In Service Information Ref.: ISI 29.00.00173 Issue: July 2017 Single Aisle Family A318/A319/A320/A321 Hydraulic system Maintenance practices Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Single Aisle Family maintenance practices _ A318 / A319 / A320 / A321 HYDRAULIC SYSTEM Purpose: This booklet provides a summary of the maintenance practices related to the hydraulic system. The purpose of this booklet is to provide a quick reference guide to line maintenance. Contents: 1. Simplified schematics003 2. Reasons and solutions for system failures009 3. Installation/Removal & Repairs027 4. Necessary tools for hydraulic system061 001 002 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 A320 Family maintenance practices _ Please note: These instructions do not amend or supersede any information contained in the Aircraft Maintenance Manual. This booklet will not be updated and the AMM remains the principle reference. This booklet is not a repair guide. For additional information refer to: AMM references: • 12-12-29 PB 301 • 12-14-29 PB 301 • 12-32-29 PB 301 • 20-21-12 PB 201 • 20-23-11 PB 201 • 20-23-14 PB 201 • 20-23-21 PB 201 • 20-23-22 PB 201 • 20-29-00 PB 201 • 29-00-00 PB 201 • 29-00-00 PB 601 • 29-10-00 PB 201 • 29-19-00 PB 001 1. Simplified schematics Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 1. Simplified schematics _ 005 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 1. Simplified schematics _ 007 2. System Maintenance Procedures 2.1 2.2 2.3 2.4 Air in hydraulic system Hydraulic reservoir servicing Hydraulic fluid sampling External leaks 010 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.1 Air in Hydraulic System AMM 29-00-00 PB 201 Background: Air in the hydraulic system has a negative impact on the components reliability and can generate: • Water hammer effect Flow/pressure quick fluctuations affecting the hydraulic installation and components. • Engine Driven Pump or hydraulic system low pressure warnings pressure decreases when air arrives at pump. • Reservoir low level warning When arriving in the reservoir the air is separated from the hydraulic fluid resulting in reservoir level decrease. Low pressure indications Low level indications Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Root causes Air can be introduced in the system when a leak occurs, or during maintenance operation, or because of hydraulic accumulator defective bladder. Solution In case of doubt, an easy check can allow to make sure that the amount of air contained in the hydraulic system is within acceptable range (chapter 2.1.1). 2.1.1. Check for air in hydraulic system Please refer to AMM TASK 29-00-00-210-001-A • Ensure the reservoir pressure is 50 psi by checking the pressure gage located on the top of the hydraulic reservoir. If necessary, pressurize the reservoir and read the gage of the corresponding reservoir and record the fluid level. • Depressurize the hydraulic system and wait for 5 minutes to read the gage of the corresponding reservoir again and record the fluid level. • Make the difference between both levels. Acceptable level difference values are: - 2 L on the Green hydraulic system - 1 L on the Blue hydraulic system - 1.5 L on the Yellow hydraulic system. • If more level fluctuation is noted, bleed the related hydraulic system as per AMM 29-00-00 PB 201. Select the most appropriate procedure (Bleeding of the related Hydraulic System with or without the Ground Power Cart). Note: If the source of air contamination is due to previous leak or heavy maintenance, no further immediate action is recommended. If not, it is likely that air is mainly introduced in the hydraulic system by the hydraulic system accumulator (one accumulator per system). 011 012 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.1 Air in Hydraulic System 2.1.2. Leak check of pressure on hydraulic power accumulators AMM TASK 29-10-00-200-008-A • Ensure the hydraulic systems are depressurized. • Check if the system accumulator pressures are correct (see table hereafter): Check of System Accumulators pressure T° (°C) T° (°F) P (psi) P (bars) -10 14 1 620 112 0 32 1 710 118 10 50 1 800 124 20 68 1 890 130 30 86 1 970 136 If the pressures are not correct, continue as follows: 1. If the accumulator pressure is less than 15 bar below the correct pressure “P”, adjust the pressure as necessary as per AMM TASK 12-14-29-614-001. WARNING: ADJUST THE PRESSURE ONLY IF THE MPD TASK INTERVAL (600 FH OR 6 MO) IS RESPECTED. IF YOU DO NOT , YOU CAN MISS AN ACCUMULATOR DAMAGE BECAUSE OF TOO FREQUENT INSERTION OF AIR IN THE HYDRAULIC SYSTEM. