 PSI.
5% of tube wall thickness−system 0.625 in. thru 0.875 in. 0.010 in.
working pressure 500 PSI and higher. (15.88 mm thru 22.22 mm) (0.25 mm)
1.000 in. thru 01.750 in. 0.020 in.

2 10% of tube outside diameter−system (25.40 mm thru 44.45 mm) (0.51 mm)
working pressure less than 1000 PSI.
2.000 in. thru 2.750 in. 0.030 in.
5% of tube outside diameter−system
(50.80 mm thru 69.85 mm) (0.76 mm)
working pressure 1000 PSI and higher.
3.000 in. thru 3.750 in. 0.040 in.
(76.20 mm thru 95.25 mm) (1.02 mm)
4.000 in. and up 0.060 in.

(101.60 mm and up) (1.52 mm)
SCRATCH, SCORE, CHAFE OR GOUGE
(NONE PERMITTED AT BENDS)
DENT, BURNISH MARK OR TOOL MARK
2
ram2022002_027.dg, rm, 29/07/97
A
CROSS−SECTION OF UPPER TUBE WALL
Tube Damage Limits

Figure 201
Master
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Y
TUBE
DIAMETER
HARRISON H.M.S. TUBE ENDS
Y
TUBE
DIAMETER
SINGLE AND DOUBLE
FLARED TUBE ENDS
Y TUBE
DIAMETER
DEUTSCH TUBE ENDS
Z
NOTE
ram2022002_028.dg, kms, 22/09/99
Y Dimension Z is the maximum

bend radius.
TUBE
Dimension Y is the minimum
DIAMETER
length from the bend radius
MS21922 FLARELESS TUBE ENDS to the end of the tube.
Permitted Bend Radius for Damaged Tubing − Maintenance Practices

Figure 202
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TASK 20−22−00−910−801
Repairs of Hydraulic Tubing − Cryofit Couplings and Compatible Fittings

Subtask 20−22−00−943−001
None specified Chipless Tube Cutter or equivalent
None specified Cryofit Snap−On Fixture or O−ring (See Table 206)
None specified Cryofit Marking Gauge (See Table 206)
None specified Coupling Storage Container (See Figure 203)
None specified * − Cryofit Spray/Chiller Assembly (CryoGun)
(Optional)
None specified Cryofit Test Coupling (See Table 206)
None specified Cryofit Tube Chiller (See Table 206)
None specified Lint−Free Cotten Gloves
None specified Safety glasses
None specified Tongs (Canlab # T5011, AMCI # AT911094 or
equivalent)
None specified Work Box (AMCI # WB910825 or equivalent)
None specified Stopwatch
None specified Tube, deburring tool
* − Parts available from Aerofit Mfg. (Tel. (714) 521−5060 or e−mail
afpsales@aerofit.com)
Subtask 20−22−00−944−001
05−012 Abrasive Pad (3M Scotchbrite)
05−074 Nitrogen, liquid
13−007 Primer, epoxy, fluid resistant
None specified Permanent−type marking pen (Sharpie)
Subtask 20−22−00−946−001
TASK 12−00−06−863−801 Pressurize Hydraulic Systems No. 1 and No. 2
TASK 12−00−06−863−802 Release Hydraulic Pressure − Systems No. 1 and
No. 2
TASK 12−00−06−863−803 Pressurize Hydraulic System No. 3
TASK 12−00−06−863−804 Release Hydraulic Pressure − System No. 3
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TASK 29−00−00−910−801 Hydraulic Safety Precautions
TASK 29−10−00−870−801 Bleed Hydraulic System No. 1
TASK 51−21−11−380−801 Alodine solution treatment
TASK 51−26−00−110−801 Solvent cleaning
TASK 51−26−00−150−803 Removal of Paint by the Brush Method
SRM 51−21−16 Protective Finish Code A060 − Aluminum Alloy
Fluid Tube
Protective Finish Code A064 − Aluminum Alloy
Fluid Tube
SRM 51−25−06 Fluid Resistant (FR) Epoxy Primer
2. Job Set−Up
Subtask 20−22−00−910−001
WARNING: BEFORE YOU DO REPAIRS ON HYDRAULIC SYSTEM TUBING MAKE SURE
THAT YOU DO THE FOLLOWING:
– RELEASE THE HYDRAULIC PRESSURE FROM THE APPLICABLE
SYSTEM(S)
– OPEN, SAFETY AND TAG ALL APPLICABLE CIRCUIT BREAKERS
– INSTALL WARNING PLACARDS ON ALL APPLICABLE ELECTRICAL AND
HYDRAULIC CONTROLS
– OBEY ALL THE HYDRAULIC SAFETY PRECAUTIONS.
THIS WILL PREVENT INJURIES TO PERSONS AND/OR DAMAGE TO THE
AIRCRAFT.
A. Release the hydraulic pressure from the applicable system(s)(Ref.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804).
B. Open, safety and tag all applicable circuit breakers.
C. Install warning placards on all applicable electric and hydraulic controls.
D. Obey all the hydraulic safety precautions (Ref. TASK 29−00−00−910−801).
E. Follow the safety precautions below when liquid nitrogen and super−cooled fittings are to
be used:
(1) Work in a well ventilated area.
NOTE: Liquid nitrogen will displace air in a confined space and may cause
suffocation.
(2) Liquid nitrogen has a temperature of −320 °F (−196 °C), which can cause frostbite
and/or skin burn within seconds of skin contact.
(3) Wear close fitting boots, cuffless trousers over high top shoes or coveralls, to
prevent liquid nitrogen from being caught in clothing with skin contact.
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(4) Wear protective gloves when you touch tools cooled in liquid nitrogen.
NOTE: Always use tongs to remove parts from liquid nitrogen, do not put gloves
into liquid nitrogen.
(5) Safety glasses and insulated gloves are sufficient to work with small quantities of
liquid nitrogen, such as, the transfer of Cryofit couplings from storage containers to
a workbox.
NOTE: Heavy protective gear is not recommended and may pose a hazard by
limiting the freedom of movement to the installer.
F. If a liquid nitrogen spill occurs, do the following:
– Remain clear of the spill and allow it to evaporate through normal shop ventilation.
– Immediately remove any clothing or shoes which have been soaked in liquid nitrogen
and then flush skin with lukewarm water. Seek immediate medical attention if
burned.
– In case of eye contact, flush with water and get immediate medical attention.
3. Storage and Inspection of Cryofit Couplings

Subtask 20−22−00−910−002
Refer to Figure 203, Figure 204, Figure 205, and Figure 206.
A. Coupling Storage
(1) Special insulated liquid nitrogen containers (referred to as "dewars" in this
procedure) are used for storing Cryofit couplings. Couplings are stored in trays or
drawers within the dewar.
NOTE: To avoid coupling shrinkage while in storage, the liquid nitrogen level in
the storage container must be kept at a level above the couplings. Any
tool that touches the couplings must be pre−cooled in liquid nitrogen. If
not, the coupling will become warm and will shrink. If a coupling shrinks
before installation on a tube, it is recommended that the coupling be
returned to the fitting manufacturer for re−expansion.
B. Inspection of Coupling Inside Diameter (I.D.)
WARNING: OBEY THE SAFETY PRECAUTIONS THAT FOLLOW WHEN YOU DO
WORK WITH HIGH−PRESSURE GAS NITROGEN:
– USE A FACE SHIELD
– USE SAFETY GOGGLES
– CLOSE THE VALVES ON THE PIPING AND THE TANKS WHEN
THEY ARE NOT USED OR WHEN EMPTY
– GO TO AN AREA THAT HAS A GOOD FLOW OF CLEAN AIR AND
GET MEDICAL AID IF YOU BREATHE IN GAS NITROGEN
NITROGEN CAN CAUSE SUFFOCATION AND DEATH WHEN IT IS
BREATHED IN.
(1) If you believe that a coupling has been warmed (such as a low liquid nitrogen level
in the dewar, or if the coupling has been previously removed from liquid nitrogen),
make sure that its I.D. is correct as follows:
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(a) Use a six−inch length of tubing which is the same diameter as the tubing the
coupling is to be installed on.
(b) Cool the end of the tube in liquid nitrogen until the boiling stops.
NOTE: Keep the open end of the tube away from your face and/or body,
liquid nitrogen may spurt from the tube end.
(c) Be careful to keep the coupling in the liquid nitrogen. Put the tube into the
coupling. If the I.D. of the coupling is correct, then the tube will easily go
through the entire bore of the coupling.
(d) If the tube cannot go through the coupling, the coupling is no longer
serviceable and must be removed from stock. To be serviceable again, the
coupling must be returned to the fitting manufacturer for re−expansion.
4. Procedure
Subtask 20−22−00−910−003
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes for coupling
installation. These procedures are for the replacement of existing tube sections
as well as for new installations on the aircraft. Cryofit couplings are to be
installed on hydraulic lines only, in the areas outside the powerplant fire zones
and fuel tanks.
(1) Prepare tubes that have small defects (pinholes, less than 0.250 inches (6.35 mm))
in line sections as follows:
(a) Cut the damaged line section at the pin hole with a chipless roller−type cutter
as follows:
1 Loosen the cutter drive screw with the hex key and put the cutter head into
position on the tube. Tighten the drive screw until the cutter wheel lightly
touches the tube, then tighten the drive screw an additional 1/4 of a turn.
2 Turn the cutter on the tube until there is no more resistance. Tighten the
drive screw an additional 1/8 to 1/4 of a turn and turn the cutter again.
Continue to do this until the tube is completely cut through.
(b) Remove paint and primer and deburr the tube ends as follows:
1 Use an appropriate assembly of stem (plug) and deburring tool body.
2 Lightly lubricate the rubber plug of the deburring tool stem assembly with
swage lubricant.
3 Push in the tool plunger to extend the stem and insert it into the tube until
the cutters touch the tube end. Release the plunger to expand the stem in
the tube.
4 Push lightly on the knurled body and turn the tool clockwise against the
end of the tube . Do not deburr an excessive amount of material.
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CAUTION: USE ONLY PAINT REMOVER TO REMOVE PAINT AND
PRIMER FROM TUBES. DO NOT REMOVE PAINT AND
PRIMER MECHANICALLY. THIS CAN CAUSE
LONGITUDINAL DAMAGE TO THE TUBING AND AN
INCORRECT METAL−TO−METAL SEAL.
5 Before you remove the deburring tool, prepare the surfaces of the tubing, 2
inches (50.80 mm) from the tube end, as follows:
a Remove paint and primer from the tube ends with paint remover (Ref.
TASK 51−26−00−150−803). Do not remove paint and primer
mechanically, as you can cause damage to the tubes.
CAUTION: DO NOT POLISH TUBES IN A LONGITUDINAL
DIRECTION. THIS CAN CAUSE LONGITUDINAL
DAMAGE TO THE TUBING AND AN INCORRECT
METAL−TO−METAL SEAL.
b Polish the tubes with a 3M Scotchbrite pad and a radial motion about
its circumference. Do not rub in a longitudinal direction.
CAUTION: DO NOT PUSH IN THE PLUNGER ON THE DEBURRING
TOOL WHEN YOU REMOVE THE TOOL FROM THE TUBE.
THIS CAN CAUSE THE HYDRAULIC SYSTEM TO BECOME
CONTAMINATED WITH METAL SHAVINGS.
6 Pull on the tool plunger and remove the deburring tool to the first bulge of
the stem assembly. Wipe off any chips or paint remover and completely
remove the deburring tool.
(c) Solvent clean the tube surfaces to remove dust and chips (Ref.
TASK 51−26−00−110−801).
(d) For aluminum tube only, apply Alodine (Ref. TASK 51−21−11−380−801).
NOTE: The Alodine treatment must be performed before the installation of
the coupling.
(2) Prepare tubes that have large defects (greater than 0.250 inches (6.35 mm)) in line
sections as follows:
(a) Cut out the damaged section of line as specified in paragraph 4. A. (1) (a) and
prepare the tube ends as follows:
1 Make sure that there will be a minimum straight section of 1.25 inches
(31.75 mm) on either side of the cut.
2 Use a chipless roller−type tube cutter to remove the section of tubing (a
minimum of 4 inches (101.60 mm)) with the defect.
3 Remove paint and primer, polish and deburr the ends of the tubes.
4 Solvent clean the tube surfaces to remove dust and chips (Ref.
TASK 51−26−00−110−801).
(b) For aluminum tube only, apply Alodine (Ref. TASK 51−21−11−380−801).
the coupling.
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(c) Use the cutout section as a template and make an appropriate replacement
(splice) tube section using the same material and tube wall thickness as
follows:
1 Cut a splice tube so that the gap at either end will be less than 0.250
inches (6.35 mm).
2 deburr the ends of the tube and polish their surfaces with a Scotchbrite
pad.
TASK 51−26−00−110−801).
4 For aluminum tube only, apply Alodine (Ref. TASK 51−21−11−380−801)
on the entire tube length. For aluminum tube only, apply protective finish
((Ref. SRM 51−21−16) protective finish code A060 or A064 as required) on
the splice tube except for 2 inches (50.80 mm) on each end.
B. Tube to Tube Installation
Refer to Table 205 and Table 206 for the appropriate Cryofit couplings and installation
tools. Refer to Figure 209, Figure 210, Figure 211, Figure 212, Figure 213 and
Figure 214.
(1) If required, relieve the hydraulic pressure from the appropriate system(s). Solvent
clean the ends of tubes, as necessary (Ref. TASK 51−26−00−110−801).
(2) Make sure that the tube ends are prepared for the Cryofit repair.
(3) Put a test coupling over the tube ends to make sure that the tubes are round and
free from burrs. The test coupling must move freely on the tubes.
(4) Put the test coupling into position so that both tube ends are visible in the coupling
window. Make the tube ends touch, if possible. However, if both tube ends are
visible in the window, then this gap is less than 0.120 inches (3.05 mm) and is
acceptable.
CAUTION: USE ONLY PERMANENT−TYPE MARKERS WHEN YOU MAKE
INSTALLATION MARKS ON TUBES. IF A PENCIL IS USED, IT CAN
CAUSE CORROSIVE DAMAGE TO THE TUBE.
(5) Remove the test coupling and put the marking gauge on a tube end. Use a
permanent−type marking pen to fill in the rectangular slot in the gauge and make an
installation mark on the tube. Make another installation mark on the other tube end.
(6) Refer to the table that follows to choose a Cryofit coupling according to tube
material, tube size, and tube wall thickness:
TUBE MATERIAL TUBE O.D. WALL REQUIRED COUPLING (Aerofit
−INCHES− THICKNESS P/N)
−INCHES−
304 1/8H Stainless 1/4 0.020 3PHS111−04
21−6−9 CRES 0.016
6061−T6 0.035
Tube Material, Size, Wall Thickness and Corresponding Cryofit Coupling

Table 205
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−INCHES−
304 1/8H Stainless 3/8 0.028 3PHS111−06
21−6−9 CRES 0.020
6061−T6 0.035
304 1/8H Stainless 1/2 0.035 3PHS111−08
21−6−9 CRES 0.026
6061−T6 0.035
21−6−9 CRES 5/8 0.033 3PHS111−10
6061−T6 0.035
6061−T6 3/4 0.035 3PHS111−12
All parts supplied by Aerofit Mfg. (Tel. (714) 521−5060) or afpsales@aerofit.com)
Tube Material, Size, Wall Thickness and Corresponding Cryofit Coupling

Table 205
(7) Refer to the table that follows for the corresponding installation tool for a Cryofit
coupling:
Part Number Tube Size

Description (Aerofit P/N) −04 −06 −08 −10 −12
Marking Gauge MG3PHS111 −04 −06 −08 −10 −12
Test Coupling TC3PHS111 −04 −06 −08 −10 −12
Snap−On Fixture (or use SC4PHS111 or −04 −06 −08 −10 −12
O−Ring) SC5PHS111
O−Ring (Alternate to OS9452K −04 −06 −08 −10 −12
Snap−On Fixture)
Tube Chiller 910415 −01 −01 −01 −02 −02
3PHS111 Cryofit Installation Tools

Table 206
(8) Install a plastic installation stop (or an appropriate O−ring) on one tube end and put
it on the middle of its installation mark. This will help you to accurately install the
coupling. To make sure the position of the stop is correct, install the test coupling
on the tubes so that it touches the installation stop. Both tube ends must be visible
in the window and the test coupling must cover approximately half the installation
mark on each tube. Adjust the installation stop if necessary, and remove the test
coupling.
(a) Use the test coupling, gloves and tongs and practice a simulated installation of
the coupling. Time the simulated installation with a stopwatch, which should
not exceed the recommended installation time of 20 seconds.
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(b) Put the gloves and safety glasses on.
NOTE: Make sure that the gloves do not touch the liquid nitrogen at any
time during the installation.
(c) Carefully fill the work box with 2 inches (50.80 mm) of liquid nitrogen (enough
to cover all parts). Put the tips of the tongs and the tube chiller in the work box.
NOTE: Liquid nitrogen will boil when coming into contact with room
temperature objects, so proper care must be taken to avoid any
splashing and spills while pouring the liquid nitrogen.
(d) Use the pre−cooled tongs to transfer the coupling from the storage container to
the work box. Make sure that the time during transfer does not exceed 10
seconds.
NOTE: The Cryofit coupling is supplied with a Lexan package. Do not
remove the Lexan installation package from the coupling until the
coupling is completely installed.
NOTE: To avoid coupling shrinkage while in storage, the liquid nitrogen level
in the storage container must be kept at a level above the couplings.
Any tool that touches the couplings must be pre−cooled in liquid
nitrogen. If not, the coupling will become warm and will shrink. If a
coupling shrinks before installation on a tube, the coupling must be
NOTE: If the frozen coupling touches a tube or fitting that has not been
pre−cooled with liquid nitrogen, it is possible that the coupling will
become warm and will shrink prematurely during installation. To
avoid this, all tubes and fittings that touches the couplings must be
pre−cooled with liquid nitrogen.
(9) Do the steps that follow without delay:
(a) Install the pre−cooled tube chiller on the tube to be joined. Position the tube
chiller against the installation stop on one side, extending on the other tube to
be joined. Remove the tube chiller after 45 seconds. As an alternative, spray
the tubes with chilled nitrogen vapor from the optional Cryogun spray/chiller
assembly. In this case, spray both tubes for 45 seconds from their ends to a
minimum distance equal to one and a half times the length of the coupling.
NOTE: The tube pre−cooling should not exceed 1 minute or excessive ice
buildup will occur and obstruct expanded coupling movement on the
chilled tubes.
(b) Remove the installation sleeve (with frozen coupling) from the liquid nitrogen
with pre−cooled tongs.
(c) With gloved hands, use thumb and forefinger to hold the coupling by the
installation sleeve.
(d) Move one of the tube ends (the one that does not have the installation stop or
O−ring on it) to one side a sufficient amount to allow the coupling to be put on
this tube.
(e) Put the coupling on the tube end. Realign the tubes and move the coupling in
position against the installation stop (or O−ring).
(f) Make sure that both ends of the coupling touch their related installation mark
as described at Figure 214. Maintain this position for at least 45 seconds or
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C
until the coupling is set.
(g) Allow the coupling to become warm and shrink on the tubes. Remove the
installation sleeve from the coupling and the installation stop from the tube (or
cut off the O−ring if used).
(h) Make sure that both ends of the coupling touch their corresponding installation
mark. If either end does not touch their installation mark, the coupling is
incorrectly installed and must be removed.
Subtask 20−22−00−780−001
C. Pressure Testing
NOTE: Whenever hydraulic components are connected, air becomes trapped in the
system and must be removed for the affected system(s) (Ref.
TASK 29−10−00−870−801), (Ref. TASK 29−10−00−870−802) or (Ref.
TASK 29−10−00−870−803).
(1) Do a pressure test of the Cryofit installation as follows:
(a) Pressurize the applicable system and hold the pressure for a minimum of 15
minutes (Ref. TASK 12−00−06−863−801) or (Ref. TASK 12−00−06−863−803).
(b) Rub the fitting−to−tube interface with a white cloth and look for signs of
hydraulic fluid leaks.
(c) Do a visual inspection of the fitting−to−tube interface for hydraulic fluid leaks.
(2) If the fitting does not pass the pressure test release the pressure (Ref.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804) and repeat the
procedure, cut out an appropriate length of tubing and the fitting. Install a
replacement section of tubing with two new fittings.
Subtask 20−22−00−370−001
D. Apply Protective Finish (for Aluminum tubing only)
(1) Solvent clean the tubes (Ref. TASK 51−26−00−110−801).
(2) Apply primer (Ref. SRM 51−21−16) protective finish code A060 or apply the
topcoat (Ref. SRM 51−21−16) protective finish code A064 as required. The
conversion coating (Alodine) has been applied before coupling installation and does
not need to be applied again.
NOTE: Do not apply Alodine or primer to Cryofit fittings.
5. Close Out
Subtask 20−22−00−941−001
Master
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WORKBOX
(THERMALLY INSULATED
PLASTIC CONTAINER (THERMOS)
WITH LIQUID TIGHT BOTTOM
USED TO CARRY COUPLING
TO WORK AREA)
9.0 in.
(228.60 mm)
TONGS
(USED TO TRANSFER ASSEMBLIES
9.0 in. 11.0 in. TO AND FROM A WORKBOX)
(228.60 mm) (279.40 mm)
32.0 in.
(812.80 mm)
ram2022002_001.dg, kms/sw, 25/10/01
COUPLING STORAGE
CONTAINER (DEWAR)
(FOR COUPLING STORAGE)
18.0 in.
(457.20 mm)
Cryofit/Cryolive Workbox, Coupling Storage Container and Tongs

Figure 203
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TEST COUPLING
.120
MARKING GAUGE
ram2022002_002.dg, kms, 21/06/95
Cryofit Test Coupling and Marking Gauge

Figure 204
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TUBE CHILLER
(USED TO DECREASE THE
TEMPERATURE OF A TUBE.
GIVES ADDITIONAL
WORK TIME.)
ram2022002_003.dg, kms, 31/10/01
Cryofit Tube Chiller

Figure 205
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TRIGGER HANDLE
RELIEF VALVE
SPRAY NOZZLE
SPRAY ASSEMBLY
ram2022002_004.dg, kms, 21/06/95
Cryofit Spray Chiller Assembly (CryoGun)

Figure 206
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0.250 ± 0.050 in.

(6.35 ± 1.27 mm)
CUT OUT SECTION OF MAXIMUM LENGTH OF THE

LINE WITH DEFECT DEFECT IS 0.250 in. (6.35 mm)
SMALL DEFECTS IN
A
LINE SECTIONS
MINIMUM 4.0 in. MINIMUM

STRAIGHT (101.6mm) STRAIGHT
LENGTH MINIMUM LENGTH
DEFECT LARGER THAN

REFER TO THE 0.250 in. (6.35 mm)
MANUFACTURER’S
MANUAL FOR THIS
DIMENSION CUT OUT SECTION OF LINE WITH
DEFECT 4.0 in. (101.6 mm) MINIMUM
ram2022002_015.dg, jp/ds, 12/11/03
LARGE DEFECTS IN
B
LINE SECTIONS
Typical Defects in Tubing

Figure 207
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DRIVE SCREW
A CHIPLESS ROLLER−TYPE CUTTER
PLUNGER DEBURRING STEM

TOOL (PLUG)
B PLUNGER PUSHED IN (STEM EXTENDED)
ram2022002_016.dg, jp, 01/09/95
C PLUNGER PULLED OUT (STEM EXPANDED)
Preparation of Tubing
Figure 208
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O−RING
(INSTALLATION STOP)
ram2022002_005.dg, kms/sw, 24/10/01
SNAP−ON COUPLING
(INSTALLATION STOP)
Cryofit O−Ring and Snap−On Fixture

Figure 209
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MARKING GAUGE
MARKING PEN INSTALLATION MARK
PART OF INSTALLATION MARK

INSTALLATION MARK
COVERED BY TEST COUPLING
TEST COUPLING USED TO TUBE ENDS VISIBLE INSTALLATION STOP

CHECK INSTALLATION MARKS IN COUPLING WINDOW (O−RING)
ram2022002_006.dg, kms, 21/06/95
Installation Marks on Tubes

Figure 210
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TUBE
O−RING
INSTALLATION MARK
O−RING POSITIONED
ON CENTER OF
INSTALLATION MARK
CRYOFIT PLASTIC TUBE

INSTALLATION
STOP
INSTALLATION MARK
PLASTIC INSTALLATION STOP SNAPS

ONTO TUBE, POSITIONED TO COVER
ram2022002_007.dg, kms, 21/06/95
TO CENTER OF INSTALLATION MARK
Position of Cryofit Installation Stop

Figure 211
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TUBE TUBE
CRYOFIT
TUBE CHILLERS
ram2022002_008.dg, kms/sw, 25/10/01
Use of Cryofit Tube Chiller

Figure 212
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TUBE MOVED TO
ONE SIDE TO INSTALL
INSTALLATION STOP COUPLING
(O−RING)
CRYOFIT COUPLING IN
INSTALLATION PACKAGE
INSTALLATION MARKS
TUBE TUBE
ram2022002_009.dg, kms/sw, 25/10/01
CRYOFIT COUPLING IN
INSTALLATION STOP INSTALLATION PACKAGE
(O−RING) MOVED ONTO OTHER TUBE
AGAINST INSTALLATION STOP
Installation of Cryofit Couplings

Figure 213
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TUBES INSERTED TO EQUAL DEPTH

(NO TUBE GAP, ENDS BUTT AT CENTER)
ACCEPTABLE
0.120 INCH BOTH TUBES INSERTED TO MINIMUM DEPTH

(TUBE GAP MAXIMUM)
ACCEPTABLE
ONE TUBE INSERTED TO MIN. DEPTH, ONE

TO MAX. (NO TUBE GAP, OFF−CENTER BUTT)
ACCEPTABLE INSTALLATION MARK
BOTH TUBES INSUFFICIENTLY

INSERTED (TUBE GAP BEYOND
0.120 INCH MAXIMUM) − JOINT
MAY LEAK OR ENDS MAY BE
BLOWN OFF
UNACCEPTABLE
ONE TUBE INSERTED BEYOND

MAX. DEPTH, ONE INSERTED
TO INSUFFICIENT DEPTH
ram2022002_010.dg, kms, 21/06/95
(JOINT MAY LEAK OR ENDS

MAY BE BLOWN OFF)
UNACCEPTABLE
Cryofit Coupling Installation Checks

Figure 214
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TASK 20−22−00−910−804
Repairs of Hydraulic Tubing − Cryolive Flareless Sleeve Assemblies and Compatible
Fittings

NOTE: Cryolive flareless sleeve assembly will now be known as Cryolive coupling.
Subtask 20−22−00−943−004
None specified Chipless Tube Cutter or equivalent
None specified Coupling Storage Container (See Figure 203)
None specified Lint−Free Cotten Gloves
None specified Safety glasses
None specified Tongs (Canlab # T5011, AMCI # AT911094 or
equivalent)
None specified Work Box (AMCI # WB910825 or equivalent)
None specified Stopwatch
None specified Tube, deburring tool
Parts available from Aerofit Mfg. (Tel. (714) 521−5060 or e−mail afpsales@aerofit.com)
Subtask 20−22−00−944−004
05−074 Nitrogen, liquid
13−007 Primer, epoxy, fluid resistant
Subtask 20−22−00−946−004
No. 2
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SRM 51−21−16 Protective Finish Code A060 − Aluminum Alloy
Fluid Tube
Protective Finish Code A064 − Aluminum Alloy
Fluid Tube
SRM 51−25−06 Fluid Resistant (FR) Epoxy Primer
2. Job Set−Up
Subtask 20−22−00−910−010
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
A. Release the hydraulic pressure from the applicable system(s) (Ref.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804).
E. Follow the safety precautions below when liquid nitrogen and super−cooled fittings are to
be used:
(1) Work in a well ventilated area.
NOTE: Liquid nitrogen will displace air in a confined space and may cause
suffocation.
(2) Liquid nitrogen has a temperature of −320 °F (−196 °C), which can cause frostbite
and/or skin burn within seconds of skin contact.
(3) Wear close fitting boots, cuffless trousers over high top shoes or coveralls, to
prevent liquid nitrogen from being caught in clothing with skin contact.
(4) Wear protective gloves when you touch tools cooled in liquid nitrogen.
NOTE: Always use tongs to remove parts from liquid nitrogen, do not put gloves
into liquid nitrogen.
(5) Safety glasses and insulated gloves are sufficient to work with small quantities of
liquid nitrogen, such as, the transfer of Cryolive assemblies from storage containers
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to a workbox.
NOTE: Heavy protective gear is not recommended and may pose a hazard by
limiting the freedom of movement to the installer.
F. If a liquid nitrogen spill occurs, do the following:
– Remain clear of the spill and allow it to evaporate through normal shop ventilation.
– Immediately remove any clothing or shoes which have been soaked in liquid nitrogen
and then flush skin with lukewarm water. Seek immediate medical attention if
burned.
– In case of eye contact, flush with water and get immediate medical attention.
3. Storage and Inspection of Cryolive Couplings

