Aviation Maintenance

Technician Handbook–General

2023

U.S. Department of Transportation

FEDERAL AVIATION ADMINISTRATION
Flight Standards Service
Chapter 9
Fluid Lines & Fittings

Introduction
Aircraft fluid lines are usually made of metal tubing or higher tensile strength permits the use of tubing with thinner
flexible hose. Metal tubing (also called rigid fluid lines) is walls; consequently, the final installation weight is not much
used in stationary applications and where long, relatively greater than that of the thicker wall aluminum alloy tubing.
straight runs are possible. They are widely used in aircraft Steel lines are used where there is a risk of foreign object
for fuel, oil, coolant, oxygen, instrument, and hydraulic lines. damage (FOD) (i.e., the landing gear and wheel well areas).
Flexible hose is generally used with moving parts or where Swaged or MS flareless fittings are used with corrosion-
the hose is subject to considerable vibration. resistant tubing. Although identification markings for steel
tubing differ, each usually includes the manufacturer’s name
Occasionally, it may be necessary to repair or replace or trademark, the Society of Automotive Engineers (SAE)
damaged aircraft fluid lines. Very often the repair can be made number, and the physical condition of the metal.
simply by replacing the tubing. However, if replacements are
not available, the needed parts may have to be fabricated. Titanium 3AL–2.5V
Replacement tubing should be of the same size and material Titanium 3AL–2.5V tubing and fitting is used extensively in
as the original tubing. All tubing is pressure tested prior to transport category and high-performance aircraft hydraulic
initial installation and is designed to withstand several times systems for pressures above 1,500 psi. Titanium is 30 percent
the normal operating pressure to which it is subjected. If a stronger than steel and 50 percent lighter than steel. Cryofit
tube bursts or cracks, it is generally the result of excessive fittings or swaged fittings are used with titanium tubing.
vibration, improper installation, or damage caused by Do not use titanium tubing and fittings in any oxygen
collision with an object. All tubing failures should be system assembly. Titanium and titanium alloys are oxygen
carefully studied and the cause of the failure determined. reactive. If a freshly formed titanium surface is exposed in
gaseous oxygen, spontaneous combustion could occur at
Rigid Fluid Lines low pressures.
Tubing Materials
Copper Material Identification
In the early days of aviation, copper tubing was used Before making repairs to any aircraft tubing, it is important to
extensively in aviation fluid applications. In modern aircraft, make accurate identification of tubing materials. Aluminum
aluminum alloy, corrosion-resistant steel, or titanium tubing alloy, steel, or titanium tubing can be identified readily by
have generally replaced copper tubing. sight where it is used as the basic tubing material. However,
it is difficult to determine whether a material is carbon
Aluminum Alloy Tubing steel or stainless steel, or whether it is 1100, 3003, 5052-O,
6061-T6, or 2024-T3 aluminum alloy. To positively identify
Tubing made from 1100 H14 (1⁄2-hard) or 3003 H14 (1⁄2-hard)
the material used in the original installation, compare
is used for general purpose lines of low or negligible fluid
code markings of the replacement tubing with the original
pressures, such as instrument lines and ventilating conduits.
markings on the tubing being replaced.
Tubing made from 2024-T3, 5052-O, and 6061-T6 aluminum
alloy materials is used in general purpose systems of low and
On large aluminum alloy tubing, the alloy designation is
medium pressures, such as hydraulic and pneumatic 1,000
stamped on the surface. On small aluminum tubing, the
to 1,500 psi systems, and fuel and oil lines.
designation may be stamped on the surface; but more often it
is shown by a color code, not more than 4" in width, painted
Steel
at the two ends and approximately midway between the ends
Corrosion-resistant steel tubing, either annealed CRES 304, of some tubing. When the band consists of two colors, one-
CRES 321, or CRES 304-1⁄8-hard, is used extensively in half the width is used for each color. [Figure 9-1]
high-pressure hydraulic systems (3,000 psi or more) for the
operation of landing gear, flaps, brakes, and in fire zones. Its If the code markings are hard or impossible to read, it may