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. If the accumulator pressure is more than 15 bar below the correct pressure “P”, do the following steps: a) Adjust the accumulator pressure to the correct nominal value “P” (AMM TASK 12-14-29-614-001). b) After 20 minutes, do a check of the accumulator pressure: - If the accumulator pressure has the correct value “P”, plus/minus 7 bar, no more steps are necessary - If the accumulator pressure is 7 bar or more above the correct value “P”, reduce the accumulator pressure to the correct value “P” - If the accumulator pressure is 7 bar or more below the correct value “P”, do a leak check of accumulator nitrogen charging circuit using Material N°14CCB6 on the gas manifold of the accumulator. Example of nitrogen leak on A320 Family Hydraulic Accumulator c) If leaking component is found, replace it (accumulator, gage, charging valve or manifold). d) If no external leak is found : - Replace the accumulator as per AMM TASK 29-1X-42-X00-001-A 013 014 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.2 Hydraulic reservoir servicing Background: In many cases, in-service experience shows a need of hydraulic reservoir adjustment due to an incorrect reservoir servicing. Root causes The hydraulic reservoir level can be influenced by: • Air in the Hydraulic System • Temperature • Consumer position 2.2.1. Check of the hydraulic reservoir fluid level AMM 12-12-29 PB 301 • Ensure the aircraft is in the correct configuration: - Speed Brakes and Spoilers retracted - Thrust Reversers stowed - LG extended with doors closed - Reservoir pressurised - Cargo doors closed - Brake Accumulator filled For further information, please refer to ISI 29.00.00021. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2.2.2. Fill the hydraulic reservoir • Monitor the increase of the fluid level of the related system on the quantity indicator and do these steps: 1. Stop the flow of the hydraulic fluid when the pointer is almost to the fill level (refer to picture above). 2. Slowly continue to fill again, until the pointer shows almost to the fill level (refer to picture above). CAUTION: MAKE SURE THAT YOU DO NOT PUT TOO MUCH FLUID IN THE RESERVOIR. IF THE RESERVOIR IS TOO FULL, YOU CANNOT PRESSURIZE IT SUFFICIENTLY. LOW AIR PRESSURE CAN CAUSE THE MESSAGE “RSVR LO AIR PR” TO SHOW IN FLIGHT ON THE UPPER AND LOWER ECAM DISPLAY UNITS Please take into account : Fill level ≠ Total reservoir volume ≠ Maximum gaugeable level Total volume: 10L Max gaugeable: 8L Fill level (at 20°C): 6L Low level warning: 2L ± 0.3L Total volume: 23L Max gaugeable: 18L Fill level (at 20°C): 14L Low level warning: 3L ± 0.4L Total volume: 20L Max gaugeable: 18L Fill level (at 20°C): 12L Low level warning: 3L ± 0.4L Note: The hydraulic fluid volume in the reservoirs can change with the temperature. For each 10 DEG.C scale Celsius change in outside air temperature: •T he volume in the Green or Yellow hydraulic system reservoir can change by 0.5 L • The volume in the Blue hydraulic system reservoir can change by 0.25 L 015 016 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.3 Hydraulic Fluid Sampling Background: Hydraulic fluid contamination has a negative impact on hydraulic line and component reliability. Hydraulic fluid condition has to be monitored in accordance with MPD TASK 29-1000-15-1 interval. In case of contamination, AMM 12-32-29 PB 301 requires immediate corrective actions that can lead to additional grounding time. In-service experience shows that most of contamination issues are particle related often due to incorrect sampling (refer to OIT 999.0048/14). It is therefore necessary to strictly follow AMM 12-32-29 PB 301 recommendations when collecting fluid samples. Possible root causes of fluid contamination A. Particle contamination • Contaminated fluid from ground cart Cart fluid condition has to be monitored on a periodical basis. • Component internal wear Internal leak test as per AMM 29-19-00 PB 001 will allow identification and replacement of faulty component. • Maintenance operation on the hydraulic circuit • Incorrect fluid sampling AMM 12-32-29 PB 301 recommendations to be strictly followed (chapter 2.3.1). Refer to AMM 12-32-29 PB 301 flowchart for correctives actions. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 B. Chemical contamination As for particle, chemical contamination can be introduced by: • Contaminated fluid used for reservoir servicing or from the ground cart maintenance incorrect sampling In service experience show that most of chemical contamination issues are water or acid related. Water can also be introduced from hydraulic reservoir pressurization circuit. The acid accretion is the result of combination of hydraulic fluid and water in high temperature environment. Possible corrective actions in case of chemical contamination (refer to AMM 12-36-29 PB 301): • Complete fluid replacement • Replacement of fluid in the reservoir for acid only • Use of PALL Purifier for water and chlorine. Note: PALL Purifier is also particle filter. 