Subtask 20−22−00−910−011
A. Cryolive Coupling Storage
NOTE: The Cryolive coupling is supplied as an assembly with the expanded sleeve
and the coupling nut contained in a disposable molded installation package
that is also used as an installation check tool. The Cryolive couplings are
shipped in liquid nitrogen.
(1) Special insulated liquid nitrogen containers (referred to as "dewars" in this
procedure) are used for storing Cryolive couplings. Cryolive couplings are stored in
trays or drawers within the dewar.
NOTE: To avoid sleeve shrinkage while in storage, the liquid nitrogen level in the
storage container must be kept at a level above the coupling. Any tool
that touches the coupling must be pre−cooled in liquid nitrogen. If not, the
sleeve will become warm and will shrink. If a the sleeve shrinks before
installation on a tube, it is recommended that the Cryolive coupling be
B. Inspection of Cryolive Coupling Sleeve Inside Diameter (I.D.)
WARNING: OBEY THE SAFETY PRECAUTIONS THAT FOLLOW WHEN YOU DO
WORK WITH HIGH−PRESSURE GAS NITROGEN:
– USE A FACE SHIELD
– USE SAFETY GOGGLES
– CLOSE THE VALVES ON THE PIPING AND THE TANKS WHEN
THEY ARE NOT USED OR WHEN EMPTY
– GO TO AN AREA THAT HAS A GOOD FLOW OF CLEAN AIR AND
GET MEDICAL AID IF YOU BREATHE IN GAS NITROGEN
NITROGEN CAN CAUSE SUFFOCATION AND DEATH WHEN IT IS
BREATHED IN.
(1) If you believe that a coupling has been warmed (such as a low liquid nitrogen level
in the dewar, or if the coupling has been previously removed from liquid nitrogen),
make sure that its I.D. is correct as follows:
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(a) Use a six−inch length of tubing which is the same diameter as the tubing the
coupling is to be installed on.
(b) Cool the end of the tube in liquid nitrogen until the boiling stops.
NOTE: Keep the open end of the tube away from your face and/or body,
liquid nitrogen may spurt from the tube end.
(c) Be careful to keep the Cryolive coupling in the liquid nitrogen. Put the tube into
the sleeve. If the I.D. of the sleeve is correct, then the tube will easily go
through the entire bore of the sleeve. The tube should bottom out against the
assembly end.
(d) If the tube cannot go through the sleeve, the Cryolive coupling is no longer
serviceable and must be removed from stock. To be serviceable again, the
Cryolive coupling must be returned to the fitting manufacturer for
re−expansion.
4. Procedure
Subtask 20−22−00−910−012
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes for Cryolive
coupling installation. To install the coupling, the swaged portion of the tubes’
flareless end must be removed. This would affect the tube length, and a new
section of tube needs to be added. These procedures are for the replacement
of existing tube sections as well as for new installations on the aircraft.
Cryolive couplings are to be installed on hydraulic lines only, in the areas
outside the powerplant fire zones and fuel tanks.
(1) Prepare the tube end as follows:
(a) Cut the damaged end with a chipless roller−type cutter as follows:
the tube.
3 Push lightly on the knurled body and turn the tool against the tube end. Do
not deburr an excessive amount of material.
Master
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TASK 51−26−00−110−801).
the Cryolive coupling.
B. Cryolive Coupling Installation
Refer to Table 207 for the appropriate Cryolive coupling and Table 208 for the Cryolive
coupling installation torque. Refer to Figure 217, Figure 218.
(1) If required, relieve the hydraulic pressure from the appropriate system(s)(Ref.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804). Solvent clean the
ends of tubes, as necessary (Ref. TASK 51−26−00−110−801).
(2) Make sure that the tube ends are prepared for the Cryolive repair.
(3) Refer to the table that follows to choose a Cryolive coupling according to tube
material, tube size, and tube wall thickness:
NOTE: The letters J or W refer to specific materials, J refers to steel, and W
refers to aluminum.
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−INCHES−
304 1/8H Stainless 1/4 0.020 921721J04
21−6−9 CRES 0.016
6061−T6 0.035 921721W04
304 1/8H Stainless 3/8 0.028 921721J06
21−6−9 CRES 0.020
6061−T6 0.035 921721W06
304 1/8H Stainless 1/2 0.035 921721J08
21−6−9 CRES 0.026
6061−T6 0.035 921721W08
21−6−9 CRES 5/8 0.033 921721J10
6061−T6 0.035 921721W10
6061−T6 3/4 0.035 921721W12
Tube Material, Size, Wall Thickness and Corresponding Cryolive Coupling

Table 207
(4) Prepare for the installation as follows:
(a) Time the installation with a stopwatch. The installation should not exceed the
recommended time of 20 seconds.
(b) Put the gloves and safety glasses on and begin the installation.
NOTE: Make sure that the gloves do not touch the liquid nitrogen at any
time during the installation.
(c) Carefully fill the work box with 2 inches (50.80 mm) of liquid nitrogen (enough
to cover all parts). Put the tips of the tongs in the work box.
NOTE: Liquid nitrogen will boil when coming into contact with room
temperature objects, so proper care must be taken to avoid any
splashing and spills while pouring the liquid nitrogen.
(d) Use the pre−cooled tongs to transfer the coupling from the storage container to
the work box. Make sure that the time during transfer does not exceed 10
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seconds.
NOTE: The Cryolive coupling is supplied with a disposable LEXAN molded
installation package. Do not remove the LEXAN installation package
from the coupling until the coupling is installed.
NOTE: To avoid coupling shrinkage while in storage, the liquid nitrogen level
in the storage container must be kept at a level above the couplings.
Any tool that touches the couplings must be pre−cooled in liquid
nitrogen. If not, the coupling will become warm and will shrink. If a
coupling shrinks before installation on a tube, the coupling must be
NOTE: If the frozen coupling touches a tube or fitting that has not been
pre−cooled with liquid nitrogen, it is possible that the coupling will
become warm and will shrink prematurely during installation. To
avoid this, all tubes and fittings that touches the couplings must be
pre−cooled with liquid nitrogen.
NOTE: The Cryolive flareless sleeve installation package is designed to
provide a specific amount of tube protrusion. To do so the tube must
be fully bottomed against the inside end of the package. Immediately
after inserting the tube, check to see that the tube is fully seated by
visually inspecting the end of the installation package. The tube end
should be visible in the slot (inspection window) and should butt
against the inside end of the package. Leave the plastic installation
package on the tube end until final installation, to protect the sleeve
and act as a dust cover.
(5) Do the steps that follow without delay:
NOTE: Tube pre−cooling is not required for Cryolive flareless sleeve installation.
(a) Remove the Cryolive coupling from the liquid nitrogen with pre−cooled tongs
and allow the excess liquid nitrogen to run off.
(b) With gloved hands, use thumb and forefinger to hold the coupling by the
installation sleeve.
(c) Put the Cryolive assembly on the tube end and push it until the tube end is
firmly seated against the end stop inside the plastic installation package.
(d) Maintain this position for at least 30 seconds or until the coupling shrinks on
the tube.
(e) Make sure that the end of the tube is seated against the end stop inside the
LEXAN installation package. If the end does not touch, the sleeve is incorrectly
installed and must be removed. (Refer to Figure 217, for the tube insertion
inspection window.)
(f) Unscrew and move the coupling nut away from the LEXAN installation
package. Open and remove the LEXAN installation package.
(6) Torque the Cryolive coupling nuts as follows:
(a) Refer to the table that follows for the corresponding installation torque for a
Master
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Cryolive coupling:
NOTE: It is recommended that the nose of the Cryolive sleeve be wiped with
a light film of system operating fluid before mating. For 921721JXX
(XX refers to the coupling size) Cryolive coupling (carbon steel nut),
it is recommended that the mating threads be lubricated with a small
amount of system operating fluid before engaging the threads.
Installation Torque for Coupling Installation Torque for Coupling
Cryolive Coupling 921721JXX (See Note) 921721WXX (See Note)
Size (−XX) (pound−inches) (N·m) (pound−inches) (N·m)
−04 135−145 15.3−16.4 135−145 15.3−16.4
−06 215−245 24.3−27.7 215−245 24.3−27.7
−08 470−510 53.1−57.6 470−510 53.1−57.6
−10 610−680 68.9−76.8 610−680 68.9−76.8
−12 NA NA 810−945 91.5−106.8
Note: −XX refers to the Cryolive Coupling Size.
Cryolive Coupling Installation Torque

Table 208
Subtask 20−22−00−780−004
C. Pressure Testing
NOTE: Whenever hydraulic components are connected, air becomes trapped in the
system and must be removed for the affected system(s) (Ref.
TASK 29−10−00−870−803).
(1) Do a pressure test of the Cryolive installation as follows:
minutes (Ref. TASK 12−00−06−863−801) or (Ref. TASK 12−00−06−863−803).
(2) If the fitting does not pass the pressure test release the pressure (Ref.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804), cut out an
appropriate length of tubing with the fitting and repeat the procedure. Install a
replacement section of tubing with a new fitting.
Subtask 20−22−00−370−004
D. Apply Protective Finish (for Aluminum tubing only)
(2) Apply primer (Ref. SRM 51−21−16) protective finish code A060 or apply the
topcoat (Ref. SRM 51−21−16) protective finish code A064 as required. The
conversion coating (Alodine) has been applied before coupling installation and does
not need to be applied again.
NOTE: Do not apply Alodine or primer to Cryolive fittings.
Master
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5. Close Out
Subtask 20−22−00−941−004
Master
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WORKBOX
(THERMALLY INSULATED
PLASTIC CONTAINER (THERMOS)
WITH LIQUID TIGHT BOTTOM
USED TO CARRY COUPLING
TO WORK AREA)
9.0 in.
(228.60 mm)
TONGS
(USED TO TRANSFER ASSEMBLIES
9.0 in. 11.0 in. TO AND FROM A WORKBOX)
(228.60 mm) (279.40 mm)
32.0 in.
(812.80 mm)
ram2022002_001.dg, kms/sw, 25/10/01
COUPLING STORAGE
CONTAINER (DEWAR)
(FOR COUPLING STORAGE)
18.0 in.
(457.20 mm)
Cryofit/Cryolive Workbox, Coupling Storage Container and Tongs

Figure 215
Master
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DRIVE SCREW
FLARELESS
TUBING

TOOL (PLUG)
ram2022002_029.dg, jp/rm, 29/10/01
Preparation of Flareless Tubing

Figure 216
Master
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COUPLING
NUT
TUBE CRYOLIVE LEXAN INSTALLATION

SLEEVE PACKAGE
TUBE INSTALLATION
TUBE END
TUBE INSERTION LEXAN

TUBE INSPECTION INSTALLATION
ram2022002_030.dg, rm, 29/10/01
WINDOW PACKAGE
TUBE INSERTION CHECK
Installation and Check of Cryolive Sleeves

Figure 217
Master
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LEXAN
COUPLING INSTALLATION
NUT PACKAGE
UNSCREW COUPLING NUT
LEXAN
COUPLING INSTALLATION
NUT PACKAGE
ram2022002_031.dg, rm, 29/10/01
OPEN AND REMOVE

LEXAN INSTALLATION PACKAGE
LEXAN Installation Package Removal

Figure 218
Master
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TASK 20−22−00−910−802
Repairs of Hydraulic and Pneumatic Tubing − Deutsch Permaswage Fittings
NOTE: The tube materials used on the CRJ−100 and CRJ−200 hydraulic systems are as
follows:
– Aluminum alloy (6061−T6), size −04 to −12, used on hydraulic return tubing and
drains
– Stainless steel (21−6−9 CRES), size −04 to −10, used on hydraulic pressure tubing
and most −04 tubing.

Subtask 20−22−00−943−002
DLTFRPSKT3001 Swaging Kit − Deutsch Permaswage
NOTE: The manufacturer’s manual supplied with your swaging kit gives specific
information for that kit. Refer to that manual for the correct selection of all the
tools necessary to complete your repair. Tools and pumps from the DM 12000
series and the DLT series Deutsch Permaswage kits are not interchangeable.
Subtask 20−22−00−944−002
13−002 Primer coating
Subtask 20−22−00−946−002
No. 2
TASK 20−21−00−910−802 Torque Procedures for Plumbing Lines
Master
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2. Job Set−Up
Subtask 20−22−00−910−004
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
TASK 12−00−06−863−802 or TASK 12−00−06−863−804).
3. Procedure
Subtask 20−22−00−910−005
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes for
Permaswage fitting installation. These procedures are for the replacement of
existing tube sections as well as for new installations on the aircraft.
(1) Prepare tubes that have small holes or cracks that extend along the tube less than
0.250 inches (6.35 mm) as follows:
(a) Cut the damaged tube at the pin hole with a chipless roller−type cutter as
follows:
1 Use the correct assembly of stem (plug) and deburring tool body.
2 Push in the tool plunger to extend the stem. Put it into the tube until the
cutters touch the end of the tube. Release the plunger to expand the stem
in the tube.
3 Push lightly on the knurled body and turn the tool against the end of the
tube. Do not deburr an excessive amount of material.
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4 Before you remove the deburring tool, prepare the surface of the tube 2
inches (50.80 mm) from the end of the tube, as follows:
mechanically, because you can cause damage to the tubes.
b Polish the tubes with a 3M Scotchbrite pad in a radial motion about its
circumference. Do not rub in a longitudinal direction.
TASK 51−26−00−110−801).
(2) Prepare tubes that have defects that extend along the tube for more than 0.250
inches (6.35 mm) as follows:
(a) Cut out the damaged section of line and prepare the tube ends as follows:
1 Make sure that there will be a minimum straight length before a bend on
either side of the cut. This will allow the Permaswage fitting to be properly
seated.
NOTE: Refer to the Permaswage instruction manual for the minimum
straight length dimension.
2 Use a chipless roller−type tube cutter to remove a minimum of 4 inches
(101.60 mm) of the damaged part of the tube.
TASK 51−26−00−110−801).
(b) Use the part of the tube that you removed as a template and make a
replacement insert tube as follows:
1 Cut the insert so that the gap at each end of the tube will be less than
0.250 inches (6.35 mm).
2 Deburr the ends of the tube and polish their surfaces with a Scotchbrite
pad.
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TASK 51−26−00−110−801).
4 Apply Alodine (Ref. TASK 51−21−11−380−801) and primer on the insert
tube except for 2 inches (50.80 mm) on each end.
B. Marking of Tubes
(1) Put the marking tool into position on the tube. Use a permanent−type marker pen to
fill in the appropriate slot and make a mark on the tube.
NOTE: Make sure that you use the correct slot in the marking tool. The
dimensions marked on the tool (in increments of one sixteenth of an inch)
are applicable to the diameter of the tube. For example, use the slot
marked 03 for a 3/16 in. diameter tube. Mark the tube over the full length
of the slot.
NOTE: If you replace the marker pen that comes with the Permaswage kit, make
sure the new pen contains no chlorine.
(2) Make two more marks, evenly−spaced, around the circumference of the tube.
These marks will help you to put the Permaswage fitting into the correct position
before you swage the connection.
C. Preparation of Swaging Tools
NOTE: Refer to the applicable Permaswage manual for the swaging tools required for
this procedure.
(1) Do a visual inspection of the swaging tools as follows:
– Make sure that the serial numbers on the upper and lower die segments are
identical.
– Make sure that each die segment is installed in the die block so that the
chamfered end of the segment is against the end plate.
– Make sure that there is no foreign matter on the swaging tools, especially
between the die segments and their blocks.
– Make sure that all the swaging tools that you use are from the same part
number kit.
NOTE: Keep the hydraulic power unit, the swaging tool and all accessories clean.
Repair or replace worn or damaged parts immediately.
NOTE: Written authorization and instructions from the manufacturer are
necessary for any modification to these tools.
(2) Align and install the lower die block into the swage head yoke so that the die
segments face each other.
(3) If you use the DM 12000 tool kit, make sure that the upper and lower end plates
face each other correctly.
(4) Align and install the swage head yoke on the power unit.
(5) Connect the hydraulic pressure hose to the power unit and to the hydraulic power
supply.
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D. Operation of Hydraulic Power Supply
CAUTION: MAKE SURE THAT ALL THE PERMASWAGE COMPONENTS ARE
CORRECTLY ASSEMBLED INTO THE SWAGE HEAD YOKE BEFORE
YOU OPERATE THE HYDRAULIC POWER SUPPLY. IF THIS IS NOT
DONE, DAMAGE TO THE COMPONENTS AND TO THE AIRCRAFT
STRUCTURE AND SYSTEMS CAN OCCUR.
(1) Follow the manufacturer’s instructions to prepare the hydraulic pump for the
swaging operation.
NOTE: The full swaging pressure is 10000 psi ± 250 psi for the DLT series kit.
Use the manufacturer’s recommended swaging pressure for any other
Permaswage kit.
E. Preparation of Fittings
(1) Keep the new Permaswage fittings in their protective packages until required for the
installation.
NOTE: Permaswage fittings are Teflon lubricated. Do not clean them chemically.
(2) Deutsch Permaswage fittings − D10036 unions are recommended for use with
replacement insert tubes or similar repairs.
NOTE: Refer to the Permaswage kit manual for the applicable fitting size and
type of material.
F. Assembly of Permaswage Fitting to Tubing
(1) Make sure that the tubes have been prepared for the Permaswage fitting.
(2) Put the fitting on one tube end, align the other tube, and move the fitting into
position on the tubes so that it is between the installation marks.
NOTE: The fitting must move freely over the tube ends. If it does not, repair or
replace the applicable tube assembly.
G. Installation of Tube/Fitting in the Swage Tool Assembly
(1) Obey all the hydraulic safety precautions (Ref. TASK 29−00−00−910−801).
(2) Remove the swage head yoke from the swage tool assembly and put the swage
head yoke into position over the fitting. Make sure that the end plate on the swage
tool assembly faces the end of the fitting .
NOTE: If you cannot insert the fitting and the tube into the swaging tool, remove
the swage head yoke from the assembly. Assemble the yoke over the
fitting again and lock the yoke into place.
(3) Move the swage tool against the fitting until the end plates lightly contact the end of
the fitting .
(4) (DM 12000 series kit only.) To make allowance for the increase in fitting length
during swaging, move the swage head assembly away from the fitting
approximately 0.030 inch (0.76 mm).
NOTE: The upper and lower end plates on the DM 12000 series tool are made of
metal. These plates are attached to the tool with small screws. When the
fitting is swaged, it can expand in length and break the heads off the end
plate screws. The end plates on the DLT series tool are made of
nonmetallic material that can expand during the swage process.
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H. Swaging the Fitting
(1) Operate the swage pump until you have the maximum hydraulic pressure.
NOTE: The full swaging pressure is 10000 psi ± 250 psi for the DLT series kit.
Use the manufacturer’s recommended swaging pressure for any other
Permaswage kit.
(2) Release the hydraulic pressure from the swage pump.
(3) Remove the swaged fitting from the tool and do a dimensional and visual inspection
of the swage.
I. Dimensional Inspection
(1) Refer to the Permaswage kit manual for the applicable GO/NO−GO gauge
(inspection gauge) for the swaged tube size.
(2) Put the GO/NO−GO gauge on the fitting and make sure that the outside diameter of
the fitting is correct. Make sure that the swaged part of the fitting has a sufficient
length. You must be able to see the die marks on the fitting past the end of the
inspection gauge.
(3) Make sure that the shoulder of the gauge is against the end of the fitting. so that the
swage diameter can be examined at the correct location.
(4) Fittings that do not pass the dimensional inspection must be rejected. Find the
cause of the defective fitting before you swage again.
(5) The die segments make longitudinal ridges on the swaged fitting. Do the
dimensional inspection of the outside diameter of the fitting in the area between the
ridges.
(6) Reject the swaging tool if you think it is responsible for the defective fittings.
(7) Do not swage the other end of the fitting until the first swage has passed the
GO/NO GO check
(8) It is possible to swage a fitting that is too large a second time. Before swaging the
fitting again, make sure that there is no foreign matter between the die segments.
Make sure that the power unit hydraulic pressure is correct. Swage the fitting again
once only at ninety degrees to the original position of the swage head assembly.
J. Visual Inspection
(1) Examine the swaged fitting and adjacent tube area for signs of cracks, dents, folds
or gouges.
(2) Make sure you can see part of the installation mark on the tube at the end of the
fitting. If you can see all of the mark, or if the mark is not visible, the swaged joint
must be rejected.
K. Final Installation
(1) If you used a threaded fitting, torque the fitting (Ref. TASK 20−21−00−910−802).
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Subtask 20−22−00−780−002
L. Pressure Testing
NOTE: If a repair is done to the hydraulic system, bleed the applicable system (Ref.
TASK 29−10−00−870−801, TASK 29−10−00−870−802 or
TASK 29−10−00−870−803).
(1) Do a pressure test of the Permaswage installation as follows:
minutes (Ref. TASK 12−00−06−863−801 or TASK 12−00−06−863−803).
(2) If you find leaks, do the steps that follow:
(a) Depressurize the applicable system (Ref. TASK 12−00−06−863−802 or
TASK 12−00−06−863−804).
(b) Swage the fitting again, at right angles to the first swage. Make sure that you
use the correct swage tool assembly.
NOTE: The maximum recommended number of swages on the same fitting
is 4.
(c) Do the pressure test again.
(3) If the fitting does not pass the pressure test, cut out that part of the tube and the
fitting. Install a replacement piece of tube with two new fittings.
Subtask 20−22−00−370−002
M. Apply Alodine and Primer
(2) On exposed aluminum tubing, apply Alodine (Ref. TASK 51−21−11−380−801) and
primer where necessary.
NOTE: Do not apply Alodine or primer to Permaswage fittings.
4. Close Out
Subtask 20−22−00−941−002
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0.250 ± 0.050 in.

(6.35 ± 1.27 mm)

SMALL DEFECTS IN
A
LINE SECTIONS

DEFECT LARGER THAN

MANUFACTURER’S
MANUAL FOR THIS
ram2022002_015.dg, jp/ds, 12/11/03
LARGE DEFECTS IN
B
LINE SECTIONS

Figure 219
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DRIVE SCREW

TOOL (PLUG)
ram2022002_016.dg, jp, 01/09/95
Figure 220
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MARKING MARKING
SLOT TOOL
−4
−6
END OF TOOL
TOUCHES END INSTALLATION
OF TUBE MARK
A MARKING TOOL
INSTALLATION MARKS ON TUBES

B
WITH SMALL DEFECTS
SPLICE SECTION
ram2022002_017.dg, jp, 01/09/95
INSTALLATION MARKS ON TUBES

C
WITH LARGE DEFECTS
Permaswage Repair − Marking of Tubes

Figure 221
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UPPER OUTBOARD
END PLATE
SWAGED
FITTING
FITTING END ON CENTER

OF INSTALLATION MARK
LOWER OUTBOARD
END PLATE
LOCATION OF TUBE AND FITTING IN INSTALLATION

A MARKS
THE SWAGE TOOL ASSEMBLY
PERMASWAGE REPAIR OF
B SMALL DEFECT
SPLICE
SECTION ram202200_022.dg, ds, 03/12/03
INSTALLATION
MARKS
C PERMASWAGE REPAIR OF LARGE DEFECT
Permaswage Repair − Swaging of Fittings

Figure 222
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ACCEPT REJECT
MARK IS MARK IS
PARTIALLY NOT
VISIBLE VISIBLE
MARK IS MARK IS
PARTIALLY TOTALLY
VISIBLE VISIBLE
A VISUAL INSPECTION OF SWAGED FITTINGS
SHOULDER OF GAUGE MUST

TOUCH END OF FITTING
PERMASWAGE INSPECTION
(GO/NO GO) GAUGE
YOU MUST BE ABLE

TO SEE DIE MARKS PAST
THE END OF THE GAGE
ram2022002_021.dg, jp/ds, 12/11/03
B DIMENSIONAL INSPECTION OF SWAGED FITTINGS
Permaswage Repair − Inspection of Swaged Fittings

Figure 223
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TASK 20−22−00−910−803
Repairs of Hydraulic and Pneumatic Tubing − Harrison "H" Fittings
NOTE: Because of the increased weight of "H" fittings, the data that follows is for temporary
repairs only. You must replace the repaired tubing with a new item after a maximum of
500 flight hours.
This type of repair is not permitted on hydraulic lines installed in the locations that follow:
– Outboard of the engine firewall
– On landing gear
– In fuel tanks.
The clearance between the "H" fitting and the adjacent tubing, equipment or structure
must be 0.125 in. (3.17 mm) minimum. Refer to TASK 20−22−01−220−801 for other
clearances.

Subtask 20−22−00−943−003
None specified Chipless (roller−type) tube cutter
None specified Deburring tool
None specified Applicable Harrison "H" Fittings
5175K19 Swager Kit − (Harrison). The kit includes specific
fittings, tube lengths, a tube cutter, a deburring tool,
an installation template, and installation
instructions.
Subtask 20−22−00−944−003
05−011 Tape, masking
None specified Permanent−type marking pen (Sharpie)
Subtask 20−22−00−946−003
No. 2
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TASK 51−21−11−380−801 Alodine Solution Treatment
TASK 51−26−00−110−801 Solvent Cleaning
2. Job Set−Up
Subtask 20−22−00−910−006
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
TASK 12−00−06−863−802) or (Ref. TASK 12−00−06−863−804).
3. Procedure
Subtask 20−22−00−910−007
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes for the
installation of Harrison "H" fittings. These procedures are for the replacement
of existing tube sections as well as for new installations on the aircraft.
(1) Prepare tubes that have small defects (pinholes, less than 0.250 inches (6.35 mm))
in line sections as follows:
(a) Cut the damaged line section at the pin hole with a chipless roller−type cutter
as follows:
Master
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the tube.
TASK 51−26−00−110−801).
(2) Prepare tubes that have large defects (greater than 0.250 inches (6.35 mm)) in line
sections as follows:
Refer to Figure 207 and Figure 208 .
(a) Cut out the damaged section of line and prepare the tube ends as follows:
1 Make sure that there will be a minimum straight section of 1.25 inches
(31.75 mm) on either side of the cut (this will allow the Harrison "H" fitting
to be properly seated).
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2 Use a chipless roller−type tube cutter to remove the section of tubing (a
minimum of 4 inches (101.60 mm)) with the defect.
TASK 51−26−00−110−801).
(b) Use the cutout section as a template and make an appropriate replacement
(splice) tube section as follows:
1 Cut a splice tube so that the gap at either end will be less than 0.250
inches (6.35 mm).
2 deburr the ends of the tube and polish their surfaces with a Scotchbrite
pad.
TASK 51−26−00−110−801).
4 Apply Alodine (Ref. TASK 51−21−11−380−801) and primer on the splice
tube except for 2 inches (50.80 mm) on each end.
Subtask 20−22−00−910−008
B. Marking of Tubes
(1) Mark the tubes as follows:
(a) Put the tubes into position so that the gap between their ends is a maximum
of 0.250 inches (6.35 mm).
(b) Put the installation template in position adjacent to the tubes so that the arrow
on the template is aligned with the center of the gap between the two tube
sections.
(c) Apply a strip of masking tape opposite to the shaded area on the template, to
one end of the tube.
(d) Use a permanent−type marking pen to make a mark on the other tube that is
adjacent to the dot on the template.
Subtask 20−22−00−550−001
C. Storage of Fittings
(1) Keep Harrison "H" fitting components in their protective packages or in the fitting
repair kit until they are required for installation.
Subtask 20−22−00−910−009
D. Assembly of Harrison "H" Fitting Components on to the Tube
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(1) Make sure that the tubes have been prepared for the Harrison "H" fitting.
(2) Install the components as follows:
(a) Put the nut and the slide onto the end of the tube that has the masking tape.
Make sure that you install the nut so that the wrench flats are away from the
tube end.
(b) Put the coupling and the union onto the other tube. Make sure that you install
the coupling so that the wrench flats are near the tube end.
(c) Align the tube sections and move the union into position so that it gently
touches the masking tape.
NOTE: The union must move freely over the tube ends. If it does not, repair
or replace the applicable tube assembly.
(d) With the union against the masking tape, engage the nut and the coupling by
hand. Use the appropriate wrenches to hold the coupling and to turn the nut.
Tighten the assembly (Ref. TASK 20−21−00−910−802) until there is a large
increase in torque and approximately half of the installation mark can be seen.
Subtask 20−22−00−210−001
E. Visual Inspection
(1) When approximately half of the installation mark can be seen on the tube, do a
visual inspection of the completed joint as follows:
(a) Hold the coupling with a wrench, loosen the nut, and move it away from the
union.
(b) Make sure that the slide and the coupling are completely engaged against the
shoulder of the union.
(c) Make sure that the union touches the masking tape.
(d)
Make sure that approximately half of the installation mark can be seen.
NOTE: If you do not get these results, assemble the nut to the coupling
again, tighten the assembly again until there is a large increase in
torque and approximately half of the installation mark can be seen,
and do this visual inspection again.
NOTE: If the completed joint is still not satisfactory, remove and discard the
section of tubing with the repair fitting and install a new section of
tubing with another Harrison "H" repair fitting.
(2) If the visual inspection is satisfactory, tighten the nut and coupling again to the
manufacturers’ specified torque to complete the installation.
Subtask 20−22−00−780−003
F. Pressure Testing
NOTE: If a repair is done to the hydraulic system, bleed the applicable system(s) (Ref.
TASK 29−10−00−870−803).
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(1) Do a pressure test of the Harrison "H" installation as follows:
minutes.
NOTE: Pressurize the hydraulic system (Ref. TASK 12−00−06−863−801) or
(Ref. TASK 12−00−06−863−803).
(2) If you find leaks, do the steps that follow:
(a) Depressurize the applicable system(s) (Ref. TASK 12−00−06−863−802) or
(Ref. TASK 12−00−06−863−804).
(b) Loosen the nut and the coupling.
(c) Tighten the nut and coupling again to the manufacturers’ specified torque and
do this pressure test again.
(3) If the fitting does not pass the pressure test, cut out an appropriate length of tubing
and the fitting. Install a replacement section of tubing with two new fittings.
Subtask 20−22−00−370−003
G. Apply Alodine and Primer
(2) Apply Alodine (Ref. TASK 51−21−11−380−801) and primer to the exposed
aluminum tubing where necessary.
NOTE: Do not apply Alodine or primer to Harrison "H" fittings.
4. Close Out
Subtask 20−22−00−941−003
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0.250 ± 0.050 in.

(6.35 ± 1.27 mm)

SMALL DEFECTS IN
A
LINE SECTIONS

DEFECT LARGER THAN

MANUFACTURER’S
MANUAL FOR THIS
ram2022002_015.dg, jp/ds, 12/11/03
LARGE DEFECTS IN
B
LINE SECTIONS

Figure 224
Master
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DRIVE SCREW

TOOL (PLUG)
ram2022002_016.dg, jp, 01/09/95
Figure 225
Master
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PERMANENT
MASKING MARKING
TAPE PEN
0.250 IN. MAX
CENTER ARROW BETWEEN

ENDS OF TUBING TO BE
SPLICED
LOCATE POSITIONING
Positioning
TAPE TO THE LINE
Template
MARKING DOT MUST

BE VISIBLE AFTER
TIGHTENING
SHADED AREA
ARROW INSTALLATION
(POINTS TO THE CENTER (POSITIONING)
OF GAP IN TUBES) TEMPLATE
ram2022002_023.dg, sw, 31/08/95
Harrison "H" Repair − Marking of the Tubing

Figure 226
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INSTALLATION
MARK
NUT TAPE
SLIDE
UNION COUPLING
ram2022002_024.dg, sw, 31/08/95
Harrison "H" Repair − Assembly of the Fittings on the Tubes

Figure 227
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NUT
COUPLING
INSTALLATION MARK
(Visible when fitting is correctly installed)
ram2022002_025.dg, rt, 25/10/95
Harrison "H" Repair − Installation of the Fitting

Figure 228
Master
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SLIDE AND COUPLING

ARE COMPLETELY ENGAGED
NUT SLIDE AGAINST THE SHOULDER
OF UNION
COUPLING
CENTER OF UNION
UNION ONE HALF OF THE
TOUCHES TAPE INSTALLATION MARK
IS VISIBLE
A INSPECTION OF COMPLETED JOINT
TAPE
COUPLING
SLIDE UNION NUT INSTALLATION
MARK
B CROSS SECTION OF FITTING BEFORE INSTALLATION
TAPE
ram2022002_026.dg, sw, 01/09/95
COUPLING
INSTALLATION
SLIDE UNION NUT MARK
C CROSS SECTION OF FITTING AFTER INSTALLATION
Harrison "H" Repair − Inspection of the Completed Joint

Figure 229
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TASK 20−22−00−910−805
Repair of Plumbing Lines − Flareless Fittings (MS 21922 Sleeves and MS 21921 Nuts)
NOTE: Use MS 21922 flareless sleeves when the use of Sierracin/Harrison HMS flareless
sleeves are not possible. It is preferred to use Sierracin/Harrison HMS sleeves over MS
21922 type sleeves. Sierracin/Harrison HMS sleeves are more resistant to overtorquing
and are less prone to leakage while MS 21922 type sleeves do not require special
installation and inspection tools for some tube materials.