9-1
be necessary to test samples of the material for hardness by Too much pressure on the cutting wheel at one time could
hardness testing. deform the tubing or cause excessive burring. After cutting
the tubing, carefully remove any burrs from inside and outside
Sizes the tube. Use a knife or the burring edge attached to the tube
Metal tubing is sized by outside diameter (OD), which is cutter. The deburring operation can be accomplished by the
measured fractionally in sixteenths of an inch. For example, use of a deburring tool. [Figure 9-3] This tool is capable of
number 6 tubing is 6⁄16" (or 3⁄8") and number 8 tubing is 8⁄16" removing both the inside and outside burrs by just turning
(or 1⁄2") and so forth. The tube diameter is printed on all the tool end for end.
rigid tubing. In addition to other classifications or means
of identification, tubing is manufactured in various wall When performing the deburring operation, use extreme care
thicknesses. Thus, it is important when installing tubing to that the wall thickness of the end of the tubing is not reduced
know not only the material and outside diameter, but also or fractured. Very slight damage of this type can lead to
the thickness of the wall. The wall thickness is printed on fractured flares or defective flares, which do not seal properly.
the tubing in thousandths of an inch. To determine the inside Use a fine-tooth file to file the end square and smooth.
diameter (ID) of the tube, subtract twice the wall thickness
from the outside diameter. For example, a number 10 piece of If a tube cutter is not available, or if tubing of hard material
tubing with a wall thickness of 0.063" has an inside diameter is to be cut, use a fine-tooth hacksaw, preferably one having
of 0.625" – 2(0.063") = 0.499". 32 teeth per inch. The use of a saw decreases the amount of
work hardening of the tubing during the cutting operation.
Fabrication of Metal Tube Lines After sawing, file the end of the tube square and smooth,
Damaged tubing and fluid lines should be repaired with removing all burrs.
new parts whenever possible. Unfortunately, sometimes
replacement is impractical and repair is necessary. Scratches, An easy way to hold small diameter tubing, when cutting it, is
abrasions, or minor corrosion on the outside of fluid lines to place the tube in a combination flaring tool and clamp the
may be considered negligible and can be smoothed out with tool in a vise. Make the cut about one-half inch from the flaring
a burnishing tool or aluminum wool. Limitations on the tool. This procedure keeps sawing vibrations to a minimum
amount of damage that can be repaired in this manner are and prevents damage to the tubing if it is accidentally hit with
discussed in this chapter under “Rigid Tubing Inspection the hacksaw frame or file handle while cutting. Be sure all
and Repair.” If a fluid line assembly is to be replaced, the filings and cuttings are removed from the tube.
fittings can often be salvaged; then the repair involves only
tube forming and replacement. Tube Bending
The objective in tube bending is to obtain a smooth bend
Tube forming consists of four processes: cutting, bending, without flattening the tube. Tubing under 1⁄4" in diameter
flaring, and beading. If the tubing is small and made of soft usually can be bent without the use of a bending tool. For
material, the assembly can be formed by hand bending during larger sizes, either portable hand benders or production
installation. If the tube is 1⁄4" diameter or larger, hand bending benders are usually used. Figure 9-4 shows preferred methods
without the aid of tools is impractical. and standard bend radii for bending tubing by tube size.

Tube Cutting
When cutting tubing, it is important to produce a square
end, free of burrs. Tubing may be cut with a tube cutter or a Aluminum Alloy Number Color of Band
hacksaw. The cutter can be used with any soft metal tubing, 1100 White
such as copper, aluminum, or aluminum alloy. Correct use of 3003 Green
the tube cutter is shown in Figure 9-2. Special chipless cutters 2014 Gray
are available for cutting aluminum 6061-T6, corrosion-
2024 Red
resistant steel, and titanium tubing.
5052 Purple

A new piece of tubing should be cut approximately 10 percent 6053 Black

longer than the tube to be replaced to provide for minor 6061 Blue and Yellow
variations in bending. Place the tube in the cutting tool with 7075 Brown and Yellow
the cutting wheel at the point where the cut is to be made.
Rotate the cutter around the tubing, applying light pressure to Figure 9-1. Painted color codes used to identify aluminum
alloy tubing.
the cutting wheel by intermittently twisting the thumbscrew.

9-2
Using a hand bender, insert the tubing into the groove of The ordinary production tube bender accommodates tubing
the bender so that the measured end is left of the form ranging from 1⁄4" to 11⁄2" outside diameter. Benders for larger
block. Align the two zeros and align the mark on the tubing sizes are available, and the principle of their operation is
with the L on the form handle. If the measured end is on similar to that of the hand tube bender. The radius blocks are
the right side, then align the mark on the tubing with the so constructed that the radius of bend varies with the tube
R on the form handle. With a steady motion, pull the form diameter. The radius of bend is usually stamped on the block.
handle until the zero mark on the form handle lines up
with the desired angle of bend, as indicated on the radius Alternative Bending Methods
block. [Figure 9-5] When hand or production tube benders are not available or
are not suitable for a particular bending operation, a filler of
Hand benders come in different sizes that correspond to the metallic composition or of dry sand may be used to facilitate
tube diameter. Make sure to select the correct bender for bending. When using this method, cut the tube slightly longer
the desired tube diameter. Figure 9-6 shows hand benders than required. The extra length is for inserting a plug (which
available for different sizes of tubing. Typically, the tubing may be wooden) in each end. The tube can also be closed
size is stamped in the bender. [Figure 9-7] by flattening the ends or by soldering metal disks in them.