017 018 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.3 Hydraulic Fluid Sampling 2.3.1. Hydraulic fluid sampling procedure AMM 12-32-29 PB 301 CAUTION: DO NOT FORGET TO PRESSURIZE THE APPLICABLE HYDRAULIC SYSTEM BEFORE PERFORMING THE HYDRAULIC FLUID SAMPLING. • Carefully clean the hydraulic sampling valve with Methyl-Ethyl-Ketone (Material 08BBF1). • Use a container of 1L to flush 0.2 L of the fluid sampling valve (AMM Subtask 12-32-29-680-050-A) and discard it. • Put the clean poly-ethylene bottle and collect 0.2 L (0.052 USGAL) for analysis. CAUTION: DO NOT USE A CONTAINER/BOTTLE MADE OF PVC. THIS MATERIAL WILL EFFECT THE RESULTS FOR THE HYDRAULIC FLUID SAMPLE. Please refer to AMM TASK 12-32-29-281-001-A for the complete procedure Particles can be accumulated in the lower part of the manifold. 0.2 L Fluid need to be discarded to have representative sample. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2.4 External leaks Background: several leaks, leakages or stain have been experienced in service. 2.4.1.Check of hydraulic components external leaks AMM TASK 29-00-00-790-001-A If the inspection reveals a total failure of hydraulic system and an EDP continuous running for more than 10 min, please: • Pressurize the failed hydraulic system • Perform the leak test. 1. Operate the component for the time or number of cycles necessary. 2. Stop the operation of the component and compare the amount of leakage with the maximum permitted values given in the following table. Note: The table that follows is applicable only for Green, Yellow and Blue Hydraulic Systems. It is not applicable for Alternate-Braking Low-Pressure System. 019 020 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.4 External leaks 2.4.2.Hydraulic leakage - Maximum permitted values Refer to AMM TASK 29-00-00-790-001-A Equipment Location Normal Operation Limit Dispatch limit to avoid delay (See Note 6) HYD PUMPS (EDP, EMP, RAT) Static Seals (at unions and connections) None 2 drops in 10 min Static Casing (Housing) 1 drop in 10 min 1 drop/min Shaft Seal (System pressurized) 2 drops/min 8 drops/min EDP: 5 drops/min EDP: 60 drops/min EMP: 5 drops/min EMP: 30 drops/min RAT: 1 drop/min RAT: 1 drop/min PTU: 5 drops/min PTU: 30 drops/min Shaft Seal (In operation) (See Note 6) SERVO CONTROL Elevator, Aileron, Rudder, Spoiler & Yaw Damper (See Note 4) Static Seals (System pressurized) None 2 drops in 10 min Elevator: 6 drops in 10 min (See Note 1) Dynamic Seal (System pressurized) 1 drop in 10 min Aileron: 6 drops in 10 min (See Note 1) Rudder: 30 drops/min Spoiler: 30 drops/min Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Equipment SERVO CONTROL Elevator, Aileron, Rudder, Spoiler & Yaw Damper (See Note 4) ACTUATORS LG Actuator, LG Door Actuator & Cargo Door Actuator (Note 7) Location Normal Operation Limit Dispatch limit to avoid delay Elevator: 3 drops in 10 cycles (See Note 1) Dynamic Seal (In operation) 1 drop in 10 cycles Aileron: 3 drops in 10 cycles (See Note 1) Rudder: 15 drops/cycle Spoiler: 15 drops/cycle (See Note 6) Static Seals None 2 drops in 10 min Rod Seal (System pressurized) 1 drop/min 30 drops/min Rod Seal (In operation) 1 drop/cycle 2 drops/cycle (See Note 6) CONNECTIONS Removable Pipe to Pipe None 2 drops in 10 min (See Note 2) Permanent Pipe to Pipe None None Swivel fitting None 30 drops/min Manifold Fitting None 2 drops in 10 min (See Note 2) Bobbins None 2 drops in 10 min (See Note 2) Removable Pipe to Pipe None 2 drops in 10 min (See Note 2) Sliding unions Slight leakage 1 drop in 10 min (See Note 2) 021 022 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.4 External leaks Equipment Normal Operation Limit Location Dispatch limit to avoid delay (See Note 6) OTHER (Distributor, Unlocking Jack) Static Seals None 2 drops in 10 min Dynamic Seal (System pressurized) None 1 drop/min Hyd Motor Shaft Seal: Slats, Flaps, THS (pressurized and in operation) 5 drops/min 30 drops/min Constant Speed Motor/Generator 1 drop/min 6 drops/min Alternate Brake System (See Note 3) (See Note 3) Brake Unit (at rest) None None Brake Unit (pressure applied) 1 drop/min 2 drops/min (See Note 5) Ground Leakage Measurement Manifold (at rest) 2 drops/day 4 drops/day Ground Leakage Measurement Manifold (system pressurized) 1 drop in 5 cycles 2 drops in 5 cycles Ground Leakage Measurement Manifold (after pressurization and operation) 1 drop in 15 min 2 drops in 15 min Hand Pumps (Cargo Doors, RSVR Filling) 5 drops/min 30 drops/min Priority Valves None 2 drops in 10 min Manual Selector Valve 2 drops per 100 operations 2 drops/10 min Hydraulic Accumulator nitrogen charging-circuits None None Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Note1: For the elevator and the aileron servo-controls, two leaks of more than the normal operation limit are not permitted on the same flight surface. Note2: It is mandatory that the connection is tight and the correct torque value is applied. Note3: It is mandatory that no component or connection in the alternate brake system (such as the safety valves, manifold, etc.) have leaks which are more than 10 drops per minute. Note4: Obey the leakage limits for the Yaw Damper Servo-Actuators: • If the leakage rate is less than 4 drops per minute , no more steps are necessary • If the leakage rate is between 4 and 14 drops per minute, replace the yaw damper servo-actuator(s) before the subsequent 750 flight hours • If the leakage rate is between 15 and 30 drops per minute, replace the yaw damper servo-actuator(s) before the subsequent 100 flight hours • If the leakage rate is more than 30 drops per minute, replace the yaw damper servo-actuator(s) immediately • Do the visual inspection of the yaw damper servo actuators with the part number SC4700-3 Note5: A leak rate of 10 drops per minute is permitted, if the temperature is less than -40 deg.C (-40.00 deg.F). 