Subtask 20−22−00−943−005
None specified Weatherhead No. MT−10044 (for tube dia. up to
3/4 in. (19.05 mm) (−12)
None specified MS 21922 Sleeve, and MS 21921 Nut
Subtask 20−22−00−944−005
06−002 Petrolatum, (petroleum jelly) technical, soft
Subtask 20−22−00−946−005
No. 2
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2. Job Set−Up
Subtask 20−22−00−910−013
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
A. If repairs are to be made on the hydraulic system, release the hydraulic pressure from
the applicable system(s) (Ref. TASK 12−00−06−863−802) or (Ref.
TASK 12−00−06−863−804).
3. Procedure
Subtask 20−22−00−910−014
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes to preset the
bite type MS 21922 coupling sleeve. These procedures are for the
replacement of existing tube sections as well as for new installations on the
aircraft.
NOTE: Tube ends shall be cut square within 0.5° maximum.
the tube.
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NOTE: The chamfer on either the outside or inside corner shall not
exceed 25% of the thickness of the tube wall.
TASK 51−26−00−110−801).
B. Presetting the Bite Type Sleeve
NOTE: The procedures that follow must be done prior to assembly. The sleeve (MS
21922) may be preset by machine or manually on aluminum, 304 1/8H CRES,
21−6−9 CRES, or annealed CRES tubing.
(1) Machine Preset
NOTE: The machine will preset sleeves up to tube diameters of 3/4 in. (19.05
mm) (or −12). Tubing larger than this will be preset manually.
(a) The machine (Weatherhead No. MT−10044) used to preset sleeves shall have
a pressure reservoir to compensate for the pressure fluctuation.
(b) The pressure gauges used to indicate the preset pressure will be of such size
and range to allow the pressure to be read easily and accurately to ±1psi.
(c) Use the appropriate dies for the sleeve size to be preset on the tube.
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(d) Use machine preset forces recommended by the manufacturer and/or
sufficient to produce a satisfactory preset.
(e) The sleeve and working surfaces of the tooling shall be lubricated with the
approved system lubricant Refer to Table 212.
(2) Manual Preset
(a) Use either a hardened steel hand tool with one end machined identical to a
standard male fitting, or a flareless fitting to preset the sleeve manually.
(b) Place the tool in a vise and apply a thin coat of thread compound, to the
threads and angular internal seat of the tool, and to the back of the sleeve
shoulder Refer to Table 212.
NOTE: If the flareless fitting threads and fitting sealing surface (24° cone)
have solid film lubricant, do not lubricate with system fluid.
NOTE: On hydraulic lines, the thread compound will be the hydraulic oil
used in the hydraulic line to be installed.
Application Appropriate Lubricant
Engine Fuel System Fluid
Engine Lubricant (Phosphate Base) System Fluid
Hydraulic (Phosphate Base) System Fluid
Oxygen None
Pneumatic MIL−G−4343 Grease
Water VV−P−236 Petrolatum
Thread Lubricant Selection

Table 212
(c) Hold the tubing firm and square on the seat of the tool and slowly turn the nut
with a wrench until the cutting edge of the sleeve grips the tube sufficiently to
prevent rotation of the tube by the thumb and fingers (also known as ring grip).
(d) Preset the sleeve by turning the coupling nut to a specified number of turns
past the point of ring grip, Refer to Table 213 , Table 214 and Table 215 as
applicable.
NOTE: The wrench movement required can be judged by the hexagon of
the nut (i.e. each flat of the hexagon is equal to 1/6 turn).
Tube 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000 1.250 1.500
Size
No. of 1 1/6 1 1/6 1 1 5/6 5/6 2/3 2/3 2/3 2/3 2/3
Turns
Number of Turns to Preset Flareless Sleeves with Mandrels

Table 213
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304 1/8H CRES, 21−6−9 CRES Tubing

Tube Tube Tube Tube Tube Tube Tube Tube Tube
Wall Size Size Size Size Size Size Size Size Size
Thickness 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000
0.012 1 1/6
0.018 1 1/6 1 1/6 1 1/6 1 1/6
0.020 1 1/6 1 1/6 1 1/6 1 1/6 [1]
0.022 1 1/6 1 1/6 1 1/6 1 1/6 1 1/6
0.025 1 1/6 1 1/6 1 1/6 1 1/6 1 1/6 [1] [1]
0.028 1 1/6 1 1/6 1 1 1/6 1 1 1/6 1 1/6 [1]
0.035 1 1/6 1 1 1 1/6 1 1/6 1 1/6 [1]
0.042 1 1 1 1 1/6 1 1/6 1 1/6
0.049 1 5/6 1 1 1 1 1/6
0.058 5/6 1 5/6 1
0.065 5/6 5/6 5/6 1
0.072 5/6 5/6
0.083 5/6
[1] − Use mandrel for this size and thinner wall tubing.
Number of Turns to Preset Flareless Sleeves without Mandrels

Table 214
Aluminum Alloy and Annealed CRES Tubing

Thickness 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000
0.018 1 1/6 1 1/6
0.020 1 1/6 1 1/6
0.022 1 1/6 1 1/6 [1]
0.025 1 1/6 1 1/6 1 1/6 [1]
0.028 1 1/6 1 1/6 1 1/6 1 1/6 [1] [1]
0.035 1 1 1/6 1 1/6 1 1/6 1 1/6 [1] [1]
0.042 1 1 1/6 1 1/6 1 1/6 1 1/6 [1]
0.049 1 1 1 1 1/6 1 1/6 1 1/6
0.058 1 5/6 1 1 1 1 1/6
0.065 5/6 5/6 1 1 1 1/6
0.072 5/6 1
0.083 5/6 5/6
0.095 5/6

Table 215
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Aluminum Alloy and Annealed CRES Tubing

Thickness 0.125 0.188 0.250 0.312 0.375 0.500 0.625 0.750 1.000
[1] − Use mandrel for this size and thinner wall tubing.

Table 215
(e) The sleeve is now preset, and after backing off the tool, the tube and sleeve
are ready for final assembly or installation.
(3) Inspection of Preset Sleeves
(a) Longitudinal movement of the sleeve is allowed, but shall not exceed 0.020 in.
(0.51 mm).
NOTE: After the sleeve is preset, it may or may not rotate on the tube.
(b) Check for scratches, nicks, dents, foreign material etc. on the sealing surfaces
of the coupling.
(4) Final Assembly of Plumbing Lines with MS 21922 Sleeves and MS 21921 Nuts
(a) Apply a thin coat of thread compound to the threads of the male fitting and to
the back of the sleeve shoulder Refer to Table 212.
NOTE: On hydraulic lines, the thread compound shall be the hydraulic oil
used in the hydraulic line to be installed.
(b) Place the tube assembly with preset sleeve in the installed position and align
the sleeve to meet the fitting squarely and fully.
NOTE: Never use the nut to draw the sleeve into the fitting.
(c) Turn the nut onto the male fitting using a wrench under very light pressure,
until a sudden rise in the resistance. Place a second wrench on the fitting to
prevent it from turning.
(d) From the point of resistance the nut can be tightened either by the torque
method or the nut turn method as follows:
1 Torque Method
a From the point of resistance tighten the nut with a torque wrench (Ref.
TASK 20−21−00−910−802).
2 Nut Turn Method
a From the point of resistance, tighten the nut with a standard open end
wrench an additional 1/6 to 1/3 turn.
NOTE: The wrench movement required can be judged by the
hexagon of the nut (i.e. each flat of the hexagon equals to 1/6
turn).
NOTE: Do not exceed 1/3 turn total tightening beyond the point of
resistance
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(5) Pressure Testing
NOTE: If a repair is done to the hydraulic system, bleed the applicable system(s)
(Ref. TASK 29−10−00−870−801), (Ref. TASK 29−10−00−870−802) or
(Ref. TASK 29−10−00−870−803).
(a) Do a pressure test of the installation as follows:
1 Pressurize the applicable system and hold the pressure for a minimum of
15 minutes.
NOTE: Pressurize the hydraulic system (Ref.
TASK 12−00−06−863−801) or (Ref. TASK 12−00−06−863−803).
2 Check the hydraulic system fitting−to−tube interface with a white cloth for
signs of hydraulic fluid leaks.
3 Do a visual inspection of the fitting−to tube interface for hydraulic fluid
leaks.
(b) If the connection leaks, do the steps that follow:
1 Loosen the coupling nut and remove the tube end from the fitting.
2 Inspect the seal areas of the sleeve and mating fitting for scratches, nicks,
dents, foreign material etc..
3 Reassemble the connection with new parts if necessary.
4 Tighten the connection with the method of choice.
5 Check the installation again for leaks.
Subtask 20−22−00−370−005
C. Apply Alodine and Primer
(2) Apply Alodine (Ref. TASK 51−21−11−380−801) and primer to the exposed
aluminum tubing where necessary.
NOTE: Do not apply Alodine or primer to the MS 21922/21921 fittings.
4. Close Out
Subtask 20−22−00−941−005
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DRIVE SCREW

TOOL (PLUG)
ram2022002_016.dg, jp, 01/09/95
Figure 230
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CHAMFER
0.002 in. Min. CHAMFER
0.006 in. Max. OVER 0.006 in.
RADIUS RADIUS
CORRECT INCORRECT INCORRECT
CUTTING OF TUBE ENDS
OUTSIDE OF TUBE
INSIDE OF TUBE
HEAVY CHAMFER ON INSIDE PRESET DIE

OF TUBE END, TO CLEAR
RAISED RING ON PRESET
DIE SEAT
PRESET
DIE SEAT RAISED RING
CHAMFER PER FIGURE 1

ram2022012_006.dg, rt, 15/08/01
CL APPROX. 0.020 in.

WIDE FLAT ON TUBE END
INSIDE CHAMFERING OF THICK WALLED TUBES
Cutting of Tube Ends

Figure 231
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NUT
MS21921
SLEEVE
MS21922 TUBE
SHOULDER OF
SLEEVE
BITE TYPE FLARELESS SLEEVE

TUBE ASSEMBLY
LIP OF TUBE
SEALING SURFACE
MATERIAL RAISED
OF SLEEVE
UNDER PILOT
LIP OF
SLEEVE
0.002 in. min.

(0.051 mm)
CUTTING EDGE
OF SLEEVE
ram2022012_007.dg, sw/kms, 25/01/02
TYPICAL TUBE CUT PRODUCED BY

BITE TYPE SLEEVE
Preset Assembly
Figure 232
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TASK 20−22−00−910−806
Repair of Plumbing Lines − Sierracin/Harrison HMS Flareless Sleeves and Unions
NOTE: It is preferred to use Sierracin/Harrison HMS sleeves over MS 21922 type sleeves.
Sierracin/Harrison HMS sleeves are more resistant to overtorquing and are less prone to
leakage while MS 21922 type sleeves do not require special installation and inspection
tools for some tube materials.

Subtask 20−22−00−943−006
None specified Sierracin/Harrison Portable Hand Swager Model
5175 (HMS 35235 sleeve) for tube dia. 0.25 in. to
0.50 in.
5720 (HMS 35235 sleeve) for tube dia. 0.65 in. to
1.50 in.
1777 (HMS 35211 sleeve) for all tube dia.
None specified Sierracin/Harrison HMS 35235 Sleeve and 35066
Union − sizes (−04 to −16)
None specified Sierracin/Harrison HMS 35211 Sleeve and 35312
Union/35230 Bulkhead Union − sizes (−04 to −16)
None specified Tube Micrometer (Intertest)
Subtask 20−22−00−944−006
04−005 Grease, MIL−G−23827
06−002 Petrolatum, (petroleum jelly) technical, soft
08−025 Retaining compound, single, component, anaerobic
Subtask 20−22−00−946−006
No. 2
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2. Job Set−Up
Subtask 20−22−00−910−017
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
A. If repairs are to be made on the hydraulic system, release the hydraulic pressure from
the applicable system(s) (Ref. TASK 12−00−06−863−802) or (Ref.
TASK 12−00−06−863−804).
3. Procedure
Subtask 20−22−00−910−018
A. Tube Preparation
NOTE: The steps that follow give the procedures to prepare the tubes, to swage HMS
35211, 35235 sleeves and HMS 35066, 35212 and 35230 unions. These
procedures are for the replacement of existing tube sections as well as for new
installations on the aircraft.
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NOTE: Tube ends shall be cut square within 1° maximum.
NOTE: If necessary determine the straight tube length before the bend (refer
to Figure 236).
the tube.
NOTE: Do not chamfer the outer edge, break the sharp outer edge and
chamfer the inner edge accordingly .
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6 Verify that the tube ends meet, and rework tube if required (refer toFigure
234).
(c) Solvent clean the unions, sleeves and tube surfaces to remove dust and chips
(Ref. TASK 51−26−00−110−801).
NOTE: Do not apply alodine to the cadmium plated sleeves and unions.
B. Swaging the Sierrracin/Harrison HMS Fitting
(1) Choose the applicable sleeve and union according to the plumbing line material as
follows:
— Plumbing line material shall conform with Table 216.
— Passivated sleeves and unions shall be used with 21−6−9 CRES, 321 CRES,
and 304−1/8H CRES type tubing.
— Cadmium plated sleeves and unions shall be used with 6061−T6 and 5052−O
aluminum alloy tubing.
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TUBE MATERIAL PART NUMBER MATERIAL CHEMICAL FINISH

21−6−9 CRES, 35235V04
AMS 5561 thru −16
304−1/8H CRES 35044V20 Passivated
thru −24 (QQ−P−35)
MIL−T−6845 35055V04
thru −24
Aluminum Alloy − 35235VN04
6061−T6 thru −16
CMS 517−01 35044VN20
Cadmium Plated
thru −24
(QQ−P−416)
Aluminum Alloy −
35066VN04
5052−O
thru −24
WW−T−700/4 CRES 15−5PH
304−1/8H CRES 35211V04 AMS5659
thru −16
MIL−T−6845 35212V04 Passivated
thru −16 (QQ−P−35)
321 CRES, 35230V04
AMS 5570 thru −16
Aluminum Alloy − 35211V04
6061−T6 thru −16
CMS 517−01 35212V04
Cadmium Plated
thru −16
(QQ−P−416)
Aluminum Alloy −
35230V04
5052−O
thru −16
WW−T−700/4
Plumbing Lines and Fittings

Table 216
(2) Prepare union(s) and tubing for swaging as follows:
NOTE: The following procedure is for the HMS 35066 union only.
(a) Apply 13−002 primer to the swage area on the tube end and the inside surface
of the union. Drain off the excess primer and allow to dry for a minimum of 15
minutes.
NOTE: Do not allow 13−002 primer to enter the bore of the tube.
Contamination of the bore is cause for rejection.
(b) Refer to Figure 235.
Apply a drop of 08−025 anaerobic retaining compound to the applicable area
on the tube. Slide the union onto the tube with a rotating motion so the entire
area covered by the union is coated with the 08−025 compound. Bottom the
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C
tube into the union and remove the excess 08−025 compound.
NOTE: Do not allow the 08−025 anaerobic retaining compound to enter the
bore of the tube. Contamination of the bore is cause for rejection.
(c) Before 30 minutes elapse, swage the union.
(d) Allow one hour minimum for the 08−025 anaerobic retaining compound to cure
before pressure testing or degreasing the tubes.
(3) Select the applicable swaging tool approved for the diameter and thickness of the
tubing material.
(4) Swaging machines, swaging pressures and swaging torque shall be in accordance
to manufacturers’ instructions.
NOTE: All mating surfaces shall be clean and free from foreign objects, scratches
and lubricants.
WARNING: DO NOT EXCEED THE CORRECT SWAGING PRESSURE.
EXCESSIVE PRESSURE COULD CAUSE DRAWBOLT FAILURE WITH
A CONSEQUENT RISK OF PERSONAL INJURY. NEVER STAND IN
DIRECT LINE WITH THE DRAWBOLT.
(5) For pressure swaging, the external diameter of the expander, seal rings and
bushing shall be lightly lubricated with 04−005 grease.
(6) For roller swaging, apply abundant coating of 04−005 grease to the rollers before
each swage, or as recommended per the manufacturers’ instructions.
(7) The anvil, retaining ring and split dies, jaws, retainer and expander shall be
maintained in a clean condition and shall seat easily over the fitting.
(8) The tube end and fitting shall be correctly located against their respective stops in
the anvil before the external tooling is applied.
C. Visual Inspection
(1) Do a visual inspection for all processes as follows:
(a) The internal diameter of the tube shall be visually examined to ensure that
there is proper expansion of the tube into the fitting grooves.
(b) The groove pattern shall be clearly defined, the second depression from the
tube end being the deeper. If the depressions are shallow and the groove
pattern is not clearly defined, insufficient swage pressure has been used.
(c) If the depressions are sharp edged, excessive pressure has been applied and
the fitting shall be rejected.
(d) Die marks on the outside diameters of the fittings shall not exceed 0.002
inches (0.051 mm) in height or cause interference with the nut.
(e) Score and burnish marks on the internal diameter of the tube are acceptable
provided their depth is less than 10% of the nominal wall thickness of the tube.
All other marks shall be cause for rejection.
(f) All outside diameters shall be inspected for cracks. Evidence of cracking shall
be cause for rejection.
(2) Do these additional inspection steps for roller swaging as follows:
(a) Tube inner surfaces at the swaged area shall be free from scratches or marks
due to defective rollers.
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(b) The following is not cause for rejection:
1 At the extreme end of the rolled area, helical extrusion marks can be
sometimes seen with the naked eye. These radial marks result from the
first revolution of the rollers and the subsequent growth of the tube wall.
2 The rotating cage may rub the tube internally at the rear of the rolled area.
This results in a polished surface and a slight extrusion may occur at the
end of the cage slots to produce a rough edge.
NOTE: The edge should be broken with a fine file and polished slightly.
D. Dimensional Inspection
(1) After swaging, do a dimensional inspection of the HMS 35211 sleeves, HMS 35212
unions, or HMS 35230 bulkhead union as follows:
(a) The inside diameter (I.D.) of the swaged joint shall be measured with a tube
micrometer (Interest type) to determine if the swage is adequate.
NOTE: Do not scratch the tube I.D. by pulling the expander micrometer
feelers out of the tube. If required, take the measurements at two
places, 90° apart.
(b) The values obtained shall be in accordance with the following, Refer to Table
217.
TUBE O.D. TUBE WALL TUBE MATERIAL I.D. AFTER SWAGE − in.
(in.) THICKNESS − in. (mm)
(mm)
−04 (1/4) 0.020 0.220−0.227
(0.508) (5.588−5.766)
−04 (1/4) 0.028 0.206−0.211
304 1/8H CRES
(0.711) (5.232−5.359)
−08 (1/2) 0.035 0.441−0.449
(0.889) (11.201−11.405)
−04 (1/4) 0.028 21−6−9 CRES 0.206−0.211
(0.711) (5.232−5.359)
−06 (3/8) 0.028 5052−O 0.332−0.339
(0.711) (8.433−8.631)
−10 (5/8) 0.028 0.581−0.586
(0.711) (14.757−14.884)
321 CRES
−12 (3/4) 0.035 0.694−0.702
(0.889) (17.628−17.831)
After Swage Dimensions for HMS 35211 Sleeves, HMS 35212 Unions, and HMS 35230 Bulkhead
Unions
Table 217
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TUBE O.D. TUBE WALL TUBE MATERIAL I.D. AFTER SWAGE − in.
(in.) THICKNESS − in. (mm)
(mm)
−04 (1/4) 0.028 0.206−0.211
(0.711) (5.232−5.359)
−04 (1/4) 0.035 0.190−0.197
(0.889) (4.826−5.004)
−06 (3/8) 0.028 0.332−0.339
(0.711) (8.433−8.631)
−06 (3/8) 0.035 0.317−0.323
(0.889) (8.052−8.204)
−08 (1/2) 0.035 0.445−0.450
6061−T6
(0.889) (11.303−11.430)
−10 (5/8) 0.035 0.573−0.579
(0.889) (14.554−14.707)
0.035 0.693−0.699
(0.889) (17.602−17.755)
−12 (3/4)
0.049 0.669−0.675
(1.245) (16.993−17.145)
−16 (1) 0.028 0.956−0.960
(0.711) (24.282−24.384)
After Swage Dimensions for HMS 35211 Sleeves, HMS 35212 Unions, and HMS 35230 Bulkhead
Unions
Table 217
(2) After swaging, do a dimensional inspection of the HMS 35235 sleeves and HMS
35066 unions as follows:
(a) The depth of the second groove from the tube end shall be measured by
means of an inside dial caliper. The values obtained shall conform to Figure
237.
(b) The dimensions of sleeves and tube ends after swaging shall be in accordance
with Figure 238 and Figure 239.
E. Installation of the Sierracin/Harrison HMS Sleeves and Unions
(1) Obey all the hydraulic safety precautions (Ref. TASK 29−00−00−910−801).
(2) Apply a thin coat of thread compound to the threads of the male fitting and to the
back of the sleeve shoulder (Ref. TASK 20−22−01−910−801).
NOTE: On hydraulic lines, the thread compound shall be the hydraulic oil that will
be used in the system into which the hydraulic line is being installed.
(3) Place the assembly and sleeve in the installed position, making certain that the
sealing surfaces are not scratched during installation and that the sleeve meets the
fitting squarely and fully.
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(4) Turn the nut onto the male fitting using a wrench under light pressure. A second
wrench should be used on the hexagon or flat of the male fitting to prevent the
fitting from turning.
NOTE: Never use the nut to draw the sleeve into the fitting.
(5) Final assembly shall be torqued (Ref. TASK 20−21−00−910−802).
Subtask 20−22−00−370−006
F. Apply Primer
(2) Apply primer to the exposed aluminum tubing where necessary.
NOTE: Do not apply primer to the cadmium plated sleeves and unions.
4. Close Out
Subtask 20−22−00−941−006
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DRIVE SCREW

TOOL (PLUG)
ram2022002_016.dg, jp, 01/09/95
Figure 233
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BREAK SHARP
TUBE THICKNESS
EDGE o
30
t/2
NO BURR 0.010 in.
PERMITTED (0.254 mm)
MINIMUM
o
1 MAXIMUM
TUBE END PREPARATION FOR 35235 SLEEVES AND 36066 UNIONS
BREAK SHARP EDGE

(NO CHAMFER)
o
45
(REF)
0.008 in.
NO BURRS
(0.203 mm)
ALLOWED
MINIMUM
‘C’
TUBE END PREPARATION FOR 35211 SLEEVES AND
35212 UNIONS AND 35230 BULKHEAD UNIONS
NOMINAL TUBE ‘C’

DIAMETER MINIMUM
INCHES INCHES (MM)
ram2022002_032.dg, pw/kms, 08/03/02
0.250 0.006 (0.152)

0.312 0.010 (0.254)
0.375 0.010 (0.254)
0.500 0.015 (0.381)
0.625 0.020 (0.508)
0.750 0.020 (0.508)
1.000 0.030 (0.762)
Tube End Preparation − Sierracin/Harrison HMS Sleeves and Unions

Figure 234
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WIPE OFF
TUBE SKIRT
EXCESS "LOCKTITE"
APPLY "LOCKTITE" TO X DISTANCE FROM TUBE

THIS AREA OF TUBE END FOR APPLICATION
UNDER THE UNION SKIRT OF "LOCKTITE" (SEE TABLE)
TUBE SIZE APPROXIMATE DIMENSION "X"

INCH (MM)
−04 THRU −08 0.50 (12.70)

−10 THRU −16 0.60 (15.24)
−20 THRU −24 0.70 (17.78)

ram2022002_033.dg, sw, 15/02/02
ANAEROBIC COMPOUND DISTANCE FROM TUBE END
Application of Anaerobic Compound

Figure 235
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D
A B
R= 3 x O.D. R= 3 x O.D.
35211 SLEEVE 35212 UNION
R= 3 x O.D.
35230 BULKHEAD
Minimum straight tube lengths before bends
Size R −04 −06 −08 −16
A 3 x O.D. 1.30 1.30 1.38 1.40
B 3 x O.D. 1.22 1.30 1.48 1.50

ram2022002_038.dg, gg, 11/03/02
Protrusion ’D’ Before swage (Ref) 0.070 0.070 0.060 0.060
NOTE
Tube protrusion ’D’ defines the length before rolling.
Minimum Straight Tube Length Before Bends

Figure 236
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AREA FOR ADJUSTING

DEPTH GUAGE TO ZERO
Q P
1/4
1/8
INTERNAL SWAGED GROOVE DEPTH LIMITS FOR 35235 SLEEVES AND 35066 UNIONS
DEPTH 2P OR 2Q
TUBE SIZE MEASURED ON DIAMETER
INCHES
MIN MAX
INCHES (MM) INCHES (MM)
1/4 (−04) 0.020 (0.508) 0.030 (0.762)
5/16 (−05) 0.020 (0.508) 0.030 (0.762)
3/8 (−06) 0.020 (0.508) 0.030 (0.762)
1/2 (−08) 0.020 (0.508) 0.030 (0.762)
5/8 (−10) 0.022 (0.559) 0.032 (0.813)
3/4 (−12) 0.026 (0.660) 0.036 (0.914)
1 (−16) 0.028 (0.711) 0.038 (0.965)
1 1/4 (−20) 0.032 (0.813) 0.042 (1.067)

0.032 (0.813)
ram2022002_034.dg, sw/kms, 08/03/02
1 1/2 (−24) 0.042 (1.067)
NOTE
The depth 2P, measured on diameter, may be up to 0.005 inch less than the
minimum value shown provided that the outer groove depth 2Q, measured
on diameter, is no more than 0.005 inch below the minimum value shown.
Dimensional Inspection − Depth Limits − HMS 35235 Sleeves and HMS 35066 Unions
Figure 237
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DIMENSIONS
TUBE SIZE V Z
INCHES +
− 0.010 in. MAX
(+
− 0.254 mm) INCH
(MM)
1/4 (−04) 0.080 (2.032) 0.260 (6.604)
5/16 (−05) 0.096 (2.438) 0.322 (8.179)
3/8 (−06) 0.100 (2.540) 0.385 (9.779)
1/2 (−08) 0.100 (2.540) 0.511 (12.979)
ram2022002_035.dg, pw/kms, 08/03/02
5/8 (−10) 0.141 (3.581) 0.636 (16.154)

3/4 (−12) 0.141 (3.581) 0.761 (19.329)
1 (−16) 0.205 (5.207) 1.011 (25.679)
1 1/4 (−20) 0.200 (5.080) 1.262 (32.055)
1 1/2 (−24) 0.275 (6.985) 1.517 (38.532)
Dimensions After Swaging

Figure 238
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SWAGE LENGTH
0.030 in. min.
(0.762 mm) S
SWAGE FOR TUBE SIZES 1/4 INCH (−04) THROUGH 3/4 (−12)
S MAX
TUBE SIZE
INCHES
INCHES
(MM)
1/4 (−04) 0.111 (2.819)

3/8 (−06) 0.160 (4.064)
1/2 (−08) 0.210 (5.334)
5/8 (−10) 0.218 (5.537)
3/4 (−12) 0.225 (5.715)
ram2022002_036.dg, kms, 15/02/02
Dimensional Inspection − Swage Length Limits

Figure 239
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TASK 20−22−00−910−807
Repair of Hydraulic Tubing − Rynglok Fittings

Subtask 20−22−00−943−007
RSTK8−02−008 (Commercially Swaging Kit − Rynglok fittings
Available)
Commercially Available Intensifier − Oil (Shop Air Powered)
Subtask 20−22−00−944−007
05−001 Cloth, Cleaning
Subtask 20−22−00−946−007
No. 2
TASK 51−26−00−110−802 Detergent (Alkaline) Cleaning
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2. Job Set−Up
Subtask 20−22−00−910−021
A. Obey all the hydraulic safety precautions (Ref. TASK 29−00−00−910−801).
Subtask 20−22−00−863−001
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
B. Make sure that hydraulic system No.1 and No.2 pressure is released (Ref.
TASK 12−00−06−863−802).
C. Make sure that hydraulic system No.3 pressure is released (Ref.
TASK 12−00−06−863−804).
Subtask 20−22−00−865−001
D. If you do work on the hydraulic system No.1, open and tag the circuit breaker that
follows:
CB PANEL CB NO. NAME ZONE
CBP−2 G14 HYD SYST AC PUMP CONT 1 222
E. If you do work on the hydraulic system No.2, open and tag the circuit breaker that
follows:
CBP−1 G14 HYD SYST AC PUMP CONT 2 221
F. If you do work on the hydraulic system No.3, open and tag the circuit breakers that
follow:
CBP−1 G11 HYD SYST AC PUMP CONT 3B 221
CBP−2 G15 HYD SYST AC PUMP CONT 3A 222
3. Procedure
Subtask 20−22−00−910−020
Refer to figure 240
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A. Repair the tube with Rynglok fittings as follows:
(1) Prepare the tubes that have small damages (less than 0.250 in. (6.35 mm)) in the
tube section as follows:
(a) Before you cut the tube, make sure you respect the conditions that follow:
– The tube cut length (as per single union value in Table 201)
– The tube minimum straight length from the cut end (as per table 201 )
(b) Use a roller cutter and cut the tube section where the damage is located as
follows:
position on the tube.
2 Tighten the drive screw until the cutter wheel touches the tube, then turn
the drive screw an additional 1/4 of a turn.
3 Turn the cutter on the tube until there is no resistance.
4 Tighten the drive screw an additional 1/8 to 1/4 of a turn.
6 Repeat these steps until the tube is fully cut.
(c) Deburr the ends of the tube and polish the surface with an abrasive pad.
(d) Clean the tube surface to remove the chips and the dust with an approved
solvent.
(2) Prepare the tubes that have large damages (more than 0.250 in. (6.35 mm)) in the
tube section as follows:
(a) Before you cut the tube, make sure you respect the conditions that follow:
– The tube cut length (as per two unions value in Table 201)
– The tube minimum straight length from the cut end (as per table 201 )
(b) Use a roller cutter and cut the tube section where the damage is located as
follows:
position on the tube.
2 Tighten the drive screw until the cutter wheel touches the tube, then turn
the drive screw an additional 1/4 of a turn.
4 Tighten the drive screw an additional 1/8 to 1/4 of a turn.
6 Repeat these steps until the tube is fully cut.
(c) Deburr the ends of the tube and polish the surface with an abrasive pad.
(d) Clean the tube surface to remove the chips and the dust with an approved
solvent.
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TABLE 201
Tube Size Fitting P/N Tube Cut−Out Length Min. Tube
Dash No. Outside Single Union Two Unions Straight
Diameter in. Lmax in. (mm) Lmin in. (mm) Length in.
(mm) (mm)
−4 0.250 (6.35) R80101T4 0.300 (7.62) 2.38 (60.45) 0.936 (23.77)
−6 0.375 (9.52) R80101T6 0.300 (7.62) 2.64 (67.05) 1.062 (26.97)
−8 0.500 (12.70) R80101T8 0.350 (8.89) 2.92 (74.16) 1.130 (28.70)
−10 0.625 (15.87) R80101T10 0.350 (8.89) 3.18 (80.77) 1.278 (32.46)
−12 0.750 (19.05) R80101T12 0.400 (10.16) 3.56 (90.24) 1.427 (36.24)
TABLE 202
Corresponding Tools For Specific Rynglok Fitting (Kit RSTK8−02−0008)
Dash No. Marking Gauge (P/N) Swaging Tool P/N) Inspection Gauge (P/N)
−4 RSTSG0−01−04 RTST8−02−04 RSTSG0−51−04
−6 RSTSG0−01−06 RTST8−02−06 RSTSG0−51−06
−8 RSTSG0−01−08 RTST8−02−08 RSTSG0−51−08
−10 RSTSG0−01−10 RTST8−02−10 RSTSG0−51−10
−12 RSTSG0−01−12 RTST8−02−12 RSTSG0−51−12
(3) Prepare a new tube section as follows:
(a) Measure the tube section that you removed.
(b) Cut a splice tube to replace the section of tube that you removed and make
sure of the conditions that follows:
– The splice tube as a gap of less than 0.250 in. (6.35 mm) on each side of
the tube.
(c) Deburr the ends of the splice tube and polish the surface with an abrasive pad.
(d) Clean the splice tube surface to remove the chips and the dust with an
approved solvent.
(4) Do the marking of the tube as follows:
(a) Put the appropriate marking gauge in position on the tube (refer to table 202).
(b) Use a permanent type marking pen to fill in the appropriate marking slot to
make an inspection mark and a position mark on the tube.
(5) Install the Rynglok fitting on the tube as follows:
(a) Put the fitting in position on the tube and make sure that it is between the
position marks.
(b) If necessary, loosen the clamps on the tube.
(c) Connect the intensifier, the hydraulic hand pump and the appropriate swaging
tool (refer to table 202) as per the manufacturer’s instructions.
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(d) Put the swaging tool in position on the fitting and make sure of the conditions
that follow:
– Make sure that the fitting is bottomed in the swaging tool.
– If you use the swaging tool in the push mode, make sure that the front jaw
of the swaging tool is positioned in the fitting groove.
– If you use the swaging tool in the pull mode, make sure that the aft jaw of
the swaging tool is positioned in the fitting groove.
(e) Apply a pressure of 8250 ± 250psi (56881.75 ± 1723.69 kPa).
(f) Release the pressure.
(g) Remove the swaging tool from the fitting.
(h) If necessary, tighten the clamps.
(6) Do a visual inspection of each Rynglok fitting as follows:
(a) Use the appropriate inspection gauge (refer to table 202) and make sure that
the ring is fully advanced on the fitting.
(b) Make sure that the edge of the fitting is within the inspection marks.
(c) Make sure that there is a minimum clearance of 0.125 in. (3.17 mm) between
the fitting and the adjacent tubes and structure.
4. Close Out
Subtask 20−22−00−941−007
Subtask 20−22−00−870−001
B. If applicable, bleed the hydraulic system No.1 (Ref. TASK 29−10−00−870−801).
C. If applicable, bleed the hydraulic system No.2 (Ref. TASK 29−10−00−870−802).
D. If applicable, bleed the hydraulic system No.3 (Ref. TASK 29−10−00−870−803).
Subtask 20−22−00−790−001
E. Do a leak check of the hydraulic system as follows:
(1) If applicable, pressurize hydraulic systems No.1 and/or No.2 (Ref.
TASK 12−00−06−863−801).
(2) If applicable, pressurize hydraulic systems No.3 (Ref. TASK 12−00−06−863−803).
(3) Maintain the pressure for a minimum of 15 minutes.
(4) Use a cloth to check the fitting and tube interface and make sure there is no leaks.
(5) If applicable, release the pressure of hydraulic systems No.1 and/or No.2 (Ref.
TASK 12−00−06−863−802).
(6) If applicable, release the pressure of hydraulic systems No.3 (Ref.
TASK 12−00−06−863−804).
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DRIVE SCREW
0.250 in. (6.35 mm)

MAXIMUM
POSITION
MARK
BEFORE ASSEMBLY
INSPECTION
MARK
ram2022002_039.dg, rm, 15/06/05
POSITION
AFTER ASSEMBLY MARK
Hydraulic Tube Repair − Rynglok Fittings

Figure 240 (Sheet 1 of 4)
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MARKING
GAUGE
(REF)
FITTING
GROOVE
INSPECTION
MARKING THE TUBE MARK
POSITION
MARK
POSITIONING THE FITTING
FITTING
GROOVE
ram2022002_040.dg, rm, 15/06/05
POSITIONING THE TOOL

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FRONT JAW
(REF)
PUSH MODE
AFT JAW
(REF)
ram2022002_041.dg, rm, 15/06/05
PULL MODE

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SWAGING THE FITTING
INSPECTION
GAUGE
(REF)
INSPECTION
MARK
ram2022002_042.dg, rm, 15/06/05
POSITION
MARK
INSTALLATION INSPECTION

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**ON A/C ALL
PLUMBING LINES − MAINTENANCE PRACTICES
1. General
A. The procedures that follow give the instructions for the correct installation of plumbing
lines. The routing necessary and the clearances between the plumbing lines and other
parts of the aircraft are also given.
B. The procedures show the application of thread compounds and tape to threaded fittings
on plumbing lines.
C. The procedures also give instructions for temporary repairs to the hydraulic tubing using
flexible hose.
TASK 20−22−01−220−801
Bend Radii, Clearances and Tolerances of Plumbing Lines
1. Bend Radii
Subtask 20−22−01−220−001
A. Observe the dimensions given in Table 201 for the minimum bend radii of the plumbing
lines.
Hose Specification Size Minimum Bend Radius in. (mm)
MIL−H−8794 (MIL−H−5511) Up to and including −6 8 x OD
More than −6 5 x OD
MIL−H−8788 (MIL−H−5512) Up to and including 1.25 in. 6 x ID
(31.7) ID
More than 1.25 in. (31.7) 12 x ID
MIL−H−5593 All 12 x ID
−4 2.0 (50.8)
−6 4.0 (101.6)
−8 4.63 (117.6)
MIL−H−22579
−10 5.5 (139.7)
−12 6.5 (165.1)
−16 7.38 (187.5)
Permitted Repair Limits − Minimum Bend Radii for Hoses

Table 201
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Hose Specification Size Minimum Bend Radius in. (mm)

−4 1.25 (31.8)
−6 2.25 (57.2)
−8 2.88 (73.2)
AS 620
−10 3.00 (76.2)
−12 3.75 (95.3)
−16 5.00 (127.0)
AS 1339 −4 1.50 (38.1)
−6 2.50 (63.5)
−8 2.88 (73.2)
−10 3.25 (82.6)
−12 4.00 (101.6)
−16 5.00 (127.0)
Permitted Repair Limits − Minimum Bend Radii for Hoses

Table 201
NOTE: Where the hoses have anti−chafe or fire sleeves, increase the minimum bend
radii by the quantities in Table 202.
FLEXIBILITY MATERIAL
TYPE FACTOR DESCRIPTION PART STANDARD
Spiral Wrap Abrasion 1.3 Nylon Coil AS 1294
Sleeve Color Black
Heat Shrinkable 1.3 Seamless Polyolefin AS1073
Abrasion Sleeve Tubing
Integral Fire Cover 1.2 Extruded Red Silicone AS 1722
Rubber AS 1723
Spiral Wrap Abrasion 1.3 Polytetrafluoroethylene AS 1293
Sleeve (PTFE) Coil
Fire Sleeve 1.2 Fiberglass Sleeve, AS 1072
Silicone Rubber
Coated
Integral Abrasion 1.2 Braided Polyester NONE
Sleeve
Permitted Repair Limits − Flexibility Factors for Hoses with Sleeves

Table 202
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2. Routing, Clearance and Tolerances of Plumbing Lines
Subtask 20−22−01−220−003
A. Where plumbing lines and electrical cables are near each other, install the electrical
cables above plumbing lines that have flammable fluids. If the plumbing lines contain
flammable gases, install the electrical cables below them.
B. Do not install wires nearer than 0.5 in. (12.7 mm) to a flammable gas or fluid line.
C. Do not use a flammable fluid or gas line to give support to an electrical cable. If there is a
clearance of 0.5 to 2.0 in. (12.7 to 50.8 mm), install rubber−backed clamps as shown
(Refer to Figure 204).
D. Keep the air clearance between the wires and the plumbing lines (Refer to Table 203).
Clearance From Wires No Protection Special Protection With Intervening
in. (mm) Necessary Necessary Barrier − Min. Distance
Fluid and Gas Lines More than 6.0 in. 6.0 to 0.5 in. 0.5 in. (12.7mm)
(152.4 mm) (152.4 to 12.7 mm)
Oxygen Lines More than 6.0 in (152.4 6.0 to 0.5 in. 0.5 in. (12.7 mm)
mm) (152.4 to 12.7 mm)
High Temperature − − 0.5 in. (12.7 mm)
Equipment or Ducts
Permitted Repair Limits − Clearance Between Wires and Plumbing Lines

Table 203
NOTE: Where there are conductive barriers (ribs, frames, or channels) between the
wires and plumbing lines, keep the 0.5 in. (12.7 mm) distance if the routing
design makes it possible.
E. Where the wires are installed 6.0 to 0.5 in. (152.4 to 12.7 mm) from the fluid or gas lines,
keep the wires safe with clamps. When the wires are installed above the plumbing line,
put cable ties at distances less than the distance between the wires and the plumbing
line. This will prevent an electrical arc because a broken wire touches the plumbing line.
F. The installation of more cable ties is not necessary where a fuel line has a shroud
around it. Keep the mandatory minimum distance of 0.5 in. (12.7 mm) between the wires
and the fuel line. If the shroud is conductive, think of the shroud in the same way as the
fuel line.
G. If wires come as near as 2.0 to 0.5 in. (50.8 to 12.7 mm) to an oxygen line, put them in a
conduit with insulation. Also, make sure the wires have clamps to keep them safe.
H. Keep a minimum of 0.13 in. (3.3 mm) clearance (where there is no relative motion)
between the plumbing lines or hoses and the structure adjacent to a support clamp
(Refer to Figure 201).
I. The minimum clearance can be decreased as follows for rigid plumbing lines only:
– The clearance on short line assemblies can be decreased to 0.063 in. (1.6 mm) if
space is not available to keep the 0.13 in. (3.3 mm) clearance. This applies to lines
that are near together and to bends that are near end flares.
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– Parallel lines that are attached together become more rigid. In these cases, the
space available, and frequently, the clip design gives no more than 0.063 in. (1.6
mm) clearance. This is satisfactory.
– Lines that are attached to flat panels where there are no stiffener angles or adjacent
rivets can have the 0.063 in. (1.6 mm) clearance. The installation must be rigid to
prevent the lines movement because of vibration or hydraulic loads.
J. Where there is relative motion between a plumbing line and a projection (for example, a
bolt, a nut, or the structure), keep a minimum clearance of 0.75 in. (19 mm) between the
line and the projection (Refer to Figure 202).
K. Where a plumbing line goes through a grommet, the line must not cause a cut on the
grommet during service (Refer to Figure 202).
L. Make sure there is no tension on the tubes or flexible lines between attachment points.
The tension can cause the clamp pad to come out as shown (Refer to Figure 203). On
hose installations, put the clamps and supports where the hose will not be pulled or
twisted in use. The clamps must not cause the tubes or hoses to bend more than the
minimum permitted bend radius. Do not put clamps in bend areas or on Permaswage
fittings.
M. Do not put tension on flexible hoses between the attachment clamps. Let approximately
five percent of the hose length remain loose to allow operation and shrinkage.
N. When a clamp supports a flexible hose, make sure the clamp does not decrease the
hose diameter.
Subtask 20−22−01−220−005
Refer to Figure 205
O. For flared and flareless fittings, observe the tube angular and radial mismatch tolerances
that follow:
(1) The free tube end must not be more than 2 degrees out of parallel with the axis of
the mating connector.
(2) The radial mismatch of the free end of the tube from the fitting must be not be more
than 0.031 in. (0.79 mm). This dimension is applicable to each 10 in. (25.4 cm) of
tube length from the last support.
(3) The axial gap or interference must not be more than ±0.031 in. (0.79 mm).
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STRUCTURE
0.13 in. (3.30 mm) CLAMP

MINIMUM CLEARANCE
0.13 in. (3.30 mm)

MINIMUM CLEARANCE
STRUCTURE
MINIMUM CLEARANCE WHERE THERE IS NO

RELATIVE MOTION BETWEEN TUBE OR HOSE
AND ADJACENT STRUCTURE
ram2022012_001.dg, rt/rm, 20/12/04
Minimum Clearance Between Tube or Hose and Adjacent Structure

Figure 201
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0.750 in.
(19.05 mm)
MINIMUM CLEARANCE
MINIMUM CLEARANCE WHERE THERE IS RELATIVE

MOTION BETWEEN TUBE OR HOSE AND A PROJECTION
ram2022012_002.dg, rt/rm 20/12/04
CORRECT INCORRECT
CLEARANCE BETWEEN TUBE AND A GROMMET
Clearance Between Tube or Hose and a Projection

Figure 202
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CLAMP PAD WORKED OUT
CLAMP
PAD
Tension
No Tension
CORRECT (NO TENSION) INCORRECT (TENSION)
TUBING OR HOSE INSTALLED

BETWEEN SUPPORTS
ram2022012_003.dg, rt, 14/08/01
Tube Installed Between Supports

Figure 203
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TYPICAL MOUNTING ARRANGEMENT

OF HOSE TO ELECTRICAL CONDUIT
ram2022012_005.dg, rt/kms, 25/01/02
Rubber−cushioned Clamps
Figure 204
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NOTE
Flareless fittings shown,
flared fittings similar.
TUBE
ASSEMBLY
0.031 in.
(0.79 mm)
2 DEGREES MAXIMUM
MAXIMUM
MISALIGNMENT
0.031 in.
(0.79 mm)
MAXIMUM
ram2022012_002.dg, jc/rm 20/12/04
RADIAL MISMATCH ANGULAR MISMATCH
Offset, Axial Gap and Misalignment Tolerances − Plumbing Lines

Figure 205
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TASK 20−22−01−910−801
Application of Thread Compounds and Tape to Threaded Fittings on Plumbing Lines
1. Installation of Straight and Taper Threaded Fittings

Refer to Figure 206
Subtask 20−22−01−910−001
A. Threaded Fittings − All Systems
NOTE: The procedure set out in this paragraph shall apply generally to straight and
taper threaded fittings on plumbing lines.
(1) Immediately before the installation of the tubes, lubricate the male threads of the
fittings as follows:
(a) Use the thread compound in accordance with Table 204, that applies to the
type of installation.
(b) Carefully apply a small quantity of the thread compound to the male threads
only, but not to the first two male threads to engage the female threads as
shown Refer to Figure 206.
(c) If possible, turn the first two threads of the male fitting into the female threads
before applying the thread compound to the remaining threads.
(d) Put a small amount of the specified thread compound on the rear of the sleeve
shoulder as shown Refer to Figure 206.
(e) Use a small brush to apply the compound. Do not apply the compound to the
female threads.
(f) Make sure that the thread compound does not touch or stay on the end of a
fitting. The thread compound can get into the system and contaminate the
system fluid.
(2) Install the threaded fittings (Refer to AMM 20−22−00_201) and torque the fitting
onto the plumbing lines (Ref. TASK 20−21−00−910−802).
B. Taper (Pipe) Threaded Fittings − Oxygen/Fuel Systems
(1) Make sure that there is no tension on the tubes.
(2) Immediately before the installation of the tubes, lubricate the male threads of the
fittings as follows:
(a) Tape the threaded fitting (Refer to Table 204), that applies to the applicable
installation.
(b) Make sure that the threads on the fittings are fully clean. On taper (pipe)
fittings, remove all installed teflon tape before you put new tape on the fitting.
(c) Start at the first thread of the male fitting then wind the tape in the same
direction as the tightening direction. Make sure that the tape does not extend
in front of the first thread (Refer to Figure 206).
(d) Be careful not to make the tape dirty when you install it. Make the last turn a
small overlap.
(e) Use Size I tape, ¼ in. (6.4 mm) wide on 1/8 in. (3.2 mm), ¼ in. (6.4 mm) and
3/8 in. (9.6 mm) taper threads. Use Size II tape, ½ in. (12.7 mm) wide on ½ in.
Master
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(12.7 mm) and larger taper threads.
NOTE: Do not put teflon tape on oxygen fittings that have flared or cone
end−fittings.
(3) Install the threaded fittings (Refer to AMM 20−22−00_201) and torque the fitting
onto the plumbing lines (Ref. TASK 20−21−00−910−802).
Thread Compound Specification
Type of Installation Straight Threads Taper Threads
Fuel or Oil Pressure Gasoila Varnish Gasoila Varnish
Instruments − A−1 Type
Transmitter
Fuel or Oil Pressure TT−S−1732 TT−S−1732
Instruments − Autosyn Type
Transmitter
Fuel System Fluid or VV−P−236 MIL−T−27730 Tape
Engine Oil System Fluid or VV−P−236 System Fluid or VV−P−236
Hot Air MIL−T−5544 MIL−T−5544
Hydraulic System Fluid or VV−P−236 System Fluid or VV−P−236
See Note
Pneumatic MIL−G−4343 MIL−G−4343
Oxygen MIL−T−5542 MIL−T−27730 Tape
Permitted Repair Limits − Thread Compounds

Table 204
NOTE: Where the system fluid is MIL−H−5606 hydraulic fluid, replace the VV−P−236
Petrolatum with the system fluid. Where the system fluid is a phosphate−ester
base hydraulic fluid (for example, Skydrol), then replace the VV−P−236
Petrolatum with the system fluid. But, do NOT use MIL−H−5506 for the thread
compound where the system fluid is a phosphate−ester base fluid. Also, do
NOT use a phosphate−ester base fluid for the thread compound where the
system fluid is MIL−H−5506.
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APPLY COMPOUND TO
THESE AREAS ONLY
APPLICATION OF THREAD COMPOUND TO STRAIGHT THREADED FITTINGS
TAPE
NO TAPE FORWARD OF
FIRST THREAD
DO NOT PUT TAPE

ON FEMALE THREADS
APPLY TAPE TO THIS

AREA ONLY
ram2022012_004.dg, rt, 14/08/01
APPLICATION OF TAPE TO TAPER THREADED FITTINGS
Application of Thread Compound and Tape

Figure 206
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TASK 20−22−01−360−801
Temporary Repairs to Hydraulic Tubing Using Flexible Hoses

Subtask 20−22−01−943−001
B0302123−0406 [1] Adapter − Tube Size −04 (2 required)
AE2460010G0150 [2] Hose Assembly − Tube Size −04
AE2460010H0150 [2] Hose Assembly − Tube Size −06
AE2460010J0170 [2] Hose Assembly − Tube Size −08
AE2460010J0170 [2] Hose Assembly − Tube Size −10
AE2460010K0190 [2] Hose Assembly − Tube Size −12
[1] − Bombardier Standard part numbers
[2] − Parts supplied by Aerofit Products Inc. (CAGE Code 30974)
NOTE: Use hose assembly as specified, or equivalent (specification AS1339).
NOTE: If necessary, it is permitted to use a hose assembly with a flareless elbow type
of end fitting. The hose length can also be different to the length specified (the
last 4 digits of the part number give the length, e.g. AE2460010K0190 is 19.0
inches in length).
Subtask 20−22−01−946−001
No. 2
TASK 20−22−01−220−801 Bend Radii and Clearance of Plumbing Lines
TASK 20−22−01−910−801 Application of Thread Compounds and Tape to
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2. Job Set−Up
Subtask 20−22−01−910−004
SYSTEM(S)
HYDRAULIC CONTROLS
AIRCRAFT.
TASK 12−00−06−863−802 or TASK 12−00−06−863−804).
B. Open, safety and tag all the applicable circuit breakers.
C. Install warning placards on all applicable electrical and hydraulic controls.
3. Procedure
Subtask 20−22−01−910−005
NOTE: The repair procedure that follows is applicable to the hydraulic lines between two
adjacent clamp locations. It is not permitted in the locations that follow:
– Hydraulic lines located outboard of the engine firewall
– Hydraulic lines in the engine cowls
– Hydraulic lines on the landing gear
– Hydraulic lines in the fuel tanks.
NOTE: The aircraft is permitted to fly for a maximum of 450 flight hours or not more than 3
months with this type of repair.
A. Prepare the tubing and install the fittings (Ref. AMM 20−22−00 Fittings and Connections
− Maintenance Practices) approximately 2 in. from the tube clamp locations.
NOTE: A flexible hose repair must not be installed next to a second repair (e.g. with a
flexible hose, a cryofit coupling, deutch permaswage fittings, Harrison "H"
fittings etc.) between two supports.
NOTE: Only one hydraulic system (System No. 1, No. 2, or No. 3) is permitted to be
temporarily repaired at one time.
B. Record the part numbers of the components used for the repair.
NOTE: Use the proper bend radius for the type of hose that is necessary (Refer to
Tools and Equipment and Table 205).
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C. Clamp the hose as necessary to prevent abrasive wear, kinking, or deflection of the rigid
plumbing line.
NOTE: The clamps that you use must be resistant to phosphate ester−based hydraulic
fluids.
D. Refer to Table 205 for the minimum inner bend radius for the hose assembly that you
use.
TUBE SIZE (OD) HOSE SIZE MIN INNER BEND RADII − INCH (MM)
1/4 (−04) G (−06) 2.50 in (63.50 mm)
3/8 (−06) H (−08) 2.88 in (73.15 mm)
1/2 (−08) J (−10) 3.25 in (82.55 mm)
5/8 (−10) J (−10) 3.25 in (82.55 mm)
3/4 (−12) K (−12) 3.88 in (98.55 mm)
Hose Assembly − Bend Radii
Table 205
E. Keep the correct clearances between the structure and adjacent system components
(Ref. TASK 20−22−01−220−801).
F. Immediately before the installation, lubricate the male threads of fittings (Ref.
TASK 20−22−01−910−801).
G. Torque the fittings (Ref. TASK 20−21−00−910−802).
H. Make sure that the hose assembly did not twist during the installation or when the fittings
were torqued.
I. Remove the tags and close all the applicable circuit breakers.
J. Pressurize the repaired hydraulic system (Ref. TASK 12−00−06−863−801 or
TASK 12−00−06−863−803). Examine the hose and connections for leaks.
NOTE: No leaks are permitted.
K. Bleed the repaired hydraulic system. (For system No. 1, Ref. TASK 29−10−00−870−801.
For system No. 2, Ref. TASK 29−10−00−870−802. For system No. 3, Ref.
TASK 29−10−00−870−803.)
L. Do a visual inspection of the flexible hose installation at intervals of not more than 50
flight hours.
4. Close Out
Subtask 20−22−01−941−001
A. Make sure there is no hydraulic fluid in the area around the repair.
B. Remove all the warning placards.
C. Remove all tools, equipment, and unwanted materials from the work area.
Master
20−22−01 Page 215
Dec 15/2004
C
**ON A/C ALL
WIRE−ROPE CONTROL CABLES − INSPECTION/CHECK
1. General
A. The maintenance procedures that follow supply inspection data and damage limits for
the wire−rope control cables and the cable pulleys.
B. Nonjacketed, preformed wire−rope that agrees with Specification MIL−W−83420, Type I,
Comp A (carbon steel) is used to make cable assemblies for flight control and
landing−gear emergency−release systems. Control cable assemblies for the flight
controls are made from 0.093−inch (2.36−mm) and 0.125−inch (3.18−mm) diameter
7X19 material. Control cable assemblies for the landing−gear emergency−release
system are made from 0.093−inch (2.36−mm) diameter 7X7 and 7X19 material.
C. For flight control cables, a tin−on−zinc coating is applied on the wire rope wires when
they are made. On the landing−gear emergency−release cables, a zinc or tin and zinc
coating is applied. Finished wire rope material is soaked with a lubricating compound
that decreases internal friction and helps to prevent corrosion. Added lubrication and
protection from corrosion is applied when the cable assemblies are made.
TASK 20−23−00−200−801
Inspection of Wire−Rope Control Cables and Related Components

Subtask 20−23−00−944−001
04−001 Grease, aircraft, general purpose, wide
temperature range
05−001 Cloths, cleaning, low−lint
11−002 Solvent, dry cleaning and degreasing
15−003 Compound, corrosion−inhibiting, penetrating
(Type I)
Subtask 20−23−00−946−001
Release Hydraulic Pressure − Systems No. 1 and
TASK 12−00−06−863−802
No. 2
TASK 12−00−07−861−802 Remove External AC Power
TASK 27−00−00−910−801 General Rigging Instructions
Master
20−23−00 Page 601
Apr 20/2004
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2. Job Set−Up
Subtask 20−23−00−910−001
WARNING: MAKE SURE THAT WARNING PLACARDS ARE INSTALLED ON THE RUDDER
PEDALS AND ON THE PILOT AND COPILOT INSTRUMENT PANELS.
ACCIDENTAL MOVEMENT OF THE FLIGHT CONTROLS CAN CAUSE INJURIES
TO PERSONS AND/OR DAMAGE TO EQUIPMENT.
WARNING: PUT THE SAFETY DEVICES, THE WARNING SIGNS, AND THE WARNING
PLACARDS IN POSITION BEFORE YOU START A PROCEDURE ON OR NEAR:
– FLIGHT CONTROLS
– FLIGHT CONTROL SURFACES
– COMPONENTS THAT MOVE.
MAKE SURE THAT THERE ARE NO PERSONS OR EQUIPMENT ON OR NEAR
THE FLIGHT CONTROL SURFACES. ACCIDENTAL MOVEMENT OF THE
FLIGHT CONTROLS CAN CAUSE INJURIES TO PERSONS AND/OR DAMAGE
TO EQUIPMENT.
WARNING: MAKE SURE THAT THE FLIGHT CONTROL SURFACES ARE CLEAR OF
PERSONS AND EQUIPMENT DURING THE FULL RANGE OF TRAVEL. FLIGHT
CONTROL MOVEMENT CAN CAUSE INJURIES TO PERSONS AND/OR
DAMAGE TO EQUIPMENT.
A. Put the safety devices and the warning signs in the applicable positions.
B. Install the applicable warning placards on the pilot’s and the copilot’s rudder pedals.
C. Obey all the precautions given in the general rigging instructions (Ref.
TASK 27−00−00−910−801).
Subtask 20−23−00−863−001
WARNING: MAKE SURE THAT THE WHEEL CHOCKS AND THE GROUND LOCKPINS
FOR THE LANDING GEAR ARE INSTALLED BEFORE YOU RELEASE THE
HYDRAULIC PRESSURE. ACCIDENTAL MOVEMENT OF THE AIRCRAFT
CAN CAUSE INJURIES TO PERSONS AND/OR DAMAGE TO EQUIPMENT.
D. Release the pressure from hydraulic systems No. 1 and No. 2 (Ref.
TASK 12−00−06−863−802).
E. Release the pressure from hydraulic system No. 3 (Ref. TASK 12−00−06−863−804).
F. Remove the external ac power (Ref. TASK 12−00−07−861−802).
3. Procedure
Subtask 20−23−00−160−001
WARNING: BE CAREFUL OF BROKEN WIRES WHEN YOU INSPECT CONTROL
CABLES. BROKEN WIRES CAN CAUSE INJURIES. FOR PROTECTION
OF YOUR HANDS, USE A CLOTH OF SUFFICIENT THICKNESS.
A. Clean the control cables and related components as follows:
Master
20−23−00 Page 602
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CAUTION: DO NOT USE VAPOR DEGREASING, STEAM CLEANING, OR
SOLVENTS TO REMOVE CORROSION−PREVENTIVE COMPOUNDS
OR OTHER UNWANTED MATERIALS FROM THE OUTER SURFACES
OF THE CONTROL CABLES. THESE PROCEDURES WILL ALSO
REMOVE THE INTERNAL LUBRICANT.
(1) Remove corrosion−prevention compound and other unwanted materials with a
clean cloth that is moist with dry−cleaning solvent.
Subtask 20−23−00−210−001
B. Examine the control cables and related items as follows:
(1) Do an inspection for broken wires as follows:
NOTE: Broken wires do not always extend from the lay of the cable. If necessary,
remove the cable and carefully bend and twist the cable with your hands
to make sure that all broken wires are found.
NOTE: When broken wires are found, carefully examine the cable with a
10−power magnifying glass to make the full level of the damage known.
(a) Rub a cloth along the cable and make a note of the areas where broken wires
catch the cloth. Use special care in the areas that follow:
– Sections of the cable that go around pulleys, quadrants, drums, and
through fairleads or pressure seals
– Parts near the turnbuckles
– Sections of the cable that are worn or have corrosion.
(b) Replace the cable if you get one of the conditions that follow:
NOTE: A critical fatigue area is defined as:
– The working length of a cable where the cable runs on a pulley,
sleeve, drum, quadrant or through a fairlead and grommet
– A section where the cable is flexed, rubbed or worked
– The area within a foot (30.5 cm) of a swaged fitting.
– Three or more wires are broken in a critical area
– On a 7X19 cable, six or more wires are broken in a section of 1.00 in. (2.54
cm) span
– On a 7X19 cable, you have five broken wires in a section of 1.00 in. (2.54
cm) span and they are one or more broken wires in the next 1.00 in. (2.54
cm) that follows or precedes that section
– On a 7X19 cable, there are height or more wires broken
– On a 7x7 cable, three or more wires are broken in a section of 1.00 in.
(2.54 cm)
– On a 7X7 cable, you have two broken wires in a section of 1.00 in. (2.54
cm) span and they are one or more broken wires in the next 1.00 in. (2.54
cm) that follows or precedes that section
– On a 7X7 cable, there are four or more wires broken between two
terminals.
Master
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Dec 10/2005
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(2) Do an inspection for corrosion as follows:
(a) Carefully examine the cable external surfaces for corrosion. Use special care
when the conditions that follow occur:
– There are cable runs through or near areas such as battery compartments,
lavatories, and wheel wells
– Broken wires are found in sections where wear is not caused by airframe
components such as pulleys, pressure seals, or fairleads
– In areas where the cable is installed with a turnbuckle and the safety clips
– Cleaning or metal−brightening procedures are done adjacent to cable runs
(b) If you find external surface corrosion, release the tension or remove the cable
(as applicable).
(c) Carefully twist the cable to visually examine the internal surfaces for damage,
wear and corrosion.
(d) If you find inner corrosion, replace the cable.
(e) If you only find external surface corrosion, clean the cable.
(3) Do an inspection for cable wear as follows:
(a) Carefully examine the cable external surfaces for wear.
(b) Replace the cable if you find one of the conditions that follow:
– Some wires in a strand are blend together (wires won by more than 40%)
– A broken wire is located in a worn area of the cable.
(4) Carefully examine the cable and replace it if you find the following conditions:
– The cable is twisted, kinked or flat
– There is a separation of strands.
(5) Examine the frame components (such as pulleys, fairleads, and guard pins) that are
related to the cables that have damage. Wear patterns on related frame
components are frequently an indication of the conditions that follow:
– The cable is too high (more than the permitted limits)
– The pulley is too large for the specified cable diameter
– The pulley bearing is seized
– The frame components are not aligned correctly
– The cables are not aligned correctly
– The turnbuckles for cracks and safety clips broken.
(6) If necessary, adjust or align the cable (or the related fame components), or replace
the applicable component to correct the problem.
(7) Lubrication
(a) Examine the full length of the cable for a sufficient external coating of lubricant
and corrosion−preventive compound. Use special care in those areas of the
aircraft where you frequently do maintenance and servicing tasks.
NOTE: It is not necessary to lubricate cables regularly unless you are
instructed to do so in a scheduled maintenance task.
Master
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(b) Remove collected quantities of lubricant/corrosion−preventive compound
where cables go through fairleads, pressure seals, or around pulleys,
quadrants, and drums.
CAUTION: DO NOT USE METALLIC WOOL, WIRE BRUSHES, OR ABRASIVE
MATERIALS TO REMOVE SURFACE CORROSION FROM
CABLES. THESE MATERIALS WILL CAUSE CONTAMINATION
THAT WILL RESULT IN SUBSEQUENT INTERNAL WEAR AND
CORROSION.
(c) Remove corrosion products from the external surfaces with a coarse−weave
cloth or a fibre brush and apply protection as follows:
1 On flight−control cable assemblies, apply water−displacing
corrosion−inhibiting compound.
2 On landing−gear emergency−release cable−assemblies, apply a thin
coating of grease.
4. Close Out
Subtask 20−23−00−430−001
A. Connect and adjust the applicable control cable system. Obey all the precautions and
the instructions given in the general rigging instructions (Ref.
TASK 27−00−00−910−801).
Subtask 20−23−00−941−001
B. Remove all tools, equipment, and unwanted materials from the work area.
Subtask 20−23−00−410−001
C. Close the access panels and doors, as necessary.
Master
20−23−00 Page 605
Dec 10/2005
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1.0 in. (25.4 mm)
7 X 19 CABLE
BROKEN WIRE
(TYPICAL)
1.0 in. (25.4 mm)
ram2023006_001.dg, jp, 07/06/93
7 X 7 CABLE
BROKEN WIRE
(TYPICAL)
BROKEN WIRES
Wire−Rope Control Cables − Inspection/Check