023 024 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2. System Maintenance Procedures _ 2.4 External leaks Note6: If one or more components have an external leak rate that is more than the normal operation limit, the aircraft can be dispatched if: • The leak rate of the component(s) is less than the dispatch limit • Only one hydraulic system has component(s) with a leak rate that is more than the normal operation limit • For a given hydraulic system, the leakage is less than the dispatch limit • The fluid level in the hydraulic reservoirs is correct. It is necessary to do the above checks again before each flight. Note7: The limit of 2 drops in 10 min is for the time of the pressurization and operation of the Cargo Door. Note8: The following fittings; PERMASWAGE, HARRISON elastomerically swaged, HARRISON internal roller-swaged, EATON, RYNGLOCK, CRYOFIT couplings and H-fittings are swaged permanent connections. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 2.4.3. How dispatch with hydraulic leak? Leakage Report to Airbus Refer to AMM 29-00-00 PB 601 Leak within limits? A/C dispatch under MEL? Leaking component replacement possibility? Repair possibility? Replacement Repair AMM 20-23-11 Contact AIRTAC DISPATCH 025 026 Single Aisle Family Hydraulic system - Ref.: SEE34/951.1497/99 - Feb 2016 3. Installation/Removal & Repairs 3.1 Hydraulic tubing repairs 3.2 Permitted damage and defects 3.2 Repair of hydraulic tubing 3.3 Tightening practices for hydraulic connections 3.4 Removal/installation of the bobbins and of O-rings on plug-in unions (or manifold plugs) 028 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ Please refer to manufacturer instructions for: • Engine tubes • Landing gear tubes. 3.1 Hydraulic tubing repairs AMM 20-23-11 PB 201 Note: These hydraulic repairs are applicable only to tubes located in airframe area: • Titanium alloy (Ti 3Al 2.5V) tubes (ABS5004) ; sizes -04 to -16 • CRES (21-6-9) tubes (ASNA3288) ; ALL sizes • Aluminium alloy (6061-T6) tubes (ASNA3410 or DAN40) ; sizes -04 to -16 and -24. Usually, tube repair is carried out with a tube made of the same material, but if this is not available, the tube can be repaired as follows: • Aluminum alloy (6061-T6) tubes, ref. ABS5144 or ASNA3410 or DAN40: with Corrosion-Resistant Steel (CRES) (21.6.9) tubes, ref. ASNA3288 or titanium alloy (Ti A3L 2.5V) tubes, ref. ABS5004 • CRES (21.6.9) tubes, ref. ASNA3288: with titanium alloy (Ti A3L 2.5V) tubes, ref. ABS5004 (but not in the pylon) • Titanium alloy (Ti A3L 2.5V) tubes, ref. ABS5004: with CRES (21.6.9) tubes, ref. ASNA3288. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Method Name Tube Material Parts part number AMM task Harrison 2 grooves 6061-T6 21-6-9 Union NSA855010 or ABS1369 Sleeve NSA855034 Nut MS21921 or ASNA3769 AMM TASK 20-23-11-300-002-A Harrison 3 grooves Ti 3Al 2.5V Union ASNA3760 Sleeve ASNA3759 Nut MS21921 or ASNA3769 AMM TASK 20-23-11-300-003-A H-fitting 6061-T6 21.6.9 Ti 3Al 2.5V 36011VXX AMM TASK 20-23-11-300-004-A Cryofit 6061-T6 21-6-9 Ti 3Al 2.5V 3PHS111-XX AMM TASK 20-23-11-300-006-A MS21922 Sleeve 6061-T6 21-6-9 MS21922 AMM TASK 20-23-11-300-005-A T.I.G welding procedure 21-6-9 Ti 3Al 2.5V Filler metal: Z2 CND 20-10-3 T40 or AMS4951 AMM TASK 20-23-11-300-008-A 029 030 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.1 Hydraulic tubing repairs * Permaswage fittings AMM TASK 20-23-11-300-001-A Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 031 032 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.1 Hydraulic tubing repairs * Rynglock fittings AMM TASK 20-23-11-300-007-A Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.1.1. Temporary/Permanent repair A. Titanium Tubes P: Permanent, T: Temporary, - : Not Applicable. Material HP or LP lines Titanium Alloy Ti-3Al-2.5V (ABS5004) In situ HP lines -4 Size Thickness (inch) -6 -8 -10 -12 -16 0,016 0,019 0,026 0,032 0,039 0,051 Permaswage Unions AMM 20-23-11-300-001 Y P P P P P P Harrison elastomer AMM 20-23-11-300-002 N - - - - - - Harrison Roller AMM 20-23-11-300-005 N P P P P P P Rynglok R8 AMM 20-23-11-300-007 Y P P P P P P Cryofit AMM 20-23-11-300-006 Y P P P P P P H-fitting AMM 20-23-11-300-003 Y P P P P P P MS21922 sleeve AMM 20-23-11-300-004 Y - - - - - - Welding AMM 20-23-11-300-008 N T T T T T T Hoses AMM 20-23-11-300-009 Y T T T T T T 033 034 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.1 Hydraulic tubing repairs 3.1.1. Temporary/Permanent repair B. CRES Tubes P: Permanent, T: Temporary, - : Not Applicable. Material HP or LP lines Stainless Steel 21-6-9 (ASNA 