Master
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Apr 20/2004
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TYPICAL OUTER WIRE WEAR

AREA ON CABLE STRAND
A
EACH OUTER WIRE WORN LESS THAN
40 PERCENT. EACH WORN AREA EASY
A
TO SEE − PERMITTED
TYPICAL CABLE WEAR
EACH OUTER WIRE WORN 40−50

PERCENT. THE WORN AREAS BLEND
TOGETHER − NOT PERMITTED
ram2023006_003(1).dg, jp/rm, 29/07/97
A CABLE WEAR
EACH WIRE WORN MORE THAN
50 PERCENT − NOT PERMITTED

Master
20−23−00 Page 607
Apr 20/2004
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SERVICEABLE CONDITION CABLE TENSION TOO HIGH
WORN ON BOTH WORN ON ONE

SIDES SIDE
PULLEY NOT ALIGNED CABLE NOT ALIGNED

CORRECTLY CORRECTLY
GROOVE IN WORN IN ONE

PULLEY AREA
ram2023006_004.dg, jp, 04/06/93
PULLEY TOO LARGE SEIZED BEARING
TYPICAL WEAR PATTERNS ON PULLEYS

Master
20−23−00 Page 608
Apr 20/2004
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**ON A/C ALL
SAFETYING DEVICES − MAINTENANCE PRACTICES
1. General
A. The maintenance procedures that follow give the standard practices for the installation of
safetying devices as follows:
– Cotter Pins − Maintenance Practices
– Lockwire − Maintenance Practices
– Safety Cable − Maintenance Practices
– Tab Lock Washers − Maintenance Practices
– Assemblies − Maintenance Practices
– Rod End Assemblies − Maintenance Practices.
TASK 20−24−00−910−801
Cotter Pins − Maintenance Practices

Subtask 20−24−00−943−001
Commercially available Glasses, Safety
2. Procedure
Subtask 20−24−00−910−001
A. Obey the precautions for cotter pin installation as follows:
WARNING: WEAR EYE PROTECTION WHEN YOU CUT COTTER PINS. WHEN
COTTER PINS ARE CUT, PIECES OF IT CAN HIT YOUR EYES AND
CAUSE INJURIES.
(1) Wear safety glasses when you cut the cotter pin. When the cotter pin is cut, pieces
can hit your eyes and cause injury.
CAUTION: DO NOT USE THE COTTER PIN AGAIN AFTER ITS REMOVAL. USED
COTTER PINS CAN BE WEAKER WHEN THEY ARE REMOVED.
WEAK COTTER PINS CAN BREAK AND CAN RESULT IN DAMAGE
TO THE EQUIPMENT.
(2) Replace used cotter pins for installation, used cotter pins should be discarded.
(3) Always use the correct type and size of cotter pin specified for the part. Cotter pins
that are not of the correct type and size can break when more than the specified
tension limits (for that type and size of cotter pin) occur.
(4) Do not accidentally cut or cause damage to the cotter pin that is installed. When
stress is put on a damaged cotter pin, it can break.
Master
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(5) Make sure to bend the two ends of the cotter pin around the nut or pin of the
fastener. Make sure that the ends of the cotter pin do not catch on the adjacent
parts, or damage can occur.
B. To install the cotter pins in castellated nuts, do the steps that follow:
(1) Use the type and size of cotter pin specified by the manufacturer for the size and
type of castellated nut.
(2) Put the two ends of cotter pin through the safety hole in the nut, with the head
parallel to the slot in the nut.
(3) Bend each of the two ends of the cotter pin in opposite directions around the bolt
end or to the nut slit adjacent to the pin end.
C. To install cotter pins in nuts (that are not castellated), do the steps that follow:
type of nut.
(2) Put the two ends of the cotter pin through the hole in the nut.
(3) Bend each of the two ends of the cotter pins in opposite directions to the back of
the bolt at approximately 90 degrees.
D. To install cotter pins in clevis pins, do the steps that follow:
type of clevis pin.
(2) Put the two ends of the cotter pin through the hole in the pin.
(3) Bend each of the two ends of the cotter pin in opposite directions around the side of
the clevis pin.
3. Close Out
Subtask 20−24−00−941−001
Master
20−24−00 Page 202
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BELOW FLUSH ABOVE
ACCEPTABLE ACCEPTABLE NOT ACCEPTABLE
LOCATION OF HOLES IN
CASTALLATED NUT INSTALLATIONS
PREFERRED OPTIONAL
ram2024002_002.dg, rm, 20/01/00
FLATE HEAD PINS
METHOD OF BENDING COTTER PINS
Cotter Pins − Installation

Figure 201
Master
20−24−00 Page 203
Apr 20/2004
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TASK 20−24−00−910−802
Lockwire − Maintenance Practices

Subtask 20−24−00−943−002
Commercially Available Glasses, Safety
Subtask 20−24−00−944−001
05−003 Lockwire, CRES 0.020 in. (0.51 mm)
05−006 Lockwire, Carbon−Steel 0.032 in. (0.81 mm)
05−007 Lockwire, Carbon−Steel 0.041 in. (1.04 mm)
05−008 Lockwire, Nickel−Chromium−Iron 0.032 in. (0.81
mm)
05−098 Lockwire, Copper 0.020 in. (0.51 mm)
Subtask 20−24−00−946−001
TASK 24−00−00−910−801 Electrical/Electronic Safety Precautions
2. Procedure
Subtask 20−24−00−910−002
A. Obey the precautions for lockwire installation as follows:
NOTE: If this procedure does not agree with the specified maintenance procedure,
use the specified maintenance procedure.
WARNING: WEAR EYE PROTECTION WHEN YOU CUT LOCKWIRE. WHEN
LOCKWIRE IS CUT, PIECES OF IT CAN HIT YOUR EYES AND CAUSE
INJURIES.
(1) Wear eye protection when you cut the lockwire. When the lockwire is cut pieces
Master
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CAUTION: DO NOT USE THE LOCKWIRE AGAIN AFTER ITS REMOVAL. USED
LOCKWIRE CAN BE WEAKER WHEN IT IS REMOVED. WEAK
LOCKWIRE CAN BREAK AND CAN RESULT IN DAMAGE TO THE
EQUIPMENT.
(2) Do not use lockwire more than one time. Always discard the used lockwire after
removal.
CAUTION: MAKE SURE THAT YOU USE THE CORRECT TYPE AND SIZE OF
LOCKWIRE FOR THE SPECIFIED TASK. MAKE SURE THAT THE
LOCKWIRE FILLS A MINIMUM OF 75 PERCENT OF THE HOLE. IF
YOU DO NOT DO THIS, YOU CAN CAUSE DAMAGE TO THE
EQUIPMENT.
(3) Always use the correct type and size of lockwire specified for the part. Lockwire
that is not the correct type and size can break when more than the specified tension
limits (for that type and size of lockwire) occur.
(4) Cut the lockwire to the necessary length. Make sure that the lockwire is of sufficient
length to make a pigtail at the ends to safety the lockwire into position.
(5) Do not over tighten the lockwire. Too much stress placed on the lockwire can break
it.
(6) Do not bend the lockwire in too small of a radius. This can put too much stress on
the lockwire, and it can break.
(7) Do not accidentally cut or cause damage to the lockwire that is installed. When
stress is put on a damaged piece of lockwire, it can break.
(8) Make sure that you put lockwire on parts that can become loose. If the lockwire is
not tightened correctly, unwanted forces can cause the parts to become loose.
CAUTION: MAKE SURE THAT THE PIGTAIL END OF THE LOCKWIRE IS BENT
AGAINST OR BELOW THE PART THAT IS LOCKWIRED, IN THE
DIRECTION OF TENSION. IF YOU DO NOT DO THIS, YOU CAN
CAUSE DAMAGE TO THE EQUIPMENT.
(9) Make sure to twist the ends of the lockwire with a minimum of three twists and a
maximum of six twists to make a pigtail. Always bend the pigtail end against or
below the part that is lockwired (in the direction of the force or tension).
B. To install the lockwire on nuts, bolts, and screws, do the steps that follow:
(1) When you install lockwire on castellated nuts, tighten the nut to the low values of
the torque range. If it is necessary, continue to tighten until the slot aligns with the
safety hole, but do not tighten it above the specified torque range.
(2) Install the lockwire in the configuration shown in the illustration.
(3) Cut the lockwire to the necessary length.
NOTE: The lockwire is of sufficient length when you can twist a pigtail at the
ends, (and not too long, or it can catch on adjacent parts that move).
(4) Twist the lockwire until the loop around the bolt head or nut is below the wire that
enters the hole.
NOTE: Make sure that the lockwire does not go above the head of the screw or
bolt.
(5) Use a single twist or double twist method as applicable. If possible and for safety of
installation, a double twist method is usually recommended.
Master
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(6) For larger size nuts, bolts, and screws, you should twist the lockwire a minimum of
two times.
(7) For smaller size screws that are installed close together (in a geometric
configuration), use the single twist method when you install the lockwire. Make
sure to use the largest size wire for the given hole.
(8) For many groups of hardware that are not installed too close together, use the
procedures that follow to install the lockwire:
(a) If you use 0.032 in (0.81 mm) diameter lockwire, the maximum number of
assemblies is limited to three with eight to ten twists used per inch.
(b) If you use 0.041 in (1.04 mm) diameter lockwire, the maximum number of
assemblies is limited to three with six to eight twists used per inch.
(c) The maximum distance between the fasteners or fittings is 6.0 in (152.4 mm).
(9) For many groups of hardware that are installed close together, use the procedures
that follow to install the lockwire:
(a) If you use 0.032 in (0.81 mm) diameter lockwire, the maximum number of
assemblies is limited to three with eight to ten twists used per inch (maximum
24 inches total length of lockwire).
(b) If you use 0.041 in (1.04 mm) diameter lockwire, the maximum number of
assemblies is limited to three with six to eight twists used per inch (maximum
24 inches total length of lockwire).
(10) For blind tapped hole installations that use fastening hardware and safety devices
that follow, safety in sets of two:
– Bolts
– Castellated nuts on studs
– Drilled head bolts or filister head screws that are not safetied with a lockwasher,
locknut or threaded insert that locks.
(a) When you install stop−bolts with locknuts, safety the stop−bolt, locknut and
structure together with lockwire.
C. To install the lockwire on electrical connectors, do the steps that follow:
(1) Obey the electrical/electronic safety precautions (Ref. TASK 24−00−00−910−801).
(2) Install the lockwire in the configuration shown in the illustration.
(3) Use the same procedures given in the installation of lockwire on nuts, bolts, and
screws (as applicable).
D. To install the lockwire on external snag rings, do the steps that follow:
(1) Install the lockwire in the configuration shown in the illustration as Method 2.
E. To install the lockwire on plain taper pins, do the steps that follow:
F. To install the lockwire on cable guard pins, do the steps that follow:
(2) Use a 0.032 in (0.81 mm) diameter lockwire to safety the cable guard pins to the
pulley brackets or the No. 10 pulley bolts.
(3) Use 0.041 in (1.04 mm) diameter lockwire to safety the cable guard installation to
0.250 in (6.35 mm) and 0.3125 in (7.94 mm) pulley bolts.
Master
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(4) Lockwire the cable guard pin until the guard pin cannot turn in the pulley bracket.
(5) Safety the lockwire as follows:
(a) Install the lockwire through the hole in the pulley bolt or through the No. 50
hole drilled in the pulley bracket.
(b) Cut the lockwire to the necessary length.
(c) Twist the lockwire until it is tightened and then put one end of the lockwire
through the hole of the pulley guard pin.
(d) Continue to twist the lockwire for four complete turns and until the lockwire is
finger tight.
G. To install lockwire on slotted spring pins, do the steps that follow:
(1) Install the lockwire as shown in Method 5 in the illustration.
(2) Use a 0.032 in (0.81 mm) diameter lockwire to safety the slotted spring pins used in
the cable guard installations.
(3) Put the lockwire through the spring pin.
(5) Attach the ends of the lockwire together at the front of the pulley.
(6) Twist the lockwire together tightly for four complete turns.
H. Install the lockwire on Wiggins rigid−tube connectors, do the steps that follow:
(1) Install the lockwire as shown in Method 6 in the illustration.
(2) Use the diameter of lockwire specified by the manufacturer for the size and type of
Wiggins connector.
(3) Put the lockwire through the hole of the coupling nut.
(5) Twist the lockwire a sufficient number of turns.
(6) Put the two ends of the lockwire through the hole in the boss.
(7) Attach the end of the lockwire together at the front of the connector.
(8) Twist the lockwire together tightly for four complete turns, and bend the pigtail
towards and along the edge of the connector.
I. To install lockwire on emergency release and safety devices, use MS20995CY20
lockwire. Install the lockwire in the method approved for the specified type of
application.
3. Close Out
Subtask 20−24−00−941−002
A. Remove all tools, equipment, and unwanted materials from the work areas.
Master
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PIGTAIL
PIGTAIL
SINGLE WIRE METHOD
(CLOSELY SPACED CLOSED GEOMETRICAL PATTERN) DOUBLE TWIST METHOD
PIGTAIL
PIGTAIL
DOUBLE TWIST METHOD
(WIDELY SPACED FASTENERS)
METHOD 1
LOCKWIRE INSTALLATION PROCEDURE FOR RH THREAD
ASSEMBLIES. REVERSE FOR LH THREAD ASSEMBLIES
PIGTAIL
ram2024002_003.dg, rm, 24/01/00
METHOD 2
LOCKWIRE INSTALLATION PROCEDURE
FOR EXTERNAL SNAP RING
(SINGLE WIRE METHOD)
Lockwire − Installation
Master
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Apr 20/2004
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LOCKWIRE PIGTAIL
AROUND PART
LOCKWIRE THROUGH
HOLE IN LARGE END
METHOD 3
LOCKWIRING OF PLAIN TAPER PINS
GUARD PIN
PULLEY BOLT
PIGTAIL
METHOD 4
LOCKWIRING OF CABLE GUARD PINS
SPRING PIN
LOCKWIRE
ram2024002_004.dg, rm, 24/01/00
PULLEY
PIGTAIL
METHOD 5
LOCKWIRING OF SLOTTED SPRING PINS
Master
20−24−00 Page 209
Apr 20/2004
C
o
30 MINIMUM
BEND PIGTAIL BACK

ALONG CONNECTOR
METHOD 6
LOCKWIRING OF WIGGINS RIGID TUBE CONNECTORS
ram2024002_005.dg, rm, 24/01/00
Master
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TASK 20−24−00−910−803
Safety Cable − Maintenance Practices

Subtask 20−24−00−943−003
DMC1000−20R Safety Cable Tool and Parts Kit
Subtask 20−24−00−944−003
Cable, safety, 0.020 in. (0.51 mm) nominal
05−132 diameter, 9.0 in. (228 mm) length, corrosion and
heat resistant steel
Ferrule, for 0.020 in. (0.51 mm) nominal diameter
05−135
safety cable
05−136 diameter, 9.0 in. (228.6 mm) length, corrosion and
Ferrule, for 0.032 in. (0.89 mm) nominal diameter
05−139
safety cable
NOTE: During the selection of safety cable, make sure you add the extra cable
necessary to engage the tension mechanism in the crimping tool. Add 6−8 in.
(152−203 mm) for a tool with a 3 in. (76.2 mm) nose. Add 10−12 in. (254−304
mm) for a tool with a 7 in. (178 mm) nose.
Master
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2. Procedure
Subtask 20−24−00−910−003
Figure 203, Table 201 and Table 202.
A. Obey the precautions for safety cable installation as follows:
WARNING: WEAR EYE PROTECTION WHEN YOU CUT SAFETY CABLE. WHEN
SAFETY CABLE IS CUT, PIECES OF IT CAN HIT YOUR EYES AND
CAUSE INJURIES.
CAUTION: DO NOT USE THE SAFETY CABLE OR THE FERRULES AGAIN
AFTER THEIR REMOVAL. USED SAFETY CABLE AND FERRULES
CAN BE WEAKER WHEN THEY ARE REMOVED. WEAK SAFETY
CABLES AND FERRULES CAN BREAK AND CAN RESULT IN
DAMAGE TO THE EQUIPMENT.
(1) Do not use safety cable and ferrules more than one time. Always discard the used
safety cable and ferrules after removal.
(2) Any cable defect, found before, during or after installation is not acceptable. The
defective cable must be discarded and replaced with new cable.
(3) If this maintenance practice does not agree with the specified maintenance
procedure, use the specified maintenance procedure.
B. Install safety cable as follows:
(1) Install safety cable so that, if a fastener tries to loosen, it is stopped by the tension
in the cable.
(2) The maximum permitted span of safety cable between two termination points is 6.0
in. (152.4 mm).
(3) The safety cable must be installed through the holes provided in the parts. It is not
permitted to torque nuts or bolts above or below the given tolerance to get correct
alignment of the holes .
(4) Safety cable must be installed in two−bolt or three−bolt patterns. A two−bolt pattern
is the recommended procedure when safety cable is applied to an even number of
fasteners.
(5) The ferrule must be crimped to the safety cable using the correct crimping tool. The
crimping tool cuts off any unwanted quantity of cable from the crimped ferrule after
installation. The length of cable that extends from the ferrule must not be more
than 0.030 in. (0.76 mm).
(6) Refer to Figure 203, Sheet 4. Use light finger pressure (approximately 2 lbf.) to
measure the cable movement at mid−span. All installed cables must not have more
movement than the limitations specified in the table that follows :
A in. (mm) B in. (mm) C in. (mm)
0.5 (12.7) 0.125 (3.2) 0.062 (1.6)
1.0 (25.4) 0.250 (6.4) 0.125 (3.2)
2.0 (50.8) 0.375 (9.5) 0.188 (4.8)
Cable Movement Limitations and Maximum Dimensions

Table 201
Master
20−24−00 Page 212
Aug 10/2005
C
A in. (mm) B in. (mm) C in. (mm)

3.0 (76.2) 0.375 (9.5) 0.188 (4.8)
4.0 (101.6) 0.500 (12.7) 0.250 (6.4)
5.0 (127.0) 0.500 (12.7) 0.250 (6.4)
6.0 (152.4) 0.625 (15.9) 0.312 (7.9)
Cable Movement Limitations and Maximum Dimensions

Table 201
(7) Make sure that the ferrule pull−off load meets the requirements of the table that
follows:
Nominal Cable Diameter in. (mm) Minimum Pull−Off Load lbf (N)
0.020 (0.51) 30 (133.4)
0.032 (0.89) 70 (311.4)
Safety Cable Minimum Crimp Requirements (Pull−Off Load)
Table 202
3. Close Out
Subtask 20−24−00−941−003
Master
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0.020 in. (0.508 mm)

DIAMETER CABLE (1X7)
OR
0.032 in (0.813 mm)
DIAMETER CABLE (3X7)
CRIMPED
FERRULE
SWAGED
FITTING
BOLT HEADS
(TYPICAL)
SAFETY CABLE SYSTEM
3x7 1x7
0.032 in. (0.813 mm) 0.020 in (0.508 mm)
DIAMETER DIAMETER
ram2024002_011.dg, yf, 05/09/03
SAFETY CABLE CONSTRUCTION

(CROSS SECTION)
NOTE
All dimensions are shown in inches
with the millimeters shown in parenthesis.
Safety Cable − Installation

Master
20−24−00 Page 214
Apr 20/2004
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ram2024002_006.dg, rm, 20/01/00
SAFETY CABLE INSTALLATION

Master
20−24−00 Page 215
Apr 20/2004
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FERRULE
SAFETY CABLE
BOLT HEAD BOLT HEAD
STOP BOLT STOP BOLT
JAM NUT SAFETY CABLE SAFETY CABLE
JAM NUT
FERRULE
ram2024002_012.dg, yf, 05/09/03
FERRULE
STRUCTURE
STRUCTURE

Master
20−24−00 Page 216
Apr 20/2004
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B
C
NOTE
For three bolt patterns
A = D + E. D
E
ram2024002_010.dg, rm, 24/01/00
SAFETY CABLE FLEX LIMITS

Master
20−24−00 Page 217
Apr 20/2004
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TASK 20−24−00−910−806
Tab Lock Washers − Maintenance Practices

Subtask 20−24−00−943−004
2. Procedure
Subtask 20−24−00−910−004
A. Install the tab lock washer as follows:
NOTE: If this procedure does not agree with the specified maintenance procedure,
use the specified maintenance procedure.
(1) Use the type and size of tab locking washer specified by the manufacturer for the
size and type of assembly used.
(2) Make sure that the (external) nut is removed from the assembly.
(3) Install the tab lock washer on the threaded part of the assembly.
(4) Install the (external) nut and tighten it against the tab lock washer.
(5) Bend the tabs of the lock washer until each tab is bent against one of the nuts in an
opposite direction to the other tab.
3. Close Out
Subtask 20−24−00−910−005
Master
20−24−00 Page 218
Apr 20/2004
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BENDING TYPICAL INSTALLATION
NOTE
1 Tab lockwasher installation procedure for
RH threaded assemblies shown.
LH assemblies procedure is opposite.
o
90 AND GREATER
1 o
LESS THAN 90
1
ram2024002_007.dg, rm, 24/01/00
ACCEPTABLE NOT ACCEPTABLE

(TENDS TO TIGHTEN NUT) (TENDS TO LOOSEN NUT)
BEND TABS AT AN ANGLE
Tab Lock Washers − Installation

Figure 204
Master
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TASK 20−24−00−910−807
Turnbuckle Safety Devices − Maintenance Practices

Subtask 20−24−00−943−005
Subtask 20−24−00−944−002
06−020 Lubricant, Anti−Corrosion
Subtask 20−24−00−946−002
TASK 20−24−00−910−802 Lockwire − Maintenance Practices
2. Procedure
Subtask 20−24−00−910−006
Refer to Figure 205, Table 203 and Table 204.
A. To safety a turnbuckle with locking clips, do the steps that follow:
(1) Install the turnbuckles at the ends of the threaded terminals.
(2) Make sure that the two threaded terminals are installed at an equal distance from
the center of the turnbuckle.
(3) Apply the correct tension to the cable (refer to the applicable maintenance
procedure for the correct cable tension).
(4) Make sure that you cannot see more than three threads of any terminal outside the
turnbuckle.
(5) Turn the turnbuckle until one of the slots in the turnbuckle is aligned with the slot in
the cable terminal.
(6) Use the table that follows as a guide in the selection of locking clips that are
available for turnbuckles.
Master
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Dec 15/2004
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Cable Diameter Thread UNF−3 Locking Clip Turnbuckle MS21251A

[1]MS21256 or B
1/16 No. 6−40 −1 2S
−2 2L
3/32 No. 10−32 −1 3S
−2 3L
5/32 1/4 to 28 −1 5S
−2 5L
3/16 5/16 to 24 −1 6S
−2 6L
1/4 3/8 to 24 −2 8L
9/32 7/16 to 20 −3 9L
5/16 1/2 to 20 −3 10L
Note: Two locking clips are necessary for each turnbuckle.
Selection of Locking Clips for Turnbuckles
Table 203
CAUTION: DO NOT USE THE TURNBUCKLE LOCKING CLIP AGAIN AFTER ITS
REMOVAL. THE USED LOCKING CLIP WILL NOT ENGAGE
CORRECTLY. THIS COULD CAUSE THE TURNBUCKLE LOCKING
CLIP TO DISCONNECT FROM THE CABLE AND LET THE CABLE
LOOSEN. THIS COULD RESULT IN THE INCORRECT OPERATION
OF THE CABLE AND DAMAGE TO EQUIPMENT.
(7) Take a locking clip that is open and not twisted. Put the straight end of the clip into
the slot in the turnbuckle.
(8) Put the locking clip hook over the hole in the center of the turnbuckle. Push the
hook end into the hole until it engages and cannot easily be removed.
(9) Push the shoulder of the hook to engage the hook in the turnbuckle.
(10) Do the same procedure to lock the cable terminal at the other end of the turnbuckle.
NOTE: You can put the locking clips in the same side, or in opposite sides, of the
turnbuckle holes.
(11) Lightly turn the turnbuckle to make sure that the two locking clips are correctly
installed.
(12) Examine the locking clips and make sure that the ends of the hooks stay engaged
in the turnbuckle.
B. To safety a turnbuckle with lockwire (double wrap method), do the steps that follow:
(1) Put an appropriate length of lockwire through the hole in the center of the
turnbuckle. Make sure that the center point of the wire is at the center of the
turnbuckle.
NOTE: Use the correct size of lockwire as shown in the table that follows:
Master
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Cable Diameter (in inches) Lockwire Ref.

1/16 05−003
3/32 or 1/8 05−004
5/32 to 5/16 05−005
Selection of Lockwire for Turnbuckles
Table 204
(2) Put the wire through the terminal at one end of the turnbuckle, as follows:
(a) If it is a swaged terminal with a hole through it, put the end of the lockwire
through the hole.
(b) If it is a fork−end terminal, put the end of the lockwire between the sides of the
fork.
(c) If it is an eye−end terminal, put the lockwire through the eye.
(3) Pull the lockwire tight and then wind the lockwire a minimum of four turns around
the terminal. Make sure that all the turns are outside the lockwire that is parallel to
the terminal.
INJURIES.
(4) Cut the lockwire after the fourth turn around the terminal.
(5) With the free end of the lockwire, repeat the safetying procedure at the opposite
end of the turnbuckle.
(6) Put a second piece of lockwire through the center of the turnbuckle.
(7) Repeat the turnbuckle safetying procedure in the opposite direction with the second
piece of lockwire.
(8) Make sure that there are four turns of lockwire in two places on each terminal.
(9) Make sure that the ends of the lockwire are near the surface of the terminal.
3. Close Out
Subtask 20−24−00−910−007
Master
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FORKED 4 TURNS WRAP CABLE EYE

TERMINAL TERMINAL
SWAGED 4 TURNS WRAP CABLE EYE

TERMINAL TERMINAL
FIN EYE 4 TURNS WRAP CABLE EYE

TERMINAL TERMINAL
TURNBUCKLE SAFETY WIRING
LOCKING CLIP UNTWISTED AND OPEN A

(READY FOR INSERTION)
LOCKING CLIP TURNBUCKLE SWAGED TERMINAL

MS21260 ram2024002_008.dg, rm, 24/01/00
METHOD OF ASSEMBLING LOCKING CLIPS,

TURNBUCKLE BODY AND TERMINALS
Turnbuckle Safetying with Clips and Lockwire

Figure 205
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TASK 20−24−00−910−809
Rod−End Assembly Safety Devices − Maintenance Practices

Subtask 20−24−00−943−006
Subtask 20−24−00−946−003
TASK 20−24−00−910−806 Tab Lock Washer − Maintenance Practices
2. Procedure
Subtask 20−24−00−910−008
A. Obey the precautions for lockwire installation as follows:
INJURIES.
(1) Wear safety glasses when you cut the lockwire. When the lockwire is cut, pieces
CAUTION: DO NOT USE THE LOCKWIRE AGAIN AFTER ITS REMOVAL. USED
LOCKWIRE CAN BE WEAKER WHEN IT IS REMOVED. WEAK LOCKWIRE
CAN BREAK AND CAN RESULT IN DAMAGE TO THE EQUIPMENT.
B. Install the rod−end assembly safety devices as follows:
(1) Adjust the rod−end on the assembly until the threads are engaged.
NOTE: To make sure that the rod−end is correctly positioned and safetied, put a
piece of lockwire in the inspection hole. When the lockwire cannot go
through the inspection hole, the rod−end is in the correct position.
(2) Install a tab lock washer on the rod−end (Ref. TASK 20−24−00−910−806).
(3) Safety the tab locking washer to the rod−end with lockwire (Ref. TASK
20−24−00−910−802).
Master
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3. Close Out
Subtask 20−24−00−941−004
Master
20−24−00 Page 225
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INSPECTION HOLE
ram2024002_009.dg, rm, 20/01/00
INSPECTION HOLE
Rod−End Assembly − Installation

Figure 206
Master
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**ON A/C ALL
BUSHINGS AND BEARINGS − MAINTENANCE PRACTICES
1. General
– Assembly of bushed joints
– Removal and installation of interference fit bushings
– Removal and installation of bearings.
TASK 20−26−00−910−801
Bushed Joint Assemblies − Assembly Data

Subtask 20−26−00−944−001
04−001 Grease, aircraft, general purpose, wide
temperature range
Subtask 20−26−00−946−008
CMM (CSP A−033) Fits and Clearances
2. Job Set−Up
Subtask 20−26−00−910−001
WARNING: USE THE APPLICABLE SAFETY EQUIPMENT WHEN YOU DO THIS
PROCEDURE. IF YOU DO NOT DO THIS, YOU CAN CAUSE INJURY TO
YOUR EYES AND OTHER BODY TISSUES.
A. Obey the safety precautions that follow:
(1) Make sure to wear the applicable safety equipment.
3. Procedure
Subtask 20−26−00−420−001
A. Assemble bushed joints as follows:
NOTE: Bushed joint assemblies are used, together with spherical self−aligning
bearings, at the flight−control hinge points and linkages, and at the
wing−to−fuselage mating joints.
Master
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(1) Apply a layer of grease on the bolts and on the straight or flanged slip−bush
surfaces.
(2) Assemble the bushed joints.
(3) Torque the nuts and install the cotter pins.
NOTE: The given tolerance and clearance dimensions apply to new items and
installations. For the worn tolerances and clearances, refer to the
Component Maintenance Manual (CSP A−033).
4. Close Out
Subtask 20−26−00−941−001
Master
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0.030 (0.76)
0.020 (0.51) 0.090 (2.29)
0.050 (1.27)
NAS538B
FLANGED
BUSHING
CLAMPED
BUSHING
A
FLANGED SLIP
BUSHING
A
BOLT 1
STRAIGHT
0.030 (0.76) BUSHING
0.090 (2.29) 0.010 (0.25)
0.090 (2.29)
CLAMPED CONFIGURATION
NAS538B STRAIGHT
BUSHING BUSHING 0.020 (0.51) STRAIGHT
(TYPICAL) 0.050 (1.27) BUSHING
(TYPICAL)
WASHER
1 BOLT
0.030 (0.76)
0.030 (0.76) 0.090 (2.29)
ANTI−ROTATION
0.090 (2.29) (TYPICAL)
DEVICE
(TYPICAL)
ram2026002_001.dg,gg,5/07/93
NOTE NOT−CLAMPED CONFIGURATION
1 The direction of the bolt is optional

unless differently shown.
2. All dimensions are given in inches
followed by millimeters in parentheses.
Bushed Joints − Configurations and Tolerances

Master
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Apr 20/2004
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INTERFERENCE FIT
NAS538B BUSHING −
+0.0000 FLANGED LINE−REAMED ON
−0.0007 CLAMPED STRAIGHT INSTALLATION
(−0.018) BUSHING BOLT BUSHING
−0.0005 +0.0008 −0.0001 +0.0008

(−0.013) (+0.020) (−0.003) (+0.020)
−0.0015 −0.0000 −0.0006 −0.0000
(−0.038) (−0.015)
1 1
0.0005 (0.013) 0.0005 (0.013) 0.0001 (0.003)

0.0023 (0.058) 0.0023 (0.058) 0.0014 (0.036)
CLEARANCE CLEARANCE CLEARANCE
0.0006 (0.015)
0.0037 (0.093)
TOTAL CLEARANCE
TOLERANCES ON CLAMPED JOINT
NOTE
ram2026002_002.dg, lc, 24/06/93
1 Compared to the nominal diameter

of the bushing or the bolt.
2. All dimensions are given in

inches followed by millimeters
in parentheses.
Bushed Joints − Configurations and Tolerances

Master
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Apr 20/2004
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TASK 20−26−00−910−802
Removal of Interference Fit Bushings

Subtask 20−26−00−943−001
None specified Hydraulic press
None specified Bushing removal tool (made locally)
None specified Threaded pulling tools (made locally)
Subtask 20−26−00−944−002
11−007 Methyl ethyl ketone
Subtask 20−26−00−946−001
SRM 51−13−01 Defect and Damage Repair Requests − Report
Procedure
2. Job Set−Up
Subtask 20−26−00−910−013
3. Procedure
Subtask 20−26−00−020−001
A. Remove incorrectly installed or worn bushings from their housings as follows:
CAUTION: DO NOT REMOVE BUSHINGS OR BEARINGS WITH A HAMMER. IF
YOU DO THIS, IT CAN CAUSE DAMAGE TO THE BUSHING OR
BEARING HOUSING.
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CAUTION: IF YOU CANNOT CORRECTLY HOLD THE HOUSING, DO NOT
REMOVE THE BUSHINGS OR BEARINGS WITH A PRESS. YOU CAN
DAMAGE THE HOUSING.
(1) Use the bushing removal tool together with the hydraulic press or a threaded pulling
tool and carefully remove the bushing.
(2) Remove all signs of primer or other material in the housing bore with methyl ethyl
ketone (Ref. TASK 51−26−00−110−801).
(3) Examine the housing bore for gouges, scores, corrosion, and other damage.
(4) Measure the housing bore diameter and compare the result with the dimensions
given in the Component Maintenance Manual (CMM) (CSP A−033), or the
applicable engineering document.
(5) If the bore is damaged or if you cannot get the minimum permitted interference fit,
refer to Bombardier Regional Aircraft Division (BRAD) for repair data (Ref. SRM
51−13−01).
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PRESS
BUSHING
REMOVAL TOOL
W + 0.100 in. 0.005 in. (0.13 mm)

(2.5 mm) MINIMUM CLEARANCE
HOUSING
BUSHING
SUPPORT
ram2026002_003.dg, lc, 29/06/93
Interference Fit Bushings − Removal

Figure 202
Master
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Apr 20/2004
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TASK 20−26−00−910−803
Thermal Installation of Interference Fit Bushings

Subtask 20−26−00−943−002
None specified Containers, metal, Styrofoam−insulated
None specified Refrigerator − approved for operation below −18 °C
(0 °F)
None specified Furnace, approved electrical type − approved for
operation thru 260 °C (500 °F)
None specified Tongs, metal
None specified Bushing installation mandrels (made locally)
Subtask 20−26−00−944−003
05−019 Carbon dioxide, solid, (dry ice)
05−074 Liquid nitrogen
13−001 Primer, fluid−resistant (Mastinox 6856)
13−002 Primer coating, epoxy, chemical, and solvent
resistant
11−018 Solvent, dry cleaning and degreasing
Subtask 20−26−00−946−002
2. Job Set−Up
Subtask 20−26−00−910−014
Master
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Apr 20/2004
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3. Procedure
Subtask 20−26−00−420−002
NOTE: This task is applicable only to interference−fit nonporous bushings. It is not applicable to
porous oil−soaked bushings.
A. Install the bushings as follows:
(1) Remove all burrs, gouges, or other defects from the bushing and the related
housing. Break all sharp edges 0.005 inches (0.127 mm).
(2) Clean the bushing and the housing with solvent (Ref. TASK 51−26−00−110−801).
(3) Refer to Table 201, Table 202, Table 203, or Table 204 for the selection of the
easiest possible procedure or combination of procedures that will temporarily
remove the interference for a given:
– Housing material
– Interference condition.
NOTE: Where it is not easy to apply heat to the housing because of problems
with the dimensions or other conditions, make the bushing cold to remove
the interference.
WARNING: USE PROTECTIVE CLOTHING AND APPROVED EYE PROTECTION
WHEN YOU USE LIQUID NITROGEN OR THE DRY ICE/DRY
CLEANING SOLVENT MIXTURE. THESE MATERIALS CAN CAUSE
INJURIES TO BODY TISSUES.
WARNING: USE TONGS OR INSTALLATION TOOLS TO PUT THE BUSHINGS
INTO THE COOLING MATERIAL AND TO REMOVE THEM FROM THE
COOLING MATERIAL. THE COOLING MATERIALS AND THE COLD
BUSHINGS CAN CAUSE INJURIES TO YOUR SKIN.
WARNING: KEEP LIQUID NITROGEN OR DRY ICE/DRY−CLEANING SOLVENT
MIXTURE IN METAL CONTAINERS THAT ARE INSULATED WITH
STYROFOAM. PLASTIC CONTAINERS CAN BREAK AND THE
LEAKAGE OF COOLING MATERIAL CAN CAUSE INJURIES OR
DAMAGE.
(4) When necessary, use a cooling procedure and make the tongs or the installation
tools cold together with the bushing. Keep the bushing and the tongs or installation
tools in the cooling material for the time specified in Table 205 for a given section
thickness.
NOTE: The section thickness is the thickest part of the bushing or the installation
tool which is fully in the cooling material.
NOTE: Use dry ice in a crushed dry form or as a mixture of crushed dry ice and
dry cleaning solvent.
CAUTION: DO NOT APPLY HEAT TO ALUMINUM ALLOY HOUSINGS MADE
FROM 2XXX MATERIAL IN THE NATURALLY AGED CONDITION
(SUCH AS −T31, −T36, −T351, −T352, −T3511, −T4, AND −T42). THIS
WILL MAKE THE PART WEAKER.
Master
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CAUTION: DO NOT APPLY HEAT TO STEEL HOUSINGS WHERE THE LAST
HEAT−TREATMENT TEMPERING PROCEDURE WAS DONE AT 260
°C (500 °F) OR LESS. IF THE HEAT TREATMENT TEMPERING
CONDITION IS UNKNOWN, CONTACT BOMBARDIER REGIONAL
AIRCRAFT DIVISION (BRAD) FOR DATA. IF YOU HEAT STEEL IN
THIS CONDITION IT BECOMES WEAKER.
(5) When necessary or applicable, apply heat to the housing as specified in Table 201,
Table 202, Table 203, or Table 204. Keep the housing in the oven for the time
specified in Table 205.
NOTE: You can heat the housing more than once, but the maximum total time at
the specified temperature must not be more than 60 minutes. Make a
record of the temperature and the time at that temperature for each part.
(6) After the housing is removed from the oven, and unless specified, apply epoxy or
Mastinox primer to the bushing installation hole.
Bushing Nominal Outer Diameter − in. (mm)
Above Above Above Above Above Above
Thermal
Thru 0.25 0.50 0.75 1.0 1.5 2.0
Operation
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Refer to
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
CAUTION
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Measured Interference − in. (mm)
Put the
bushing in a 0.0001 0.0002 0.0003 0.0004 0.0006 0.0008 0.0010
refrigerator at (0.0025) (0.005) (0.008) (0.010) (0.015) (0.020) (0.025)
−18 °C (0 °F)
Put the
bushing fully
in a dry ice 0.0002 0.0004 0.0006 0.0008 0.0012 0.0016 0.0020
mixture at (0.005) (0.010) (0.015) (0.020) (0.030) (0.041) (0.051)
−68 °C (−90
°F)
Put the
bushing fully
in liquid 0.0005 0.0011 0.0016 0.0022 0.0033 0.0043 0.0053
nitrogen at (0.013) (0.028) (0.041) (0.056) (0.084) (0.109) (0.135)
−195 °C
(−320 °F)
Apply heat at
176 °C (350 0.0008 0.0016 0.0025 0.0033 0.0050 0.0066 0.0083
°F) to the (0.020) (0.041) (0.064) (0.084) (0.127) (0.168) (0.211)
housing
THERMAL OPERATION DATA FOR BUSHING INSTALLATION IN AL ALLOY

HOUSING − 2XXX SERIES
Table 201
Master
20−26−00 Page 210
Apr 20/2004
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Thermal
Thru 0.25 0.50 0.75 1.0 1.5 2.0
Operation
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Refer to
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
CAUTION
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Apply heat at
176 °C (350
°F) to the
housing − 0.0009 0.0018 0.0028 0.0037 0.0056 0.0075 0.0093
Put the (0.023) (0.046) (0.071) (0.094) (0.142) (0.191) (0.236)
bushing in a
refrigerator at
−18 °C (0 °F)
Apply heat at
176 °C (350
°F) to the
housing −
Put the 0.0010 0.0020 0.0031 0.0041 0.0060 0.0082 0.0100
bushing fully (0.025) (0.051) (0.079) (0.104) (0.152) (0.208) (0.254)
in a dry ice
mixture at
−68 °C (−90
°F)
Apply heat at
176 °C (350
°F) to the
housing −
Put the 0.0013 0.0028 0.0041 0.0053 0.0083 0.0110 0.0136
bushing fully (0.033 (0.071) (0.104) (0.135) (0.211) (0.280) (0.345)
in liquid
nitrogen at
−195 °C
(−320 °F)

HOUSING − 2XXX SERIES
Table 201
Master
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Apr 20/2004
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Put the
bushing in a 0.0001 0.0002 0.0003 0.0004 0.0006 0.0008 0.0010
refrigerator at (0.0025) (0.005) (0.008) (0.010) (0.015) (0.020) (0.025)
−18 °C (0 °F)
Put the
bushing fully
in a dry ice 0.0002 0.0003 0.0005 0.0007 0.0011 0.0015 0.0019
mixture at (0.005) (0.008) (0.013) (0.018) (0.028) (0.038) (0.048)
−68 °C (−90
°F)
Put the
bushing fully
in liquid 0.0005 0.0011 0.0016 0.0022 0.0033 0.0043 0.0053
nitrogen at (0.013) (0.028) (0.041) (0.056) (0.084) (0.109) (0.135)
−195 °C
(−320 °F)
Apply heat at
121 °C (250 0.0005 0.0011 0.0016 0.0022 0.0032 0.0043 0.0053
°F) to the (0.013) (0.028) (0.041) (0.056) (0.081) (0.109) (0.135)
housing
Apply heat at
121 °C (250
°F) to the
housing − 0.0006 0.0013 0.0019 0.0025 0.0036 0.0050 0.0063
Put the (0.015) (0.033) (0.048) (0.064) (0.091) (0.127) (0.160)
bushing in a
refrigerator at
−18 °C (0 °F)

HOUSINGS − 6XXX AND 7XXX SERIES
Table 202
Master
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Apply heat at
121 °C (250
°F) to the
housing −
Put the 0.0007 0.0014 0.0021 0.0029 0.0043 0.0056 0.0070
bushing fully (0.018) (0.036) (0.053) (0.074) (0.109) (0.142) (0.142)
in a dry ice
mixture at
−68 °C (−90
°F)
Apply heat at
121 °C (250
°F) to the
housing −
Put the 0.0010 0.0021 0.0032 0.0044 0.0065 0.0086 0.0106
bushing fully (0.025) (0.053) (0.081) (0.112) (0.165) (0.218) (0.269)
in liquid
nitrogen at
−195 °C
(−320 °F)

HOUSINGS − 6XXX AND 7XXX SERIES
Table 202

Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Put the
bushing in a 0.0001 0.0002 0.0003 0.0004 0.0006 0.0008 0.0010
refrigerator at (0.0025) (0.005) (0.008) (0.010) (0.015) (0.020) (0.025)
−18 °C (0 °F)
THERMAL OPERATION DATA FOR BUSHING INSTALLATION IN TITANIUM

ALLOY HOUSINGS
Table 203
Master
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Put the
bushing fully
in a dry ice 0.0002 0.0003 0.0005 0.0007 0.0011 0.0015 0.0019
mixture at (0.005) (0.008) (0.013) (0.018) (0.028) (0.038) (0.048)
−68 °C (−90
°F)
Put the
bushing fully
in liquid 0.0005 0.0011 0.0016 0.0022 0.0033 0.0043 0.0053
nitrogen at (0.013) (0.028) (0.041) (0.056) (0.084) (0.109) (0.135)
−195 °C
(−320 °F)
Apply heat at
232 °C (450 0.0004 0.0009 0.0014 0.0019 0.0029 0.0039 0.0049
°F) to the (0.010) (0.023) (0.036) (0.048) (0.074) (0.099) (0.124)
housing
Apply heat at
232 °C (450
°F) to the
housing − 0.0005 0.0011 0.0017 0.0023 0.0033 0.0046 0.0056
Put the (0.013) (0.028) (0.043) (0.058) (0.084) (0.117) (0.142)
bushing in a
refrigerator at
−18 °C (0 °F)
Apply heat at
232 °C (450
°F) to the
housing −
Put the 0.0006 0.0013 0.0030 0.0026 0.0041 0.0055 0.0066
bushing fully (0.015) (0.033) (0.076) (0.066) (0.104) (0.140) (0.168)
in a dry ice
mixture at
−68 °C (−90
°F)

ALLOY HOUSINGS
Table 203
Master
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Apply heat at
232 °C (450
°F) to the
housing −
Put the 0.0010 0.0020 0.0031 0.0042 0.0063 0.0083 0.0100
bushing fully (0.025) (0.068) (0.079) (0.107) (0.160) (0.211) (0.254)
in liquid
nitrogen at
−195 °C
(−320 °F)

ALLOY HOUSINGS
Table 203

Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Put the
bushing in a 0.0001 0.0002 0.0003 0.0004 0.0006 0.0008 0.0010
refrigerator at (0.0025) (0.005) (0.008) (0.010) (0.015) (0.020) (0.025)
−18 °C (0 °F)
Put the
bushing fully
in a dry ice 0.0002 0.0003 0.0005 0.0007 0.0011 0.0015 0.0019
mixture at (0.005) (0.008) (0.013) (0.018) (0.028) (0.038) (0.048)
−68 °C (−90
°F)
THERMAL OPERATION DATA FOR BUSHING INSTALLATION IN ALLOY STEEL

HOUSINGS
Table 204
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Put the
bushing fully
in liquid 0.0005 0.0011 0.0016 0.0022 0.0033 0.0043 0.0053
nitrogen at (0.013) (0.028) (0.041) (0.056) (0.084) (0.109) (0.135)
−195 °C
(−320 °F)
Apply heat at
232 °C (450 0.0005 0.0010 0.0016 0.0021 0.0032 0.0043 0.0054
°F) to the (0.013) (0.025) (0.041) (0.053) (0.081) (0.109) (0.137)
housing
Apply heat at
232 °C (450
°F) to the
housing − 0.0005 0.0012 0.0019 0.0025 0.0038 0.0051 0.0064
Put the (0.013) (0.030) (0.048) (0.064) (0.096) (0.130) (0.163)
bushing in a
refrigerator at
−18 °C (0 °F)
Apply heat at
232 °C (450
°F) to the
housing −
Put the 0.0006 0.0014 0.0022 0.0029 0.0044 0.0059 0.0074
bushing fully (0.015) (0.036) (0.056) (0.074) (0.112) (0.150) (0.188)
in a dry ice
mixture at
−68 °C (−90
°F)

HOUSINGS
Table 204
Master
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Thru 0.25 0.50 0.75 1.0 1.5 2.0
Thermal
0.25 (6.35) to (12.7) to (19.0) to (25.4) to (38.1) to (50.1) to
Operation
(6.35) 0.50 0.75 1.0 1.5 2.0 2.5
(12.7) (19.0) (25.4) (38.1) (50.1) (63.5)
Apply heat at
232 °C (450
°F) to the
housing −
Put the 0.0010 0.0021 0.0033 0.0044 0.0066 0.0086 0.0108
bushing fully (0.025) (0.053) (0.084) (0.112) (0.168) (0.218) (0.274)
in liquid
nitrogen at
−195 °C
(−320 °F)

HOUSINGS
Table 204
Soaking Time − Minutes

Section Thickness − in. (mm)
Liquid Air
Thru 0.125 (6.35) 5 10
Above 0.125 (6.35) to 0.50 (12.7) 7 15
Above 0.50 (12.7) to 1.00 (25.4) 10 20
Above 1.00 (25.4) to 1.50 (38.1) 13 25
Above 1.50 (38.1) to 2.00 (50.8) 17 30
Above 2.00 (50.8) to 2.50 (63.5) 21 35
Above 2.5 (63.5) to 3.00 (76.2) 25 40
Above 3.00 (76.2) to 3.50 (88.9) 30 45
Above 3.50 (88.9) to 4.00 (101.6) 35 50
THERMAL SOAKING TIME AT TEMPERATURE − HOT OR COLD

Table 205
(7) After removal from the cooling material, wet−install the bushings as follows:
(a) For bushings without lubrication holes or grooves, apply epoxy or Mastinox
primer to the bushing outer diameter and install wet.
NOTE: Do not get the primer on the bushing wear surfaces.
(b) For bushings with lubrication holes or grooves, apply the same material as
used for lubrication to the bushing outer diameter and install wet.
(c) Make the bushing smaller as necessary to get a slip fit.
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(d) Make sure that you can see a fillet of the installation material around the
surface of the bushing after installation. Remove unwanted installation
material.
(8) Make sure that the mating face of flanged bushings is correctly installed against the
housing.
(9) After all components have gone back to room temperature, do a check on the
dimensions of the bushing inner diameter.
(10) If necessary, ream or machine the bushing inner diameter to engineering
specifications.
NOTE: Make sure that the bushing inner diameter is correctly axially aligned.
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TASK 20−26−00−910−804
Mechanical Installation of Interference Fit Bushings

Subtask 20−26−00−943−003
None specified Threaded pulling tools (make locally)
Subtask 20−26−00−944−004
Primer coating, epoxy, chemical, and solvent
13−002
resistant
Subtask 20−26−00−946−003
2. Job Set−Up
Subtask 20−26−00−910−015
3. Procedure
Subtask 20−26−00−420−003
A. Use this procedure when:
– The heat increases or decreases sufficiently fast that you cannot get the necessary
thermal effect
– Teflon−lined bushings are installed.
(1) Install the bushings as follows:
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(a) Remove all burrs, gouges, or other defects from the bushing and the related
housing. Break all sharp edges 0.005 inches (0.127 mm).
(b) Chamfer the bushing sufficiently to supply a lead−in.
(c) Clean the bushing and the housing (Ref. TASK 51−26−00−110−801).
(d) With a hydraulic press or threaded pulling tools, wet install the bushings as
follows:
1 For bushings without lubrication holes or grooves, apply epoxy or Mastinox
primer to the bushing outer diameter and install wet.
NOTE: Do not get the primer on the bushing wear surfaces.
2 For bushings with lubrication holes or grooves, apply the same material as
used for lubrication to the bushing outer diameter and install wet.
3 Make sure that you can see a fillet of the installation material around the
surface of the bushing after installation. Remove unwanted installation
material.
4 Make sure that the bushing does not remove metal from the housing during
installation.
5 Make sure that no damage occurs to the bushing or the housing during
installation.
(e) Make sure that the mating face of flanged bushings is correctly installed
against the housing.
(f) Do a check on the dimensions of the bushing inner diameter.
(g) If necessary and applicable, ream or machine the bushing inner diameter to
engineering specifications.
NOTE: Make sure that the bushing inner diameter is correctly axially
aligned.
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TASK 20−26−00−910−805
Removal of Staked Bearings

Subtask 20−26−00−943−004
None specified Bearing removal/installation tool (made locally)
Subtask 20−26−00−944−005
Subtask 20−26−00−946−004
Procedure
CMM (CSP A−033) Fits and Clearances Tables
Applicable Engineering Documents Dimensions and Tolerances
2. Job Set−Up
Subtask 20−26−00−910−016
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3. Procedure
Subtask 20−26−00−020−002
NOTE: Staking of replacement bearings is permitted only once. Where the bearing was replaced
and staked in position once before, all subsequent replacement bearings must be held in
position by another procedure. Refer to the Component Maintenance Manual (CMM)
(CSP A−033), or contact Bombardier Regional Aircraft Division (BRAD) for repair data
(Ref. SRM 51−13−01).
A. Remove damaged or worn staked bearings from their housings as follows:
CAUTION: DO NOT REMOVE BUSHINGS OR BEARINGS WITH A HAMMER. IF
YOU DO THIS, IT CAN CAUSE DAMAGE TO THE BUSHING OR
BEARING HOUSING.
CAUTION: IF YOU CANNOT CORRECTLY HOLD THE HOUSING, DO NOT
REMOVE THE BUSHINGS OR BEARINGS WITH A PRESS. YOU CAN
DAMAGE THE HOUSING.
(1) Use the bearing removal tool together with the hydraulic press or a threaded pulling
tool and carefully remove the bearing.
NOTE: When the bearing is installed in a shouldered housing, carefully apply
pressure on the inner race.
ketone (Ref. TASK 51−26−00−110−801).
(3) Examine the housing bore for gouges, scores, corrosion, cracks at the initial stakes,
and other damage.
(4) Examine the housing bore and make sure that the staking procedure was done only
once.
given in the CMM, or the applicable engineering document.
(6) Refer to the CMM or to BRAD for repair data (Ref. SRM 51−13−01) if:
– The staking procedure was done more than once
– You cannot get the specified minimum interference/clearance fit condition
– There is other damage in the bore.
(7) Carefully remove projections of metal caused by the removal procedure in the area
of the stakes.
NOTE: Do not chamfer or remove the sharp edges of the housing.
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REMOVAL AND
INSTALLATION TOOL
SET SCREW
HOUSING
0.005 in. (0.13 mm)

BEARING MINIMUM CLEARANCE
OUTER
BEARING
RACE
INNER
RACE
REMOVAL AND
INSTALLATION
TOOL
PILOT
SUPPORT
REMOVAL OF UNSERVICEABLE
BEARING
SET SCREW
STOP
BEARING
OUTER
RACE
NOTE
1 Apply wet−installation BEARING
material to the housing INNER
bore. RACE
ram2026002_010.dg, sb, 07/07/93
PILOT
HOUSING
SUPPORT 1
INSTALLATION OF REPLACEMENT
BEARING
Staked Bearings − Removal/Installation

Figure 203
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TASK 20−26−00−910−806
Installation of Staked Bearings

Subtask 20−26−00−943−005
Canadair tool drawing GT 995040 Staking tools
Canadair tool drawing GT 90688 Staking tools
Subtask 20−26−00−944−006
resistant
Subtask 20−26−00−946−007
2. Job Set−Up
Subtask 20−26−00−910−023
3. Procedure
Subtask 20−26−00−420−004
NOTE: This task is applicable only to ball and roller bearings that are held in position by a
staking procedure. It is not applicable to spherical bearings that are held in position by
press−swaging of the bearing race.
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A. Install the bearings as follows:
(1) Clean the housing bore and the bearing outer surfaces (Ref. TASK
51−26−00−110−801).
NOTE: Do not get the solvent into the bearing or on the ball or roller surfaces.
(2) Immediately before the bearing is installed, apply a coating of wet−installation
material on the housing bore as follows:
(a) For bearings without lubrication holes or grooves, apply Mastinox or epoxy
primer.
NOTE: Do not get the primer into the bearing or on the ball or roller
surfaces.
(b) For bearings with lubrication holes or grooves, apply the same grease or oil
that is used for lubrication.
(3) Apply pressure to the bearing outer race and push in the bearing with a hydraulic
press or a threaded pulling tool.
NOTE: Do not apply pressure to the bearing inner race, the shields, or the seals.
NOTE: It is possible that the bearing and housing bore tolerances will give a
permitted clearance−fit and permit manual installation.
(4) Make sure that there is a fillet of the wet−installation material around the edge of
the bearing outer race after the installation. Remove unwanted material.
(5) When staking of the bearing housing is permitted (less than 50 percent of the
housing bore was staked before), do the procedure that follows:
(a) Put the staking tool in position to engage the staking segments in the center
between and aligned circumferentially with the initial stakes. Where the two
sides of the housing have stakes, make sure the staking segments of the two
tools are opposite to each other.
NOTE: For housings with a wall thickness of 0.150 inch (3.8 mm) or more,
use staking tools that agree with drawing GT 995040. For housings
with a wall thickness of less than 0.150 inch (3.8 mm), use staking
tools that agree with drawing GT 90688.
(b) Make sure the bearing housing and/or the bearing are correctly held and apply
sufficient pressure to push the staking segments fully into the housing.
(c) Examine the stakes and make sure that staking depths are as follows:
1 For housings with a wall thickness of 0.150 inches (3.8 mm) or more −
0.020 ±0.002 inches (0.51 ±0.05 mm).
2 For housings with a wall thickness of less than 0.150 inches (3.8 mm) −
0.011 to 0.014 inches (0.28 to 0.36 mm).
NOTE: Do not include the thickness of paint or primer when you
measure the depth of the stakes.
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TOOL CLEARANCE
HOUSING WALL
THICKNESS
HOUSING WIDTH
DO NOT CHAMFER THE EDGE OF THE BORE

BEARING RADIUS
OR CHAMFER BEARING WIDTH
NOT−SHOULDERED HOUSING
HOUSING WALL
THICKNESS
HOUSING WIDTH
SHOULDERED HOUSING
BEARING
HOUSING
PUT THE STAKING SEGMENTS

OPPOSITE EACH OTHER AND
BETWEEN THE INITIAL STAKES
ram2026002_011.dg, sb, 07/07/93
STAKING TOOLS
Staking of Bearings
Figure 204
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TASK 20−26−00−910−807
Removal of Swaged Bearings

Subtask 20−26−00−943−006
None specified Machine tools for removing bearing swage
Subtask 20−26−00−944−007
Subtask 20−26−00−946−005
TASK 20−26−00−910−805 Removal of Staked Bearings
Procedure
CMM (CSP A−033) Fits and Clearances Tables
2. Job Set−Up
Subtask 20−26−00−910−017
3. Procedure
NOTE: This procedure is applicable to roller−swaged and press−swaged bearings.
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Subtask 20−26−00−020−003
A. Remove damaged or worn swaged spherical bearings from their housings as follows:
(1) With the applicable machine tool, carefully remove the swaged material from one
side of the bearing race.
NOTE: Be careful to prevent damage to the housing bore when you remove the
swaged material from the bearing.
(2) Apply pressure to the machined side to remove the bearing from its housing (Ref.
TASK 20−26−00−910−805).
ketone (Ref. TASK 51−26−00−110−801).
(4) Examine the housing bore for gouges, scores, corrosion, cracks, and other
damage.
given in Table 206, the CMM, or the applicable engineering document.
(6) Refer to the CMM or to BRAD for repair data (Ref. SRM 51−13−01) if:
– You cannot get the specified minimum interference/clearance fit condition
– There is other damage in the bore.
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TASK 20−26−00−910−808
Installation of Swaged Bearings