3288) In situ Size Thickness (inch) HP lines -4 LP lines -6 -8 -10 -12 -16 -20 -24 0,016 0,02 0,026 0,033 0,039 0,051 0,024 0,024 Permaswage Unions AMM 20-23-11-300-001 Y P P P P P P P P Harrison elastomer AMM 20-23-11-300-002 N P P P P P P P P Harrison Roller AMM 20-23-11-300-005 N - - - - - - - - Rynglok R8 AMM 20-23-11-300-007 Y P P P P P P P P Cryofit AMM 20-23-11-300-006 Y P P P P P P P P H-fitting AMM 20-23-11-300-003 Y P P P P P P - - MS21922 sleeve AMM 20-23-11-300-004 Y T T T T T T T T Welding AMM 20-23-11-300-008 N T T T T T T - T Hoses AMM 20-23-11-300-009 Y T T T T T T T T Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 C. Aluminium Alloy Tubes P: Permanent, T: Temporary, - : Not Applicable. Material HP or LP lines Aluminium Alloy 6061-T6 (ASNA3410/DAN40) In situ Size Thickness (inch) LP lines -4 -6 -8 -10 -12 -16 -24 0,035 0,035 0,035 0,035 0,035 0,048 0,035 Permaswage Unions AMM 20-23-11-300-001 Y P P P P P P P Harrison elastomer AMM 20-23-11-300-002 N P P P P P P P Harrison Roller AMM 20-23-11-300-005 N - - - - - - - Rynglok R8 AMM 20-23-11-300-007 Y P P P P P P P Cryofit AMM 20-23-11-300-006 Y P P P P P P P H-fitting AMM 20-23-11-300-003 Y P P P P P P - MS21922 sleeve AMM 20-23-11-300-004 Y T T T T T T T Welding AMM 20-23-11-300-008 N - - - - - - - Hoses AMM 20-23-11-300-009 Y T T T T T T T 035 036 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.1 Hydraulic tubing repairs 3.1.2. Protection Against Vibration and Chafing of Hydraulic Pipes Please refer to AMM TASK 20-23-14-910-001-A A. Minimum Distances Necessary to Prevent Chafing of Hydraulic Pipes • Measure the distance in the condition where the movement decreases the distance to its smallest value to know the minimum distance between a pipe/hose and a part that can move and compare with the figure below. Distances mini between pipes/hoses and Structure Minimum distance: 6 mm (023 in.) for rigid pipe 12 mm (0.47 in. for flexible hose Distances mini between pipes/hoses and parts that Minimum distance: can move 6 mm (023 in.) for rigid pipe 12 mm (0.47 in. for flexible hose Movement Movement Distances mini between individual pipes A Mini ITEM For pipes in the same routing For pipes in the different routings Between two hoses Between a hose and a pipe A Mini mm in. 2.5 (0.1) 6 (0.23) 12 (0.47) 12 (0.47) Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 B. P rotection from Vibration and Chafing for Hydraulic pipes When the clearance is less than the minimum distance, lacing tapes, bumpers, spacers and clamps can be used: • To get the minimum distance • To prevent chafing. Note: Hydraulic pipes shall not be attached to pipes of other systems or electrical harnesses. 1. Installation of lacing tape on pipe runs. Minimum distance • 2.5 mm (0.0984 in.) min. for pipes in the same routing • 6 mm (0.2362 in.) min. for pipes in different routings. Identification mark Minimum distance 037 038 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.1 Hydraulic tubing repairs 2. Installation of bumpers and spacers between pipes. Install bumpers or spacers to prevent vibration and chafing: • When the distance between fixed clamps is too long • To maintain a minimum distance between two pipes. Identification mark Adhesive sealant Cable tie NSA935401 Identification mark Adhesive sealant Cable tie NSA935401 Bumper NSA5586 Spacer NSA5527 3. Installation of spiral strip If a pipe is too close to a fixed part (distance less than 5 mm (0.1969 in.), you can install a spiral strip attached with a cable tie at each end on the tube to prevent damage. This method is not applicable for parts that can move. Cable tie NSA935401 Spiral tie NSA849000 If distance < 5mm (0.19 in.) Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 4. Installation of grommets ABS0648 Outer part Structure Grommet ABS0648 Nose Inner part CORRECT INCORRECT After correct installation, the pipe can move approximately 15 Deg. in each direction. 5. Installation of clamps or lacing tape to prevent chafing of pipes Clamp NSA5516 Identification mark Clamp NSA5516 Clamp installation Adhesive sealant Lacing tape Adhesive sealant on the tightened knot and the ends of the lacing tape Identification mark Lacing tape installation Spacer NSA5527 Examples of clamp positions 039 040 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.2 Permitted Damage and Defects 3.2.1. Permitted Damage and Defects on Hydraulic Tubes Please refer to AMM TASK 20-23-11-200-001-A for the complete procedure. A. Typical damages TYPE A D TYPE B Outside Diameter D Tube wall thickness DAMAGE TYPE A (with a maximum tube deformation without material removal) DAMAGE TYPE B (with a maximum material removal on the tube surface) Without time limit With time limit Without time limit With time limit • D < OD x 1% • For ABS5004 Size -16: D < OD x 1.4% • D <1.5 x OD • Damage must be in the straight pipe area, not in bend • D < 5% of the Tube wall thickness • D< 20% of the tube wall thickness • Damage must be in the straight pipe area, not in bend Outside Diameter Dash Outside Diameter (OD) mm in. -4 6.35 1/4 -6 9.53 3/8 -8 12.7 1/2 -10 15.88 5/8 Outside Diameter Dash Outside Diameter (OD) mm in. -12 19.5 3/4 -16 25.4 1” -20 31.75 1” 1/4 -24 38.1 1” 1/2 • For thickness tubes values, refer to AMM Figure 20-23-00 PB 001 or chapter 3.1.1 Table. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 B. S pecial Cases 1. For Special Case of ASNA3760 Union and ASNA3759 Sleeve, please refer to AMM Subtask 20-23-11-210-061-A 2. For Special Damage Criteria of Fire-Protection Sleeves, on Pipes in the Pylon Area, please refer to AMM Subtask 20-23-11-210-064-B 3.2.2. Permitted Damage and Defects on Hydraulic Hoses Please refer to AMM TASK 20-23-11-200-003-A Note: When the damage or defects on the flexible hoses are more than the permitted limits given below, flexible hoses have to be replaced. A. Permitted limits for signs of impact and surface defects Note: Surface defects are discontinuities such as: • Scratches • Bends • Cracks and forging laps • Corrosion pits • Scores • Nicks a) Replace the flexible hose if you find: • Surface defect with signs of dents, kinks or deformation • Two or more wires in one plait or a number of wires are broken in one small area. • The metal braid hose has wear or chafing on the metal braid that is more than the maximum permitted wear damage (see *formula next page). 041 042 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.2 Permitted Damage and Defects • The hose has a fire sleeve protection (brown neoprene overlay-protection) and there is wear or chafing on the fire sleeve protection. • The hose has a chafe guard protection (blue colour) and the wear or chafing on the metal braid is more than the maximum permitted wear damage (see *formula). b) If there is wear after chafing (on the metal braid): • Find and remove the root cause of chafing before the next flight. • Replace the flexible hose if the wear width is more than 10% of the hose circumference: Measure the width of the wear (W) and the external diameter of the hose (D) (see figures below). *Fomula: Maximum permitted wear damage: If W x 100 / D x 3.14 > 10, replace the flexible hose Chafing area D W Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.3 Tightening practices for hydraulic connections 3.3.1. Lubrication Please refer to AMM Subtask 20-23-11-917-001-A A. L ightly lubricate with Material N 02ABA1 or 03LDA1: • Only on the male thread • The shoulder of the sleeve (when possible). Note: Do not apply lubricant on the contact surfaces between the sleeve and the sealing surface of the fitting. Lubricant can cause the pipe to turn when torquing the sleeve nut. B. Remove unwanted lubricant with a clean, dry lintfree cloth. Fitting Nut Sleeve Tube Lubricate the male Thread Do not lubricate this area (contact surface between the sleeve and the sealing surface of fitting) Lubricate the sleeve shoulder (when possible) 043 044 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.2. Tightening torque application • Find the correct torque value. Note: It is important to know the material and the parts dimensions of the assembly. If the connection has different materials, torque value has to be used for the weakest material. • Get the applicable torque wrench and the wrench adapter for the nut and an applicable second wrench to apply the countertorque to the fitting (for our tool set recommendations, refer to chapter 4 - Tool Set). Use calibrated torque wrench & counter wrench • Set the torque wrench to the applicable value. When using a wrench adapter, value has to be adjusted (chapter 3.3.6). • Put the torque wrench in position on the sleeve nut and the countertorque wrench on the fitting (refer to figures on following pages). • Apply a slow and continuous force on the torque wrench until you reach the set torque value. Note: The double tightening torque is not applicable for the installation of plug-in fittings installed on manifold or equipment. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 • Apply a double tightening on the union (refer to AMM Subtask 20-23-11-917-060-A). • Torque the clamp blocks to 0.2 m.daN (17.70 lbf.in). AMM 20-21-12 PB 201 Hold Typical Harrison connection Sleeve nut Sleeve Hold the union with a second wrench and tighten the sleeve nut to the applicable torque value (chapter 3.3.3.). Tube Tube Tighten Red paint Sleeve nut Union Nut Typical Permaswage connection Sleeve Hold the union with a second wrench and tighten the sleeve nut to the applicable torque value. (chapter 3.3.3.). Hold Tighten 045 046 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.2. Tightening torque application In-line Check Valve Connection Removal union or in-line check valve Sleeve nut Tighten Sleeve nut Hold Tighten Hold the union with a second wrench and tighten the sleeve nut to the applicable torque value (chapter 3.3.3.). Flexible Hose Connection Fitting Hose sleeve nut Hold Tighten Hose hexagonal Fitting (fixed) Hold the hose hexagonal fitting with a second wrench and tighten the hose sleeve nut to the applicable torque value (chapter 3.3.3.). Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 Plug-in union Connection Plug-in union Equipment Tighten First tighten the plug-in union to the applicable torque value (chapter 3.3.4.). Hold Sleeve nut Equipment Plug-in union Tighten Then hold the plug-in union with a second wrench and tighten the sleeve nut to the applicable torque value (chapter 3.3.3.). 047 048 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.2. Tightening torque application Straight Bulkhead Connection Hold Hold Locknut Locknut Special Bulkhead fitting swaged on the tube Union Tighten Tighten First, hold the union with a second wrench and tighten the locknut to the applicable torque value (chapter 3.3.5.). Tighten Hold Tighten Hold Sleeve nut Sleeve nut Special Bulkhead fitting swaged on the tube Sleeve nut Tighten Then hold the union with a second wrench and tighten the sleeve nut to the applicable torque value (chapter 3.3.3.). Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 90° Angle Bulkhead Connection Tighten Hold Elbow union Hold Sleeve nut Locknut (not tightened) Tighten First, hold the swivel union with a second wrench and tighten the sleeve nuts to the applicable torque value (chapter 3.3.3.). Elbow union Hold Locknut Tighten Then hold the swivel union with a second wrench and tighten the locknut to the applicable torque value (chapter 3.3.5.). 049 050 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.3. Tightening Torques for HARRISON and PERMASWAGE In-line Couplings, Check Valves, Hoses and Caps/Plugs, the two Parts made of CRES or Titanium AMM 20-21-12 PB 201 Tightening Torques Item code 3 Outer DIA Cres and Titanium Tubes in. mm m.daN Ibf in. m.daN Ibf in. 3/16 4.76 1.1 97 1.2 106 Mini Maxi 4 1/4 6.35 1.5 133 1.7 150 5 5/16 7.93 2.0 177 2.3 204 6 3/8 9.52 2.9 257 3.2 283 8 1/2 12.70 5.4 478 5.9 522 10 5/8 15.87 7.5 664 8.3 735 12 3/4 19.05 8.5 752 9.5 840 16 1” 25.40 8.5 752 9.5 840 20 1” 1/4 31.75 8.5 752 9.5 840 24 1” 1/2 38.10 8.5 752 9.5 840 Note: If one of the constituents is made of aluminum, (union, sleeve or nut), apply the aluminum alloy values. Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.3.3. Tightening Torques for HARRISON and PERMASWAGE In-line Couplings, Check Valves, Hoses and Caps/Plugs, one of the Parts made of Aluminium-Alloy AMM 20-21-12 PB 201 Tightening Torques Item code 3 Outer DIA Aluminium alloy in. mm m.daN Ibf in. m.daN Ibf in. 3/16 4.76 - - - - Mini Maxi 4 1/4 6.35 1.2 106 1.3 115 5 5/16 7.93 1.5 133 1.7 150 6 3/8 9.52 1.8 159 2.0 177 8 1/2 12.70 3.0 266 3.3 292 10 5/8 15.87 3.9 345 4.3 381 12 3/4 19.05 4.8 425 5.3 469 16 1” 25.40 8.1 717 8.9 788 20 1” 1/4 31.75 9.7 859 10.7 947 24 1” 1/2 38.10 9.7 859 10.7 947 Note: If one of the constituents is made of aluminum, (union, sleeve or nut), apply the aluminum alloy values. 051 052 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.4. Tightening Torques for Plug-in Unions, MS Unions and Plug-in Check Valves (the two Parts made of Steel) Tightening Torques Item code 3 Outer DIA Cres in. mm m.daN Ibf in. m.daN Ibf in. 3/16 4.76 2.20 195 2.31 204 Mini Maxi 4 1/4 6.35 3.34 296 3.44 304 5 5/16 7.93 3.34 296 3.44 304 6 3/8 9.52 4.47 396 4.57 404 8 1/2 12.70 7.85 695 7.95 704 10 5/8 15.87 11.24 995 11.35 1 005 12 3/4 19.05 14.00 1 239 14.24 1 260 16 1” 25.40 18.53 1 640 18.75 1 660 20 1” 1/4 31.75 20.22 1 790 20.45 1 810 24 1” 1/2 38.10 20.80 1 841 21.00 1 859 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.3.4. Tightening Torques for Plug-in Union and Plugin Check Valves, One of the Parts made of Aluminum-Alloy Tightening Torques Item code 3 Outer DIA Aluminium alloy in. mm m.daN Ibf in. m.daN Ibf in. 3/16 4.76 0.83 73 0.94 83 Mini Maxi 4 1/4 6.35 1.21 107 1.32 117 5 5/16 7.93 1.21 107 1.32 117 6 3/8 9.52 1.63 144 1.75 155 8 1/2 12.70 3.47 307 3.58 317 10 5/8 15.87 5.03 445 5.14 455 12 3/4 19.05 7.29 645 7.40 655 16 1” 25.40 11.64 1 030 11.86 1 050 20 1” 1/4 31.75 13.44 1 190 13.67 1 210 24 1” 1/2 38.10 14.10 1 248 14.30 1 266 053 054 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.5. Tightening Torque Values for Bulkhead Lock Nuts on all CRES Components AMM 20-21-12 PB 201 Item code Bulkhead Connection Tube Outer DIA ref. in. mm 3 3/16 4.76 4 1/4 5 5/16 6 Tightening Torques Lock Nut Thread CRES Mini Maxi m.daN Ibf in. m.daN Ibf in. 0.3750-24 2.20 195 2.31 204 6.35 0.4375-20 3.34 296 3.44 304 7.93 0.5000-20 3.34 296 3.44 304 3/8 9.52 0.5625-18 4.47 396 4.57 404 8 1/2 12.70 0.7500-16 7.85 695 7.95 704 10 5/8 15.87 0.8750-14 11.24 995 11.35 1 005 12 3/4 19.05 1.0625-12 14.00 1 239 14.24 1 260 16 1” 25.40 1.3125-12 18.53 1 640 18.75 1 660 20 1” 1/4 31.75 1.6250-12 20.22 1 790 20.45 1 810 24 1” 1/2 38.10 1.8750-12 20.80 1 841 21.00 1 859 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.3.5. Tightening Torque Values for Bulkhead Lock Nuts, one of Part Made of Aluminium-Alloy AMM 20-21-12 PB 201 Item code Bulkhead Connection Tube Outer DIA ref. in. mm 3 3/16 4.76 4 1/4 5 5/16 6 Tightening Torques Lock