Subtask 20−26−00−943−007
G601R200007−1 Hydraulic kit, bearing swaging
G601R200008−1 Bearing tool kit, swaging and cutting
None specified Swaging tools − rudder bearings
None specified Swaging tools − spoiler bearings
None specified Swaging tools − elevator bearings
Subtask 20−26−00−944−008
resistant
Subtask 20−26−00−946−006
TASK 20−26−00−910−806 Staked Bearings − Installation
2. Job Set−Up
Subtask 20−26−00−910−018
3. Procedure
NOTE: This procedure is applicable to roller−swaged and press−swaged bearings.
Subtask 20−26−00−420−005
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(1) Clean the housing bore and the bearing outer surfaces (Ref.
TASK 51−26−00−110−801).
NOTE: Do not get the solvent into the bearing.
(a) For bearings without lubrication holes or grooves, apply 13−001 Mastinox or
13−002 epoxy primer.
NOTE: Do not get the 13−002 primer into the bearing or on the ball surface.
(3) Push in the bearing (Ref. TASK 20−26−00−910−806). Make sure that the bearing is
symmetrically installed in its housing.
permitted clearance fit and permit manual installation as per Table 206.
(4) Make sure that there is a fillet of the wet−installation material around the outer
surface of the bearing race after the installation. Remove unwanted material.
CAUTION: WHEN YOU APPLY SWAGING OR OTHER LOADS, MAKE SURE THAT
THE PRESS HAS SUFFICIENT CAPACITY AND THAT THE APPLIED
LOAD GAUGES ARE ACCURATE. IF THIS IS NOT DONE, YOU CAN
CAUSE AN INCORRECT INSTALLATION.
(5) If you use a hydraulic press to swage the bearing, do as follows:
(a) Make a swaging tool selection (by dash No.) as specified by tool drawing
G601R200008−1.
NOTE: For some bearings, a two−stage swaging operation is necessary and
tool drawing G601R200008−1 will specify two sets of tools.
(b) For one−stage press swaging, apply swaging loads as specified in Table 207.
(c) When two−stage press swaging is necessary, do the steps that follow:
1 Apply the swaging load specified in Table 207 with the first set of tools.
2 Apply the same swaging load with the second set of tools.
(6) Apply a proof load as specified in Table 207.
(7) Do a check of the tightness of the ball in the race as specified in Table 208.
NOTE: For fabric− or Teflon−lined bearings, the ball must be sufficiently tight in
the race to make measurable torque necessary to start movement
(breakaway torque). For metal−to−metal bearings, there must be no
binding between the ball and the race.
(a) For the specified bearing, measure the breakaway torque as follows:
1 Move the ball a number of times to remove all local binding.
2 Align the ball symmetrically in the race.
3 Hold the ball tightly with a threaded arbor or bolt and measure the
breakaway torque with a torque wrench.
(b) For the specified bearing, do a no−binding check as follows:
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3 Turn the ball and make sure that it is free in the race and that the maximum
free play is not more than shown.
(8) When an installed bearing does not have the specified breakaway torque or the
no−binding qualities, a torque adjustment procedure is necessary.
NOTE: Do not use the torque adjustment procedure on Teflon−lined bearings
unless specified by engineering authority. For "K" type bearings, torque
adjustment is not permitted.
(9) Do the torque adjustment procedure as follows:
(a) Put the race on a support tool. The tool must have clearance with the ball and
the housing.
(b) Use light pressure initially and apply an axial load to the ball in one direction.
(c) Apply the same axial load to the ball in the opposite direction.
NOTE: Do not apply loads to the ball sufficient to give free play that you can
feel with your fingers.
(d) Increase the applied pressure in small increments until you get the tightness
specified in Table 208.
Housing Bore Diameter (See Note
Bearing Data 1) Housing Thickness
(See Note 1)
Part No. Dash No. inches mm inches mm
MS14101 −3 0.5620−0.5630 14.27−14.30 0.153−0.163 3.89−4.14
MS21154 −4 0.6557−0.6567 16.65−16.68 0.185−0.195 4.70−4.95
MS21232 −5 0.7495−0.7505 19.04−19.06 0.226−0.236 5.74−5.99
ADB−V −5A 0.7495−0.7505 19.04−19.06 0.226−0.236 5.74−5.99
(See −6 0.8120−0.8130 20.62−20.65 0.257−0.267 6.53−6.78
Note 2) −7 0.9057−0.9067 23.00−23.03 0.288−0.298 7.32−7.57
−8 0.9995−1.0005 25.39−25.41 0.295−0.305 7.49−7.45
−9 1.0932−1.0942 27.77−27.79 0.342−0.352 8.69−8.94
−10 1.1870−1.1880 30.15−30.18 0.405−0.415 10.29−10.54
−12 1.4370−1.4380 36.50−36.53 0.498−0.508 12.65−12.90
−14 1.5620−1.5630 39.67−39.70 0.608−0.618 15.44−15.70
−16 1.7495−1.7505 44.44−44.46 0.702−0.712 17.83−18.08
−20 1.9995−2.0005 50.79−50.81 0.847−0.857 21.51−21.77
HOUSING DIMENSIONS
Table 206
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(See Note 1)
ADBY−V −3 0.5620−0.5630 14.27−14.30 0.175−0.185 4.45−4.70
−4 0.7395−0.7405 18.78−18.81 0.220−0.230 5.59−5.84
−5 0.6870−06880 17.45−17.48 0.220−0.230 5.59−5.84
−6 0.9055−0.9065 22.10−23.03 0.310−0.320 7.87−8.13
−7 0.9995−1.0005 25.39−25.41 0.310−0.320 7.87−8.13
−8 1.1245−1.1255 28.56−28.59 0.366−0.376 9.30−9.55
−10 1.3745−1.3755 34.91−34.94 0.512−0.522 13.00−13.26
−12 1.5620−1.5630 39.67−39.70 0.525−0.535 13.34−13.59
−14 1.7495−1.7505 44.44−44.46 0.530−0.540 13.46−13.72
−16 2.1245−2.1255 53.96−53.99 0.740−0.750 18.80−19.05
MS14103 −3 0.6245−0.6255 15.86−15.89 0.262−0.272 6.65−6.91
MS21230 −4 0.6245−0.6255 15.86−15.89 0.262−0.272 6.65−6.91
AW−5V −5 0.6870−0.6880 17.45−17.48 0.272−0.282 6.91−7.16
(See −6 0.8120−0.8130 20.62−20.65 0.351−0.361 8.92−9.17
Note 3) −7 0.9370−0.9380 23.80−23.83 0.387−0.397 9.83−10.08
AW10V −7A 0.9057−0.9067 23.00−23.03 0.387−0.397 9.83−10.08
(See −8 0.9995−1.0005 25.39−25.41 0.450−0.460 11.43−11.68
Note 4)
−9 1.1245−1.1255 28.56−28.59 0.481−0.491 12.22−12.47
−10 1.1870−1.1880 30.15−30.18 0.512−0.522 13.00−13.26
−12 1.3745−1.3755 34.91−34.94 0.535−0.545 13.59−13.84
−14 1.6245−1.6255 41.26−41.29 0.660−0.670 16.76−17.02
−16 2.1245−2.1255 53.96−53.99 0.910−0.920 23.11−23.37
−20 2.3745−2.3755 60.31−60.34 1.035−1.045 26.29−26.54
−22 2.5620−2.5630 65.07−65.10 1.128−1.138 28.65−28.91
−24 2.6870−2.6880 68.25−60.28 1.128−1.138 28.65−28.91
−4 0.6557−0.6567 16.65−16.68 0.185−0.195 4.70−4.95
−5 0.7495−0.7505 19.04−19.06 0.226−0.236 5.74−5.99
−6 0.8120−0.8130 20.62−20.65 0.257−0.267 6.53−6.78
−7 0.9057−.09067 23.00−23.03 0.288−0.298 7.32−7.57
M81936/1
−8 0.9995−1.0005 23.39−25.41 0.295−0.305 7.49−7.75
−9 1.0932−1.0942 27.77−27.79 0.342−0.352 8.69−8.94
−10 1.1870−1.880 30.15−30.18 0.405−0.415 10.29−10.54
−12 1.4370−1.4380 36.50−36.53 0.498−0.508 12.65−12.90
HOUSING DIMENSIONS
Table 206
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(See Note 1)
Note 1. The dimensions are applicable with or without surface treatments such as plating
or anodizing.
Note 2. For ADB−10−V bearings the housing bore diameter is 1.1875−1.1880 in.
(30.16−30.18 mm).
Note 3. For AW 20−5V bearings, the housing bore diameter is 1.9995−2.0005 in.
(50.79−50.81 mm). The housing thickness is 0.832−0.842 in. (21.13−21.39 mm).
Note 4. For AW10V bearings, the housing bore diameter is 1.1870−1.1880 in.
(30.15−30.18 mm). The housing thickness is 0.512−0.522 in. (13.00−13.26 mm)
HOUSING DIMENSIONS
Table 206
Bearing Data Swaging Load Proof Load

Part No. Dash No. Pounds Newtons Pounds Newtons
MS14101 −3 8438 ±3000 37532 ±13344 300 1334
MS21154 −4 9843 ±3000 43782 ±13344 400 1779
MS21232 −5 13500 ±3000 60048 ±13344 700 3114
−5A 13500 ±3000 60048 ±13344 700 3114
AHT−V −6 14625 ±3000 65052 ±13344 1100 4893
ADB−V −7 16312 ±3000 72566 ±13344 1400 6227
KR−CEG −8 25000 ±5000 111200 ±22240 2100 9341
−9 27343 ±5000 121622 ±22240 2460 10942
−10 29688 ±5000 132052 ±22240 3140 13967
−12 35938 ±5000 159852 ±22240 4500 20016
−14 39063 ±5000 173752 ±22240 6220 27667
−16 43750 ±5000 194600 ±22240 8100 36029
−20 57813 ±5000 257152 ±22240 9600 42701
LOAD DATA
Table 207
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C

Part No. Dash No. Pounds Newtons Pounds Newtons
ADBY−V −3 8437 ±3000 37528 ±13344 300 1334
−4 11100 ±3000 49373 ±13344 700 3114
−5 10312 ±3000 45868 ±13344 1100 4893
−6 16310 ±3000 72547 ±13344 1400 6227
−7 25000 ±3000 111200 ±13344 2100 9431
−8 28125 ±5000 125100 ±22240 2300 10230
−10 34370 ±5000 152878 ±22240 3400 15123
−12 39000 ±5000 173472 ±22240 6220 27667
−14 43750 ±5000 194600 ±22240 8100 36029
−16 53125 ±5000 236300 ±22240 9100 40477
MS14103 −3 9375 ±3000 41700 ±13344 900 4003
MS21230 −4 9375 ±3000 41700 ±13344 900 4003
−5 10313 ±3000 45877 ±13344 1100 4893
KWB−20 −6 14625 ±3000 65052 ±13344 1370 6094
KR−CWGB −7 16875 ±3000 75060 ±13344 2100 9341
AW−V −7A 16312 ±3000 72556 ±13344 1400 6227
AW−5V −8 18000 ±3000 80064 ±13344 2100 9341
ADW−V −9 20250 ±3000 90072 ±13344 2300 10230
−10 21375 ±3000 95076 ±13344 2600 11565
QML−R
−12 34375 ±5000 152900 ±22240 3400 15123
−14 40625 ±5000 180700 ±22240 4400 19571
−16 53125 ±5000 236300 ±22240 9100 40477
−20 59375 ±5000 264100 ±22240 10000 44480
−22 64063 ±5000 284952 ±22240 11000 48928
−24 67188 ±5000 298852 ±22240 12100 53821
LOAD DATA
Table 207
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Bearing Part Number

MS14101,
MS14103, MS21154,
ADB−V, ADBY−V, KWB−20,
Dash No. MS21230, QML−R MS21232
ADW−V, AHT−V, AW−V,
KR−CEG, AW−5V
KR−CWGB
Permitted Torque After Installation − Pound−Inches (Newton Meter)
−3 0.25−5 0.5−5 (0.06−0.57) 1−5 (0.113−0.57)
(0.03−0.57)
−4 0.25−5 1−5 (0.113−0.57) 1−5 (0.113−0.57)
(0.03−0.57)
−5 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−5A 1−15 (0.113−1.7) − −
−6 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−7 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−7A 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−8 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57) No binding
−9 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−10 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−12 1−15 (0.113−1.7) 1−5 (0.113−0.57) 1−5 (0.113−0.57)
−14 1−24 (0.113−2.71) 2−8 (0.226−0.904) 2−8 (0.226−0.904)
−16 1−24 (0.113−2.71) 2−8 (0.226−0.904) 2−8 (0.226−0.904)
−20 1−24 (0.113−2.71) − −
−22 1−24 (0.113−2.71) 2−8 (0.226−0.904) 2−8 (0.226−0.904)
−24 1−24 (0.113−2.71) − −
BALL−BEARING BREAKAWAY TORQUE

Table 208
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APPLIED AXIAL LOAD
LOADING TOOL
INSTALLED BEARING BEARING RACE
BALL
HOUSING
CLEARANCE BETWEEN
THE SUPPORT FIXTURE
AND THE BALL
SUPPORT FIXTURE
TORQUE ADJUSTMENT
A B
D
FREE PLAY − METAL−TO−METAL
ram2026002_013.dg, sb/rm, 01/01/04
1 BEARING
NOTE
1 No binding is permitted. The
maximum permitted free play
is 0.0005 in. (0.013 mm) in
direction A−B and 0.003 in.
(0.076 mm) in direction C−D.
Press−Swaged Bearings − Installation

Master
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C
APPLIED AXIAL LOAD
LOADING TOOL
INSTALLED BEARING BEARING RACE
BALL
HOUSING
CLEARANCE BETWEEN
THE SUPPORT FIXTURE
AND THE BALL
SUPPORT FIXTURE
TORQUE ADJUSTMENT
A B
D
FREE PLAY − METAL−TO−METAL
ram2026002_013.dg, sb/rm, 01/01/04
1 BEARING
NOTE
is 0.0005 in. (0.013 mm) in
Press−Swaged Bearings − Installation

Master
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TASK 20−26−00−910−809
Removal of Swaged Aileron Bearings

Subtask 20−26−00−943−008
Subtask 20−26−00−946−009
TASK 20−26−00−910−807 Removal of Swaged Bearings
2. Job Set−Up
Subtask 20−26−00−910−019
3. Procedure
Subtask 20−26−00−030−001
A. Locate and identify the bearing (Ref. Figure 207).
B. Carefully remove the swaged material from one side of the bearing race as follows:
NOTE: Use the applicable cutting tool listed in Table 209. Be careful to prevent
damage to the housing bore when you remove the swaged material from the
bearing.
(1) Unscrew the cap and shaft assembly of the cutting tool.
(2) Insert the shaft assembly through the farside of the bearing. Make sure the
remainder of the tool remains together.
(3) Turn the pressure nut up to the clamp nut and install the tool onto the cap and shaft
assembly.
Master
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C
(4) Tighten the clamp nut securely.
NOTE: Use a standard box or open end wrench on the hex body of the cutting
tool. Use a pin−type spanner wrench or round bar on the round body of
the cutting tool.
(5) Tighten the pressure nut to exert light pressure on the cutter.
(6) Turn the cutter one full turn clockwise and tighten the pressure nut 1/8 turn.
(7) Repeat step 6 until the cutter stops cutting. The cutter stops when it reaches the
bottom of the groove and is against the internal stop.
NOTE: An internal stop on the cutter keeps the cutter teeth from penetrating into
and damaging the housing.
BEARING PART NO. CUTTING TOOL
MS14103−7A RKC4103−7A
MS14103−8 RKC4103−8
KSC327108B RKC4103−8
KR9CWGB RKC4103−9
KSC322209B−1 RKC7112
KSC322209B−2 RKC7113
KSC322209B−3 RKC7114
CUTTING TOOL DATA

Table 209
Subtask 20−26−00−020−004
C. Remove damaged or worn swaged spherical bearings from their housings (Ref. TASK
20−26−00−910−807).
Master
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C
BEARING MS−14103−7A BEARING MS−14103−8
−15
−17
A
A
BEARING KR9−CWGB
A −19
BEARING TOOL KIT− P/N G601R200008−1
CUTTER
LEGEND
PRESSURE
CAP AND SHAFT NUT −15. Cutting tool RKC4103−7A.
ASSEMBLY −17. Cutting tool RKC4103−8.
−19. Cutting tool RKC4103−9.
NOTE
Other cutting tools for different
ram2026002_014.dg, rm/lr, 29/03/04
part number bearings are not

included in this kit.
CLAMP
NUT
A TYPICAL CUTTING ASSEMBLY
Swaged Bearing Cutting Tools

Figure 206
Master
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Jun 22/2004
C
BEARING
KR9CWGB
KSC322209B−1 2
C
KSC322209B−2 3
KSC322209B−3
B
A
AILERON STA
302.640
AILERON STA
311.539
A
VIEW LOOKING UP
NOTES
1. Left side is shown,
INB
right side is opposite. D
2 Standard for this installation.

3 First oversize.
BEARING
Second oversize. MS14103−8
B KSC327108B
AILERON STA
364.016
AILERON STA
375.430 ram2026002_015.dg, rm/rm, 31/03/04
BEARING INB
D
MS14103−8
KSC327108B
BEARING
MS14103−7A
C
Aileron Bearing Locations

Figure 207
Master
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TASK 20−26−00−910−810
Installation of Press−Swaged or Roller−Swaged Aileron Bearings

Subtask 20−26−00−943−009
None specified Threaded pulling tools (locally available)
None specified Torque Wrench 0−50 lbf·in. (0−5.65 N·m)
Subtask 20−26−00−944−009
13−002 resistant
Subtask 20−26−00−946−010
TASK 20−26−00−910−808 Installation of Press−Swaged Bearings
2. Job Set−Up
Subtask 20−26−00−910−020
3. Procedure
Subtask 20−26−00−840−001
Master
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Sep 10/2004
C
A. Prepare the installation of the bearing as follows:
51−26−00−110−801).
press or a threaded pulling tool. Make sure that the bearing is symmetrically
installed in its housing.
permitted clearance fit and permit manual installation as specified by
Table 210.
Bearing Data Housing Bore Diameter Housing Thickness
Part No. inch mm inch mm
0.9057 − 23.00 − 0.387 −
MS14103−7A 9.83 − 10.08
0.9067 23.03 0.397
0.9995 − 25.39 − 0.450 − 11.43 −
MS14103−8
1.0005 25.41 0.460 11.68
1.1245 − 28.56 − 0.481 − 12.22 −
KR9CWGB
1.1255 28.59 0.491 12.47
0.9745 − 24.75 − 0.476 − 12.09 −
KSC322209B (See Note)
0.9755 24.77 0.486 12.34
0.9995 − 25.39 − 0.495 − 12.57 −
KSC327108B
1.0005 25.41 0.508 12.90
NOTE: This bearing is available in 3 sizes. −1 is the standard size, −2 is the first
oversize and −3 is the second oversize.
HOUSING DIMENSIONS
Table 210
Subtask 20−26−00−420−008
B. For press−swaging, use the procedure that follows:
Master
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CAUTION: BEFORE YOU APPLY SWAGING OR OTHER LOADS, MAKE SURE
THE PRESS HAS SUFFICIENT CAPACITY AND THE APPLIED LOAD
GAUGES ARE ACCURATE. IF YOU APPLY AN INCORRECT LOAD
YOUR WORK WILL BE DEFECTIVE. AND, YOU COULD DAMAGE THE
AIRCRAFT OR EQUIPMENT.
(1) Use the hydraulic press (Ref. Figure 208), and do the press−swaging of the bearing
as follows:
NOTE: For optional swaging methods (Ref. TASK 20−26−00−910−808).
(a) Make a swaging tool selection (by dash no.) from Table 211, as specified by
tool drawing G601R200008−1.
NOTE: Select the applicable tools required for both stages of the two−stage
swaging operation from Table 211. This kit only contains the tools
necessary to install the bearing part numbers shown in Figure 206.
Bearing Tool Kit − Part Number G601R200008
Bearing PN Swaging Tools Proof Load Tools Torque Load Tools
MS14103−7A −3a Swaging tool −9a Anvil tool −11a Ram tool
−13a Setting tool −11a Ram tool −5a Torque pin
−7a Alignment pin −7a Alignment pin
MS14103−8 −3b Swaging tool −9b Anvil tool −11b Ram tool
−13b Setting tool −11b Ram tool −5b Torque pin
−7b Alignment pin −7b Alignment pin
KR9CWGB −3c Swaging tool −9c Anvil tool −11c Ram tool
−13c Setting tool −11c Ram tool −5c Torque pin
−7c Alignment pin −7c Alignment pin
SWAGING TOOL DATA

Table 211
(b) Do a two−stage press swaging operation as follows:
1 Use the setting anvil tool (−13), one swaging tool (−3) and an alignment pin
(−7) to align and center the tools to the bearing. Hold the setting anvil tool
(−13) against the housing and apply the swaging load specified in Table
212 to one side of the bearing.
NOTE: The setting anvil tool (−13) when placed against the housing
allows for an equal protrusion of the bearing, 0.005 inches from
either side of the housing.
2 Use two swaging tools (−3) and an alignment pin (−7) to align and center
the tools to the bearing. To complete the swaging procedure, apply the
swaging load as specified in Table 213 to each side of the bearing.
Subtask 20−26−00−420−009
C. For roller−swaging, do as follows:
(1) Refer to Table 212 for the correct selection of roller−swaging tool.
Master
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Bearing Part No. Roller−Swage Part No.

KSC322209B−1 RST4004
KSC322209B−2 RST4013
KSC322209B−3 RST4014
KSC327108B RST3010
MS14103−7A RST3007
ROLLER−SWAGING TOOL DATA

Table 212
NOTE: The roller−swaging procedure is not incorporated into this manual at this
time. Operators and maintenance facilities are requested to refer to
Bombardier Aerospace Process Specification (BAPS) 175−004
(Installation and Retention of Self−Aligning Groove Bearings by Roller or
Anvil Swaging). A copy of this document is available on request.
Subtask 20−26−00−480−001
D. Do a proof load test of the bearing installation (press or roller−swaged) as follows:
(1) Use the ram tool (−11), the anvil tool (−9) and the alignment pin (−7) to proof load
the swage. Apply a proof load as specified in Table 213.
NOTE: Select the applicable tools (by dash No.) required for the proof load from
Table 211.
NOTE: Do the proof load test on each side of the bearing.
Part No. Pounds Newtons Pounds Newtons
MS14103−7A 16312 ± 72559 1400 6228
3000 ±13345
MS14103−8 18000 ± 80068 2100 9341
3000 ±13345
KR9CWGB 20250 ± 90076 2300 10231
3000 ±13345
KSC322209B−1 17550 ± 78066 ± 2100 9341
3000 13345
KSC322209B−2 18000 ± 80068 ± 2100 9341
3000 13345
KSC322209B−3 18567 ± 82590 ± 2100 9341
3000 13345
KSC327108B 18000 ± 80068 ± 2100 9341
3000 13345
SWAGING LOAD AND PROOF LOAD DATA

Table 213
Master
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Subtask 20−26−00−820−001
E. Do a no−load breakaway−torque check of the ball in the race as follows:
(1) Move the ball a number of times to remove all local binding.
(2) For metal−to−metal bearings, make sure that there is no binding between the ball
and the race (Refer to Figure 209).
(3) Align the ball symmetrically in the race.
(4) Hold the ball tightly with a threaded arbor or bolt and measure the breakaway
torque with a torque wrench (Refer to Figure 209).
(5) Make sure that the torque required to rotate the ball is in the range specified in
Table 214.
Bearing Part No. Permitted Torque After Installation − lbf·in. (N·m)
MS14103−7A 0.25 − 8 (0.028 − 0.90)
MS14103−8 0.25 − 8 (0.028 − 0.90)
KR9CWGB 1 − 15 (0.113 − 1.7)
KSC322209B−1,
0 − 8 (0 − 0.90)
−2, or −3
KSC327108B 0 − 12 (0 − 1.36)
BALL−BEARING BREAKAWAY TORQUE

Table 214
Subtask 20−26−00−820−003
F. If the bearing does not have the breakaway torque or the no−binding qualities, do a
torque adjustment as follows:
(1) Refer to Figure 209.
(2) Use the ram tool (−11) and the torque pin (−5) to do the torque adjustment.
NOTE: Select the applicable tools (by dash no.) required for the torque
adjustment from Table 211.
(3) Use light pressure initially and apply an axial load to the ball in one direction.
(4) Apply the same axial load to the ball in the opposite direction.
NOTE: Do not apply loads to the ball sufficiently to give free play that you can
(5) Increase the applied pressure in small increments until the breakaway torque
decreases to the allowable torque range specified in Table 214.
Master
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C
HYDRAULIC
HAND PUMP
SWAGING
JAW
ENERPAC
P/NGF−10S
HYDRAULIC LEGEND
GAUGE
−3. Swaging tool.
−5. Torque pin.
−7. Alignment pin.
HYDRAULIC KIT− PART NUMBER G601R200007−1 −9. Anvil tool.
−11. Ram tool.
−13. Setting anvil tool.
BEARING MS−14103−7A BEARING MS−14103−8
−3A −3A −5A −3B −3B −5B
−9A −11A −13A −9B −11B −13B
−7A CUTTING TOOL −7B CUTTING TOOL

RKC4103−7A RKC4103−8
BEARING KR9−CWGB
−3C −3C −9C −11C −13C

ram2026002_016.dg, rm, 31/05/00
−7C CUTTING TOOL −5C

RKC4103−9
Tool and Hydraulic Kits

Figure 208
Master
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Apr 20/2004
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HOUSING BEARING RACE

0.005 in. (REF) (REF)
(0.00127 mm)
A
−13
A
−7 APPLIED
CONFIGURATION
LOAD
BEFORE SWAGING
BEARING RACE
(REF)
−3
BALL
B
(REF)
SWAGING STAGE 1
B
BALL
−3 (REF) CONFIGURATION
AFTER SWAGING
−7
APPLIED APPLIED
LOAD LOAD
ram2026002_017.dg, rm/kms, 07/02/02
−3

(REF) (REF)
SWAGING STAGE 2
Aileron and Flap Press−Swaged Bearing Installation

Master
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Apr 20/2004
C
HOUSING HOUSING
(REF) (REF)
−9 −11
−7
APPLIED −5
AXIAL
LOAD
INSTALLED BALL −11

BEARING RACE BEARING (REF)
(REF) (REF)
PROOF LOAD TORQUE ADJUSTMENT

SET−UP SET−UP
ROTATION OF THE BALL

C AROUND THE RADIAL AXIS
A B
ram2026002_019.dg, rm/kms, 08/02/02
NOTE 1 FREE PLAY− METAL−TO−METAL

BEARING
is 0.0005 in. (0.013 mm) in

Master
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Apr 20/2004
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TASK 20−26−00−910−812
Removal of Swaged Bearings in the Inboard and Outboard Flap Hinge Arm Assemblies

Subtask 20−26−00−943−010
Subtask 20−26−00−946−011
TASK 20−26−00−910−807 Removal of Press−Swaged Bearings
2. Job Set−Up
Subtask 20−26−00−910−021
3. Procedure
Subtask 20−26−00−030−002
A. Locate and identify the bearing, (Ref. Figure 211) and use the applicable cutting tool
listed in Table 215 to carefully remove the press swaged material from one side of the
bearing race as follows:
NOTE: Proper care must be taken to prevent damage to the housing bore, when you
remove the press−swaged material from the bearing.
(1) Unscrew the cap and shaft assembly of the cutting tool.
(2) Insert the shaft assembly through the farside of the bearing. Make sure the
remainder of the tool remains together.
(3) Turn the pressure nut up to the clamp nut and install the tool onto the cap and shaft
assembly.
Master
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C
(4) Tighten the clamp nut securely.
NOTE: Use a standard box or open end wrench on the hex body of the cutting
tool. Use a pin type spanner wrench or round bar on the round body of
the cutting tool.
(5) Turn the pressure nut up to exert light pressure on the cutter.
(6) Turn the cutter one full turn clockwise and tighten the pressure nut 1/8 turn.
(7) Repeat step 6 until the cutter stops cutting. The cutter will stop when it reaches the
bottom of the groove and is against the internal stop.
NOTE: An internal stop on the cutter keeps the cutter teeth from penetrating into
and damaging the housing.
Bearing Tool Kit Part Number G601R200008−1
Bearing Part Number Cutting Tool
KR9CWGB RKC4103−9
TOOLING REQUIREMENT − CUTTING

Table 215
Subtask 20−26−00−020−005
B. Remove damaged or worn press−swaged spherical bearings from their housings (Ref.
TASK 20−26−00−910−807).
Master
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BEARING KR9−CWGB
A −1

(PART OF KIT)
LEGEND
−1. Cutting tool RKC4103−9
CAP AND SHAFT CUTTER PRESSURE

ASSEMBLY NUT
CLAMP
NUT
ram2026002_020.dg, gg/gw, 15/02/02
TYPICAL CUTTING ASSEMBLY
Press−Swaged Bearing Cutting Tool

Figure 210
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1
1
LEGEND
1. Bearing KR9−CWGB
ram2026002_022.dg, gg, 10/10/01
1
1
Inboard and Outboard Flap Press−Swaged Bearing Location

Figure 211
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TASK 20−26−00−910−813
Installation of Swaged Bearings in the Inboard and Outboard Flap Hinge Arm Assemblies

Subtask 20−26−00−943−011
None specified Threaded pulling tools (locally available)
None specified Torque Wrench 0−50 pound−inches
Subtask 20−26−00−944−010
13−002 resistant
Subtask 20−26−00−946−012
TASK 20−26−00−910−808 Installation of Press−Swaged Bearings
2. Job Set−Up
Subtask 20−26−00−910−022
3. Procedure
Subtask 20−26−00−420−007
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51−26−00−110−801).
press or a threaded pulling tool. Make sure that the bearing is symmetrically
installed in its housing.
permitted clearance fit and permit manual installation as specified by
Table 216.
Bearing Data Housing Bore Diameter Housing Thickness
Part No. inch mm inch mm
1.1245 − 28.56 − 0.481 − 12.22 −
KR9CWGB
1.1255 28.59 0.491 12.47
HOUSING DIMENSIONS
Table 216
CAUTION: BEFORE YOU APPLY SWAGING OR OTHER LOADS, MAKE SURE
THE PRESS HAS SUFFICIENT CAPACITY AND THE APPLIED LOAD
GAUGES ARE ACCURATE. IF YOU APPLY AN INCORRECT LOAD
YOUR WORK WILL BE DEFECTIVE. AND, YOU COULD DAMAGE THE
AIRCRAFT OR EQUIPMENT.
(5) Use a hydraulic press as specified by tool drawing G601R200007−1, (Ref. Figure
208), and do the press−swaging of the bearing as follows:
NOTE: For optional swaging methods (Ref. TASK 20−26−00−910−808).
(a) Use the swaging tool as per Table 217, and specified by tool drawing
G601R200008−1.
NOTE: Use the tools required for both stages of the two−stage swaging
operation from Table 217.
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Bearing Tool Kit − Part Number G601R200008−1

Bearing Part Swaging Tools Proof Load Tools Torque Load Tools
No.
KR9CWGB −3 Swaging tool −9 Anvil tool −11 Ram tool
−13 Setting tool −11 Ram tool −5 Torque pin
−7 Alignment pin −7 Alignment pin
TOOLING REQUIREMENT − SWAGING

Table 217
(b) Do a two−stage press swaging operation, do the steps that follow:
1 Use the setting anvil tool (−13), one swaging tool (−3) and an alignment pin
(−7) to align and center the tools to the bearing. Hold the setting anvil tool
(−13) against the housing and apply the swaging load specified in Table
217 to one side of the bearing.
NOTE: The setting anvil tool (−13) when placed against the housing
allows for an equal protrusion of the bearing, 0.005 inches from
either side of the housing.
2 Use two swaging tools (−3) and an alignment pin (−7) to align and center
the tools to the bearing. To complete the swaging procedure, apply the
swaging load as specified in Table 218 to both sides of the bearing.
(6) Use the ram tool (−11), the anvil tool (−9) and the alignment pin (−7) to proof load
the swage. Apply a proof load as specified in Table 218.
NOTE: Use the tools required for the proof load from Table 217.
NOTE: Proof loading is to be done on both sides of the bearing.
Part No. Pounds Newtons Pounds Newtons
KR9CWGB 20250 ± 60051 ± 1533 6819
2000 8896
LOAD DATA FOR ENERPAC (PN GF−10S) HYDRAULIC GAUGE

Table 218
(7) Do a tightness check of the ball in the race as follows:
NOTE: For metal−to−metal bearings, there must be no binding between the ball
and the race (Refer to Figure 213).
(a) Measure the breakaway torque as follows:
NOTE: The measured torque specified in Table 219 is the range of torque
required to initiate the rotation of the ball in the outer race.
3 Hold the ball tightly with a threaded arbor or bolt and measure the
breakaway torque with a torque wrench (Refer to Figure 213) and (Ref.
Table 218).
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Bearing Part
Permitted Torque After Installation − lbf. in. (N·m)
Number
KR9CWGB 1 − 15 (0.113 − 1.7)
BALL−BEARING BREAKAWAY TORQUE FOR ENERPAC (PN GF−10S) HYDRAULIC