Nut Thread Aluminium alloy Mini Maxi m.daN Ibf in. m.daN Ibf in. 0.3750-24 0.83 73 0.94 83 6.35 0.4375-20 1.21 107 1.32 117 7.93 0.5000-20 1.21 107 1.32 117 3/8 9.52 0.5625-18 1.63 144 1.75 155 8 1/2 12.70 0.7500-16 3.47 307 3.58 317 10 5/8 15.87 0.8750-14 5.03 445 5.14 455 12 3/4 19.05 1.0625-12 7.29 645 7.40 655 16 1” 25.40 1.3125-12 11.64 1 030 11.86 1 050 20 1” 1/4 31.75 1.6250-12 13.44 1 190 13.67 1 210 24 1” 1/2 38.10 1.8750-12 14.10 1 248 14.30 1 266 055 056 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.3 Tightening practices for hydraulic connections 3.3.6. Torque wrench adapter B Crow-foot wrench adapter Torque wrench B Open end wrench adapter A B When using a wrench adapter, adjust the torque value in accordance with the bellow formula: T’ = T x A A+B T’= new torque value (adjusted) to be set on the torque wrench T = specified torque value (applied on the connection) Example: • Specified Torque (T) = 2 m.daN (177 lb.in) • Length of torque wrench (A) without adapter = 300 mm (11.8 in.) • Length of adapter (B) = 100 mm (3.9 in.) • Torque value to read off T’: T’ = (2 m.daN x 300 mm)/(300 + 100 mm) = 1.5 m.daN Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.3.7. Unions Red Marking in Hydraulic Systems AMM 20-23-22 PB 201 After hydraulic connection torque, identification has to be carried out with a red painted line: • To identify a tightened union. • To show possible loosening of the union. Procedure (AMM TASK 20-23-22-910-001-A) CAUTION: BEFORE YOU DO THIS PROCEDURE, MAKE SURE THAT YOU HAVE TIGHTENED THE RELATED UNION TO THE RELATED UNION TO THE APPLICABLE TORQUE VALUE AND DONE THE APPLICABLE LEAKAGE TEST. 1. Use Material 15SBA1 and Material 08BAA9 made moist with Non Aqueous Cleaner-General to clean the surfaces where make marks will be present. Note: If a new installation has to be performed, it is necessary to remove the remaining red line before a new red line application. 2. Paint one line with a width of 2 mm (0.0787 in.) to 4 mm (0.1575 in.) on the union and the nut with a Material 04SAB2 (red color). Let it dry. Note: The union marking is not applicable in the fuel tanks. 3. Apply Material No. 12ACB1 on the cadmium-plated steel union. Red marking 057 058 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.4 Removal/installation of the bobbins and of O-rings on plug-in unions (or manifold plugs) Note: Plug-in unions and bobbins are equipped with elastomeric seals (O-Rings or Square seals) which must be replaced. 3.4.1. Overall precautions • Do not use pointed, sharp or metal tools to remove the O-ring. Use spoon-type removal tool or wedge type removal tool with a hook. CORRECT Pull Push INCORRECT Spoon type Wedge type • Before installation, lubricate O-ring, square seal for at least 15 minutes with material N° 02ABA1 (Phosphate Ester Hydraulic Fluid) Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3.4.2. Removal/installation on O-rings installed for plug-in unions, check valves or manifold plug Please refer to AMM TASK 20-29-00-911-002-A Use tool PN 98A29103000XXX to install O-rings. O-RING (NAS 1602 or NAS 1612) or O-RING (EN 6075 or EN 6076) 1 PUSH 2 3.4.3. Removal/ installation of hydraulic bobbins Please refer to AMM TASK 20-23-21-911-001-A Note: Instead of O-ring and square seal removal/installations, please note that bobbin assembly NSA8687 can be installed. Leakage can occur if insufficient care is taken during Installation/Removal of the bobbins. • Use tool PN 97A29102090XXX for: - Removal/Installation of the bobbin - Installation of the O-ring and square seals on the bobbins. • Before the installation, make sure that the references of the parts you install on the bobbin are: - Manifold side (bobbin identification groove side) * O-ring: NAS1611-xx or NAS1601-xx * Back up ring: NSA8671-xx - Component side: * Square seal: NSA8213-xx * Back up ring: NSA8674-xx (see figure here after). 059 060 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 3. Installation/Removal & Repairs _ 3.4 Removal/installation of the bobbins and of O-rings on plug-in unions (or manifold plugs) 3.4.3. Removal/ installation of hydraulic bobbins Back-up ring NSA 8674 Component side Manifold side Component O-Ring Groove Bobbin Manifold Square seal Back-up ring NSA 8671 • Install the back-up rings in the grooves before you install the seals. 4. Necessary tools for hydraulic system Tool set 062 Single Aisle Family In Service Information - Ref.: ISI 29.00.00173 4. Tool set _ Tool name PN Tool In situ Repair swaging tool kit DLT series or D12000 series tools In situ Rynglock tooling RTSTx or RTSTxR Tool Inst/Rem Bobbin Tool set 97A29102090000 Torque Tool Set 98F29003000000 Fluid material 02ABA1 Red Marking 04-SAB2 Seal Tool Set 98A29103000000 Tool Picture AIRBUS S.A.S. 31707 Blagnac Cedex, France © AIRBUS S.A.S. 2016 - All rights reserved, Airbus, its logo and the product names are registered trademarks. Concept design by Airbus Multi Media Support 20171311. Photos by Airbus: P. Masclet. Printed in France by Airbus Print Centre.