GAUGE
Table 219
(b) Do a no−binding check as follows:
3 Turn the ball and make sure that it is free in the race and that the maximum
free play is not more than shown (Refer to Figure 213).
(8) When an installed bearing does not have either the specified breakaway torque or
the no−binding qualities, a torque adjustment procedure is necessary.
(9) Do the torque adjustment procedure as follows:
(a) Use the ram tool (−11) and the torque pin (−5) to do the torque adjustment.
NOTE: Use the tools required for the torque adjustment from Table 216.
(b) Use light pressure initially and apply an axial load to the ball in one direction.
(c) Apply the same axial load to the ball in the opposite direction.
NOTE: Do not apply loads to the ball sufficient to give free play that you can
(d) Increase the applied pressure in small increments until the breakaway torque
reaches the allowable torque range as specified in Table 219.
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HYDRAULIC
HAND PUMP
SWAGING
JAW
ENERPAC
P/NGF−10S
HYDRAULIC
GAUGE
HYDRAULIC KIT− PART NUMBER G601R200007−1
LEGEND
−3. Swaging tool.
−5. Torque pin.
−7. Alignment pin.
−9. Anvil tool.
−11. Ram tool.
−13. Setting anvil tool.
BEARING KR9−CWGB
−3 −3 −9 −11 −13
CUTTING TOOL −5
ram2026002_021.dg, gg/gw, 19/02/02
−7
RKC4103−9

(PART OF KIT)
Tool and Hydraulic Kits

Figure 212
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0.005 in. (REF) (REF)
(0.00127 mm)
A
−13
A
−7 APPLIED
CONFIGURATION
LOAD
BEFORE SWAGING
BEARING RACE
(REF)
−3
BALL
B
(REF)
SWAGING STAGE 1
B
BALL
−3 (REF) CONFIGURATION
AFTER SWAGING
−7
APPLIED APPLIED
LOAD LOAD
ram2026002_017.dg, rm/kms, 07/02/02
−3

(REF) (REF)
SWAGING STAGE 2

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HOUSING HOUSING
(REF) (REF)
−9 −11
−7
APPLIED −5
AXIAL
LOAD
INSTALLED BALL −11

BEARING RACE BEARING (REF)
(REF) (REF)
PROOF LOAD TORQUE ADJUSTMENT

SET−UP SET−UP
ROTATION OF THE BALL

C AROUND THE RADIAL AXIS
A B
ram2026002_019.dg, rm/kms, 08/02/02
NOTE 1 FREE PLAY− METAL−TO−METAL

BEARING
is 0.0005 in. (0.013 mm) in

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**ON A/C ALL
TUBING COUPLINGS − MAINTENANCE PRACTICES
1. General
A. The maintenance practices that follow give the installation procedures for V−band
couplings and Wiggins couplings. These couplings are used in many locations in the
aircraft to connect ducts and tubing.
NOTE: The component’s protective sealant and/or bonding check requirement are
Critical Design Configuration Control Limitation (CDCCL) items as defined in
the Maintenance Requirements Manual. The integrity of the sealant and/or
bonding requirement must be maintained to make sure that unsafe conditions
do not develop by maintenance, modification, or repair,
TASK 20−30−00−910−801
V−Band Couplings − Maintenance Practices

Subtask 20−30−00−943−001
None Specified Torque Wrench − 0 to 120 lbf·in (0 to 14.1 N·m)
2. Procedure
Subtask 20−30−00−910−001
A. Remove the locknut from the latch bolt and open the coupling.
B. Put the expanded coupling over the flange duct on one side of the joint.
C. If necessary, put a seal into the correct position to seal the seat to the flange.
D. Put the coupling into position over the flanges, compress the coupling, close the latch
and tighten the locknut by hand.
3. Torquing and Identification

Subtask 20−30−00−910−002
A. Tighten the latch−bolt locknut to 75% of the specified torque value given in Table 201 or
Table 202..
B. Lightly tap around the coupling with a soft−faced mallet to give the correct coupling
position.
C. Torque the locknut to its final value.
D. Lightly tap around the coupling again. Do a check of the torque value and, if necessary,
tighten the locknut.
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E. Do a check of the couplings for leaks as follows:
(1) For air lines, use a leak detector to do a check with the lines pressurized.
(2) For oil and/or fuel lines, do a visual check with the lines pressurized.
F. Use a white lacquer to paint a witness mark on the torqued clamp.
G. Make sure to apply the witness mark as a continuous stripe from the locknut to the latch
bolt. Thus, any relative movement will show as a displaced stripe.
H. Apply one coat of clear polyurethane on top of the witness mark.
I. If the witness mark is displaced, torque the locknut again to the specified limits.
TORQUE VALUES FOR MARMAN V−BAND COUPLINGS
Coupling Size Coupling Series and Torque Values in lbf·in (N·m)
Dash No. Outer 4562 4564 4565 24540 6148 MVB64757MVT63947
Diameter 4563 4574 4575 NM102495NM102619
of Duct 4572 J13Joint HJ13 and
inch 4573 TJ13
(mm) Joints
1.00 27 to 33 N/A N/A 32 to 38 35 to 45 45 to 50 45 to 50
−100 (25.4) (3.05 to (3.61 to (3.95 to (5.08 to (5.08 to
3.75) 4.29) 5.08) 5.65) 5.65)
1.25 27 to 33 N/A N/A 32 to 38 35 to 45 45 to 50 45 to 50
−125 (31.75) (3.05 to (3.61 to (3.95 to (5.08 to (5.08 to
3.75) 4.29) 5.08) 5.65) 5.65)
1.50 32 to 38 35 to 45 N/A 32 to 38 35 to 45 50 to 55 50 to 55
−150 (38.1) (3.61 to (3.95 to (3.61 to (3.95 to (5.64 to (5.64 to
4.29) 5.08) 4.29) 5.08) 6.21) 6.21)
1.75 32 to 38 40 to 50 N/A 32 to 38 35 to 45 50 to 55 50 to 55
−175 (44.45) (3.61 to (4.51 to (3.61 to (3.95 to (5.64 to (5.64 to
4.29) 5.64) 4.29) 5.08) 6.21) 6.21)
2.00 35 to 45 45 to 55 N/A 32 to 38 40 to 50 55 to 60 55 to 60
−200 (50.8) (3.95 to (5.08 to (3.61 to (4.51 to (6.21 to (6.21 to
5.08) 6.21) 4.29) 5.64) 6.77) 6.77)
2.25 35 to 45 50 to 60 N/A 32 to 38 40 to 50 55 to 60 55 to 60
−225 (57.15) (3.95 to (5.64 to (3.61 to (4.51 to (6.21 to (6.21 to
5.08) 6.77) 4.29) 5.64) 6.77) 6.77)
2.50 40 to 50 55 to 65 70 to 80 32 to 38 40 to 50 60 to 65 60 to 65
−250 (63.5) (4.51 to (6.21 to (7.90 to (3.61 to (4.51 to (6.77 to (6.77 to
5.64) 7.34) 9.03) 4.29) 5.64) 7.34) 7.34)
2.75 40 to 50 60 to 70 75 to 85 32 to 38 40 to 50 60 to 65 60 to 65
−275 (69.85) (4.51 to (6.77 to (8.47 to (3.61 to (4.51 to (6.77 to (6.77 to
5.64) 7.90) 9.59) 4.29) 5.64) 7.34) 7.34)
3.00 45 to 55 65 to 75 80 to 100 35 to 45 45 to 55 60 to 65 65 to 70
−300 (76.1) (5.08 to (7.34 to (9.03 to (3.95 to (5.08 to (6.77 to (7.34 to
6.21) 8.47) 11.29) 5.08) 6.21) 7.34) 7.90)
Torque Values for Marman V−Band Couplings

Table 201
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TORQUE VALUES FOR MARMAN V−BAND COUPLINGS

Coupling Size Coupling Series and Torque Values in lbf·in (N·m)
3.50 45 to 55 70 to 80 85 to 105 35 to 45 45 to 55 65 to 70 65 to 70
−350 (88.9) (5.08 to (7.90 to (9.59 to (3.95 to (5.08 to (7.34 to (7.34 to
6.21) 9.03) 11.85) 5.08) 6.21) 7.90) 7.90)
4.00 50 to 60 75 to 85 90 to 110 35 to 45 35 to 45 70 to 75 70 to 75
−400 (101.6) (5.64 to (8.47 to (10.16 to (3.95 to (3.95 to (7.90 to (7.90 to
6.77) 9.59) 12.43) 5.08) 5.08) 8.47) 8.47)
Torque Values for Marman V−Band Couplings

Table 201
TORQUE VALUES FOR JANITROL V−BAND COUPLINGS

Coupling Series Size Prefix Letter Duct Diameter Torque Value lbf·in
Number (N·m)
34H80 No Prefix 1.50 to 2.75 (38.1 to 70 to 80 (7.90 to 9.03)
69.9)
Torque Values for Janitrol V−Band Couplings

Table 202
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LATCH
BOLT NUT FOR
LATCH BOLT
DUCT DUCT
FLANGE FLANGE
COUPLING
OR CLAMP
NOTES
1. Certain coupling assemblies
require a gasket or preformed FLANGE
packing between the flange faces.
2. For channel−band couplings a
sleeve fitted over beaded duct
ends is used in place of flanges.
FLANGE
ram2030002_001.dg, gw, 20/08/01
COUPLING
OR CLAMP
V−Band Couplings − Maintenance Practice

Figure 201
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TASK 20−30−00−910−802
Wiggins Couplings − Maintenance Practices

Subtask 20−30−00−943−002
None Specified Torque Wrench
Range: Min − 60 lbf·in (6.78 N·m)
Max − 90 lbf·ft (122.02 N·m)
Subtask 20−30−00−944−001
05−001 Cloth, cleaning, low−lint
None Specified Lockwire
Subtask 20−30−00−946−001
TASK 20−22−01−910−801 Application of Thread Compounds and Tape to
TASK 51−80−00−400−803 Installation of Clamps and Electrical Bonding
Jumpers
2. Procedure
Subtask 20−30−00−910−003
A. To remove the Wiggins couplings, do the steps that follow:
(1) For the 6300, W700 and W700DE series full couplings, do the steps that follow:
(a) For the 6300 series couplings only, remove and discard the lockwire (Ref.
TASK 20−24−00−910−802).
(b) Loosen the coupling nut (2) and move it away from the body (1).
NOTE: The W700 and W700DE couplings have a locking device in the
coupling nut. The end of locking device moves out of the locked
position when sufficient torque is applied to the coupling nut.
(c) Remove the retainer (8).
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(d) Remove and discard the packings (7).
(2) For the 3600 series couplings, do the steps that follow:
(a) If installed, remove the bonding jumper from the coupling.
(b) Remove and discard the lockwire (Ref. TASK 20−24−00−910−802).
(c) Loosen the coupling nut (2) and move it away from the body (1).
(d) Remove the retainer (4).
(e) Remove and discard the packings (3).
(3) For the 6300 and W700 series half couplings, do the steps that follow:
(b) For the 6300 series couplings only, remove and discard the lockwire (Ref.
TASK 20−24−00−910−802).
(c) Loosen the coupling nut (6) and move it away from the mating boss (2).
(d) Remove and discard the packing (3).
(b) Remove and discard the lockwire (Ref. TASK 20−24−00−910−802).
(c) Loosen the coupling nut (2) and move it away from the coupling body (7).
(d) Remove and discard the packing (5).
(5) For the WD700E series half couplings, do the steps that follow:
(a) Loosen the coupling nut (2) and move it away from the mating boss (2).
(b) Remove the retainer (7).
(c) Remove and discard the packing (6).
(6) For the W900 series couplings, do the steps that follow:
(a) Release all four latches (5) at the same time.
(b) Remove the retainer (4).
(c) Move the tubing assemblies (1) apart and remove the sleeve (3).
(d) Remove and discard the packings (2).
Subtask 20−30−00−210−001
B. Before you install a Wiggins coupling, do the visual inspection of the ferrule flange that
follows:
(1) Examine the ferrule flange for wear.
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(2) Make sure that the damage to the ferrule flange is not more than the limits that
follow:
(a) The damaged surface of the flange is less than its full width (dimension B).
(b) The total damaged surface area is less than 50% of the total surface area of
the flange.
(3) If the wear on the ferrule flange is more than the permitted limit, replace the
assembly.
Subtask 20−30−00−420−001
C. To install the Wiggins couplings, do the steps that follow:
(1) For the 6300, W700 and W700DE series full couplings, do the steps that follow:
(a) Apply the applicable thread compound to the threads and to the internal
surfaces of the coupling (Ref. TASK 20−22−01−910−801).
(b) Temporarily align the tubing assemblies (4) in their correct position.
(c) Install the coupling nut (2) on the ferrule (6) on one end of the tube.
(d) Install the coupling body (1) on the ferrule (3) of the adjacent tube end.
(e) Install the split washer (5) on the ferrule (3) adjacent to the coupling body (1).
(f) Install the split washer (5) on the ferrule (6) adjacent to the coupling nut (2).
(g) Lightly lubricate the packing (7) with Petrolatum and install it adjacent to the
flange end of the ferrule (6).
(h) Lightly lubricate the other packing (7) with Petrolatum and install it adjacent to
the flange end of the ferrule (3).
(i) Put the tube ends together with a clearance of 0.150 ± 0.050 in. (3.81 ± 1.27
mm). Hold the tube ends in this position.
(j) Install the retainer (8) on the ferrules and make sure that the packings (7) are
between the split washers (5) and the retainer (8).
(k) Move the coupling body (1) in the direction of the retainer (8) until it goes over
the retainer.
(l) Hold the coupling body (1) in position and move the coupling nut (2) in the
direction of the retainer.
(m) Engage the threads of the coupling nut (2) into the coupling body (1) and
tighten the coupling nut by hand.
(n) For the 6300 series coupling only, safety the coupling nut to the coupling body
with lockwire (Ref. TASK 20−24−00−910−802).
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WARNING: DO NOT DAMAGE OR MODIFY THE FUEL TANK PLUMBING
LINES, SELF−BONDING COUPLINGS, CONDUCTIVE FITTINGS,
AND METAL−TO−METAL INTERFACE ELECTRICAL BONDING
OF THE FUEL TANK COMPONENTS. MAKE SURE THAT
PROTECTIVE SEALANT IS RE−APPLIED AND/OR BONDING
CHECK IS DONE AS INSTRUCTED. THESE DESIGN FEATURES
ARE CLASSIFIED AS CRITICAL DESIGN CONFIGURATION
CONTROL LIMITATION (CDCCL) ITEMS. THEY GIVE
ELECTROSTATIC AND LIGHTNING PROTECTION. DAMAGE OR
MODIFICATION TO THESE ITEMS CAN POSSIBLY CAUSE AN
IGNITION SOURCE INTO THE FUEL TANK BECAUSE OF
ELECTROSTATICS OR A LIGHTNING STRIKE.
(o) For the 6300 and W700 series couplings, install the electrical bonding (Ref.
TASK 51−80−00−400−803).
(c) Install the coupling nut (2) on one end of the tube.
(d) Install the coupling body (1) on the adjacent tube end.
(e) Lightly lubricate one packing (3) with Petrolatum and install it on the tubing
bead (7) adjacent to the coupling body (1).
(f) Lightly lubricate the other packing (3) with Petrolatum and install it on the
tubing bead (7) adjacent to the coupling nut (2).
(g) Put the tube ends together (use the specified clearance from Table 203). Hold
the tube ends in this position.
(h) Install the retainer (4) on the two tube ends.
(i) Move the coupling body (1) in the direction of the retainer (4) until it goes over
the retainer.
(j) Hold the coupling body (1) in position and move the coupling nut (2) in the
(k) Engage the threads of the coupling nut (2) into the coupling body (1). Tighten
the coupling nut to the torque value specified in Table 203.
WIGGINS COUPLINGS 3600 SERIES
Dash Outside F1 in Inches F2 in Inches F3, F4 in Torque Values Torque Values
No. Dia. of Inches (lbf·ft) (N·m)
Tube Min. Max. Min. Max. Min. Max. Min. Max. Min. Max.
(in.)
−12 0.75 0.00 0.25 0.13 0.38 0.07 0.32 5.00 7.08 6.78 9.61
−16 1.00 0.00 0.25 0.18 0.43 0.07 0.34 10.00 12.91 13.56 17.51
−20 1.25 0.00 0.25 0.18 0.43 0.09 0.34 15.00 17.91 20.34 24.30
−24 1.50 0.00 0.25 0.24 0.49 0.12 0.37 27.08 30.00 36.72 40.67
−28 1.75 0.00 0.25 0.24 0.49 0.12 0.37 29.17 32.08 39.55 43.49
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−32 2.00 0.00 0.25 0.24 0.49 0.12 0.37 30.00 32.92 40.67 44.63
−40 2.50 0.00 0.25 0.24 0.49 0.12 0.37 32.08 35.00 43.49 47.45
−48 3.00 0.00 0.25 0.24 0.49 0.12 0.37 59.17 62.08 80.22 84.17
−56 3.50 0.05 0.30 0.29 0.54 0.17 0.42 77.08 80.00 104.51 108.48
−64 4.00 0.05 0.30 0.29 0.54 0.17 0.42 87.08 90.00 118.06 122.02
Clearances and Torque Values
Table 203
(l) Safety the coupling nut to the coupling body with lockwire (Ref. TASK
20−24−00−910−802).
(m) Install the electrical bonding jumper (6) (Ref. TASK 51−80−00−400−803).
(3) For the 6300 and W700 series half−couplings, do the steps that follow:
(b) Temporarily align the tubing assembly (1) with the boss (2) of the installed
component, fitting or adapter.
(c) Install the coupling nut (6) on the ferrule (4) on the end of the tube.
(d) Install one split washer (5) on the ferrule (4) adjacent to the coupling nut (6).
(e) Lightly lubricate the packing (3) with Petrolatum and install it on the ferrule
adjacent to the split washer (5).
(f) Lightly lubricate the packing (7) with Petrolatum and install it adjacent to the
flange end of the ferrule (3).
(g) Install the other split washer (5) on the ferrule (4) adjacent to the packing.
(h) Put the tube end into the mating boss (2).
(i) Engage the threads of the coupling nut (6) into the mating boss (2) and tighten
the coupling nut by hand.
(j) For the 6300 series coupling only, safety the coupling nut to the boss body
with lockwire (Ref. TASK 20−24−00−910−802).
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(k) For the 6300 and W700 series couplings, install the electrical bonding (Ref.
TASK 51−80−00−400−803).
(c) Install the coupling nut (2) on the ferrule (3) on one end of the tube.
(d) Install the split washer (4) on the ferrule (3) adjacent to the coupling nut (2).
(e) Lightly lubricate the packing (5) with Petrolatum and install it in the seal groove
(6) of the coupling body (7).
(f) Put the tube ends together with a clearance of 0.030 in. (0.762 mm) between
the ferrule (3) and the coupling body (7). Hold the tube ends in this position.
(g) Engage the threads of the coupling nut (2) into the coupling body (7) and
tighten the coupling nut by hand.
(h) Safety the coupling nut (2) to the coupling body with lockwire (Ref. TASK
20−24−00−910−802).
(i) Install the electrical bonding (Ref. TASK 51−80−00−400−803).
(5) For the W700DE series half couplings, do the steps that follow:
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(b) Temporarily align the tubing assembly (1) with the boss (2) of the installed
component, fitting or adapter.
(c) Install the coupling nut (3) on the ferrule (4) on the end of the tube.
(d) Install one split washer (5) on the ferrule (4) adjacent to the coupling nut (3).
(e) Lightly lubricate the packing (6) with Petrolatum and install it on the ferrule
adjacent to the split washer (5).
(f) Install the retainer (7) on the ferrule (4).
(g) Put the tubing assembly (1) into the mating boss (2).
(h) Hold the tubing assembly (1) in position and move the coupling nut (3) in the
(i) Engage the threads of the coupling nut (3) into the mating boss (2) and
completely tighten the coupling nut by hand.
(j) Make sure that the locking device engages one of the notches at the end of
the mating boss (2).
(6) For the W900 series couplings, do the steps that follow:
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(c) Lightly lubricate the packings (2) with Petrolatum and install them on the
ferrules (6) of each tubing assembly (1).
(d) Put the tubing assemblies (1) together with a clearance of 0.150 in. ± 0.050 in.
(3.81 ± 1.27 mm) between the flanges of the two ferrules (6). Hold the tube
ends in this position.
(e) Install the sleeve (3) over the ends of the two tubing assemblies.
(f) Install the retainer (4) on the sleeve (3) and engage and lock the four latches
(5).
Subtask 20−30−00−160−001
D. Clean all fluid leaks from the tubing, the couplings and the adjacent areas.
Subtask 20−30−00−210−002
E. Do a general visual inspection of the installation:
(1) Make sure that the coupling is installed correctly and is safetied if necessary.
(2) Make sure that there are no leaks.
3. Close−Out
Subtask 20−30−00−941−001
A. Remove all tools, equipment and unwanted materials from the work area.
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LEGEND
BODY (NOTCHES AT 1. Coupling body.
BONDING DEVICE
THREADED END ON 2. Coupling nut.
(W700DE SERIES
W700 AND W700DE 3. Ferrule.
COUPLINGS ONLY)
SERIES COUPLINGS ONLY) 4. Tubing assembly.
1 8 5. Split washer.
6. Ferrule.
7 7 7. Packing.
2
8. Retainer.
5 3 6 5
CLEARANCE
0.150 in. + 0.050 in.
(3.81 mm + 1.27 mm)
LOCKING DEVICE
(W700 AND W700DE
SERIES COUPLINGS ONLY)
ram2030002_002.dg, rm, 14/07/04
Wiggins 6300, W700 and W700DE Series Full Couplings − Maintenance Practices
Figure 202
Master
20−30−00 Page 213
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FULL CONNECTOR
ASSEMBLY
6
1
5 7
7 3
5 4
8 FULL COUPLING
LEGEND
1. Coupling body. 5. Split washer.
2. Coupling nut. 6. Bonding jumper. 5 BOSS
2
3. Packing. 7. Tubing bead. FITTING
4. Retainer. 8. Tubing assembly. HALF COUPLING
F1 F2
TWO BEADED TUBE ENDS TWO FITTING ENDS
ram2030002_003.dg, rm, 23/06/04
F3 F4
BEADED TUBE END ON NUT SIDE FITTING END ON NUT SIDE
FITTING END ON BODY SIDE BEADED TUBE END ON BODY SIDE
Wiggins 3600 Series Couplings − Maintenance Practices

Figure 203
Master
20−30−00 Page 214
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(NOTCHES AT THREADED END OF

W700 SERIES COUPLING ONLY)
5
LEGEND
1. Tubing assembly.
2. Mating boss.
3. Packing.
4. Ferrule.
5. Split washer.
6. Coupling nut.
LOCKING DEVICE
(W700 SERIES COUPLING
ONLY)
ram2030002_004.dg, rm, 14/07/04
Wiggins 6300 and W700 Series Half Couplings − Maintenance Practices

Figure 204
Master
20−30−00 Page 215
Aug 10/2007
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5
3
LEGEND 6
1. Tubing assembly.
2. Coupling nut.
3. Ferrule. 4
4. Split washer.
5. Packing.
6. Seal groove.
7. Coupling body.
LOCKWIRE ram2030002_005.dg, rm, 23/06/04
3
2
Wiggins 8300 Series Couplings − Maintenance Practices

Figure 205
Master
20−30−00 Page 216
Aug 10/2007
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5
3
1
2
4
6
LEGEND
1. Tubing assembly.
2. Mating boss.
3. Coupling nut.
4. Ferrule.
5. Split washer.
6. Packing.
7. Retainer.
LOCKING DEVICE
ram2030002_006.dg, rm, 14/07/04
Wiggins W700DE Series Half Couplings − Maintenance Practices

Figure 206
Master
20−30−00 Page 217
Aug 10/2007
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1
3
2
6
LEGEND
1.Tubing assembly.
2. Packing.
6
3. Sleeve.
4. Retainer.
5. Latch mechanism. 1
6. Ferrule.
ram2030002_007.dg, rm, 14/07/04
Wiggins W900 Series Couplings − Maintenance Practices

Figure 207
Master
20−30−00 Page 218
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ram2030002_008.dg, rm, 18/06/04
Ferrule Flange Damage Limits − Maintenance Practices

Figure 208
Master
20−30−00 Page 219
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**ON A/C ALL
PLUG−IN RELAY − REMOVAL/INSTALLATION
1. General
A. The maintenance procedures that follow are for the removal and installation of the
plug−in relays.
TASK 20−42−00−960−801
Replacement of the Plug−in Relay

Subtask 20−42−00−946−001
A. Reference Information
2. Job Set−Up
Subtask 20−42−00−940−001
WARNING: OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO MAINTENANCE ON
OR NEAR ELECTRICAL/ELECTRONIC EQUIPMENT. IF YOU DO NOT DO THIS,
YOU CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT.
A. Obey all the electrical safety precautions (Ref. TASK 24−00−00−910−801).
3. Procedure
Subtask 20−42−00−960−002
Refer to Figure 401
A. Do the replacement of the relay (1) as follows:
(1) Remove the screws (2) and the washers (3) from the relay (1).
(2) Remove the defective relay (1) from the mounting rail (4).
(3) Put the new relay (1) in position on the mounting rail (4).
NOTE: Make sure the surfaces are clean with no corrosion, paint, grease or
preservation fluids.
(4) Attach the relay (1) with the screws (2) and the washers (3) to the mounting rail (4).
Master
20−42−00 Page 401
Apr 20/2004
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4. Close out
Subtask 20−42−00−940−002
Master
20−42−00 Page 402
Apr 20/2004
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LEGEND
1. Relay.
4 2. Screw.
3. Washer.
4. Mounting rail.
ram2042004_001.dg, gv, 06/09/01
Plug−In Relay − Removal/Installation

Figure 401
Master
20−42−00 Page 403
Apr 20/2004
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TASK 20−42−00−960−802
Replacement of the Relay Module

Subtask 20−42−00−943−001
M6106−31−001 Removal Tool − Relay
Subtask 20−42−00−946−002
2. Job Set−Up
Subtask 20−42−00−910−001
WARNING: OBEY ALL THE SAFETY PRECAUTIONS WHEN YOU DO MAINTENANCE ON
OR NEAR ELECTRICAL/ELECTRONIC EQUIPMENT. IF YOU DO NOT DO THIS,
YOU CAN CAUSE INJURIES TO PERSONS AND DAMAGE TO EQUIPMENT.
A. Obey all the electrical safety precautions (Ref. TASK 24−00−00−910−801).
3. Procedure
Subtask 20−42−00−960−003
Refer to Figure 402
A. Do the replacement of the relay (1) as follows:
(1) Hold the sides of the mounting bracket away from the tabs of the relay (1).
(2) Remove the defective relay (1) from the mounting bracket.
(3) Slowly push the new relay (1) into position on the mounting bracket.
NOTE: Make sure the surfaces are clean with no corrosion, paint, grease or
preservation fluids.
(4) Align the electrical pins with the electrical sockets of the module.
(5) Carefully push the new relay (1) until the tabs are correctly engaged in the detend
holes.
Master
20−42−00 Page 404
Apr 20/2004
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4. Close Out
Subtask 20−42−00−940−003
A. Remove all tools, equipment and unwanted materials from the work area.
Master
20−42−00 Page 405
Apr 20/2004
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MOUNTING BRACKET
(REF)
TAB
(REF)
MODULE
(REF)
DETEND HOLE
(REF)
LEGEND
1. Relay.
ram2042004_002.dg, gv, 06/09/01
Replacement of the Relay Module − Removal/Installation

Figure 402
Master
20−42−00 Page 406
Apr 20/2004

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AIRCRAFT MAINTENANCE MANUAL

20−30−00 201 * Aug 10/2007

20−42−00 401 Apr 20/2004

AIRFRAME STANDARD PRACTICES 20−00−00

ELECTRICAL/ELECTRONIC EQUIPMENT 20−10−00

FITTINGS AND CONNECTIONS 20−22−00

PLUMBING LINES 20−22−01

WIRE−ROPE CONTROL CABLES 20−23−00

SAFETYING DEVICES 20−24−00

BUSHINGS AND BEARINGS 20−26−00

V−BAND COUPLINGS 20−30−00

PLUG−IN RELAY − REMOVAL/INSTALLATION 20−42−00

Replacement of the Plug−in Relay

AIRCRAFT MAINTENANCE MANUAL

1. Job Set−Up Information

2. Job Set−Up Information

NOTE: A: Installation option − select test per aircraft configuration.

NOTE: A: Installation option − select test per aircraft configuration.

NOTE: A: Installation option − select test per aircraft configuration.

NOTE: A: Installation option − select test per aircraft configuration.

NOTE: A: Installation option − select test per aircraft configuration.

1. Job Set−Up Information

Typical ESDS Component Symbols and Label

CONNECT THE GROUND CORD

Typical Static−Safe Work Area

1. Job Set−Up Information

1. Job Set−Up Information

1. Job Set−Up Information

NOTE CORRECTION FACTORS

L1= Length of the adapter 65 0.423

Dial Correction Indication for Torque Wrench Adapters

Apply a continuous Apply a continuous

BOLT SCREW NUT

Apply the blob on Apply the blob on

BOLT SCREW NUT

Identification Marks on Torqued Fasteners

1. Job Set−Up Information

Torque Value − Pound−inches (Newton meters)

Torque Value − Pound−inches (Newton meters)

Torque Values for Flared Fittings on Corrosion−Resistant Steel Tubing

Torque Value − Pound−inches (Newton meters)

Torque Values for Flared Fittings on Corrosion−Resistant Steel Tubing

INSTALLATION TORQUE − [1] & [2]

Tube Outer [4] Torque − Pound−inches (Newton meters)

STRIPE OF WHITE LACQUER ACROSS

STRIPE OF WHITE LACQUER ACROSS

Identification Marks on Plumbing Lines

1. Job Set−Up Information

Use of the TG70 Mini−Strap Wrench to Torque Electrical Fittings

1. Limits of Damage to Tube Assemblies

Tube Damage Limits in Straight or Bent Sections

FLARED OR BEADED SECTIONS OF TUBE

Tube Damage Limits in Flared or Beaded Sections Table 202

Permitted Repair Limits for Damaged Tubing (Maximum Bend Radius)

Permitted Repair Limits for Damaged Tubing (Maximum Bend Radius)

Permitted Repair Limits for Damaged Tubing (Minimum Dimension)

PERMITTED ON THE INSIDE RADIUS OF LIMITS OF WRINKLES

1.000 in. thru 01.750 in. 0.020 in.

4.000 in. and up 0.060 in.

Tube Damage Limits

Y Dimension Z is the maximum

Permitted Bend Radius for Damaged Tubing − Maintenance Practices

1. Job Set−Up Information