Bend the tubing carefully to avoid excessive flattening, After plugging one end, fill and pack the tube with fine, dry
kinking, or wrinkling. A small amount of flattening in bends is sand and plug tightly. Both plugs must be tight so they are not
acceptable, but the small diameter of the flattened portion must forced out when the bend is made. After the ends are closed,
not be less than 75 percent of the original outside diameter. bend the tubing over a forming block shaped to the specified
Tubing with flattened, wrinkled, or irregular bends should radius. In a modified version of the filler method, a fusible
not be installed. Wrinkled bends usually result from trying to alloy is used instead of sand. In this method, the tube is filled
bend thin wall tubing without using a tube bender. Excessive under hot water with a fusible alloy that melts at 160 °F. The
flattening causes fatigue failure of the tube. Examples of alloy-filled tubing is then removed from the water, allowed
correct and incorrect tubing bends are shown in Figure 9-8. to cool, and bent slowly by hand around a forming block or
with a tube bender. After the bend is made, the alloy is again
Tube bending machines for all types of tubing are generally melted under hot water and removed from the tubing. When
used in repair stations and large maintenance shops. using either filler methods, make certain that all particles of
With such equipment, proper bends can be made on large the filler are removed. Visually inspect with a borescope to
diameter tubing and on tubing made from hard material. The make certain that no particles are carried into the system in
production CNC™ tube bender is an example of this type of which the tubing is installed. Store the fusible alloy filler
machine. [Figure 9-9] where it is free from dust or dirt. It can be re-melted and
reused as often as desired. Never heat this filler in any other
way than the prescribed method, as the alloy will stick to the
inside of the tubing, making them both unusable.
r
tte Cut
Tube Flaring
u
fc
eo

Two kinds of flares are generally used in aircraft tubing: the

open sid
oward
tate t
Ro

Tube Clean cut

Figure 9-2. Tube cutting. Figure 9-3. Deburring tool.

9-3
A– Hand B–Portable hand benders C–Production bender
Type Bender AB AB B B B BC B BC B BC C BC C
Tube OD ¹⁄8" ³⁄16" ¹⁄4" ⁵⁄16" ³⁄8" ³⁄8" ⁷⁄16" ¹⁄2" ¹⁄2" ⁵⁄8" ⁵⁄8" ³⁄4" ³⁄4"
Standard Bend ³⁄8" ⁷⁄16" ⁹⁄16" ¹¹⁄16" ¹¹⁄16" ¹⁵⁄16" 1³⁄8" 1¹⁄2" 1¹⁄4" 2" 1¹⁄2" 2¹⁄2" 1³⁄4"

Type Bender C B C C C C C C C C C C C
Tube OD ⁷⁄8" 1" 1" 1¹⁄8" 1¹⁄4" 1³⁄8" 1³⁄8" 1¹⁄2" 1¹⁄2" 1³⁄4" 2" 2¹⁄2" 3"
Standard Bend 2" 3¹⁄2" 3" 3¹⁄2" 3³⁄4" 5" 6" 5" 6" 7" 8" 10" 12"

Figure 9-4. Standard bend radii to which bending tools form the various sizes of tubes.

single flare and the double flare. [Figure 9-10A and B] Flares
are frequently subjected to extremely high pressures; therefore,
the flare on the tubing must be properly shaped or the
connection leaks or fails. A flare made too small produces a
weak joint, which may leak or pull apart; if made too large,
it interferes with the proper engagement of the screw thread
on the fitting and causes leakage. A crooked flare is the result
of the tubing not being cut squarely. If a flare is not made
properly, flaws cannot be corrected by applying additional
torque when tightening the fitting. The flare and tubing must be
free from cracks, dents, nicks, scratches, or any other defects.
Figure 9-6. Hand benders.
The flaring tool used for aircraft tubing has male and female
dies ground to produce a flare of 35° to 37°. Under no
circumstance is it permissible to use an automotive-type
flaring tool that produces a flare of 45°. [Figure 9-11]

The single-flare hand flaring tool, similar to that shown in

Figure 9-12, is used for flaring tubing. The tool consists of
a flaring block or grip die, a yoke, and a flaring pin. The
flaring block is a hinged double bar with holes corresponding
to various sizes of tubing. These holes are countersunk on
one end to form the outside support against which the flare is
formed. The yoke is used to center the flaring pin over the end
Figure 9-7. Size identification.
of the tube to be flared. Two types of flaring tools are used to
make flares on tubing: the impact type and the rolling type.
Cut the tube squarely and remove all burrs. Slip the fitting
Instructions for Rolling-Type Flaring Tools nut and sleeve on the tube. Loosen clamping screw used for
Use these tools only to flare soft copper, aluminum, and brass locking the sliding segment in the die holder. This permits
tubing. Do not use with corrosion-resistant steel or titanium. their separation. The tools are self-gauging; the proper size

Figure 9-5. Tube bending.

9-4
 Perfect bend Flattened bend

Good

Wrinkled bend Kinked bend

Figure 9-9. CNC™ tube bending machine.

rapidly in cold water. Open the flaring tool by unscrewing

both clamping screws. Select the hole in the flaring bar that
matches the tubing diameter and place the tubing with the
end you have just prepared, extending above the top of the
bar by a distance equal to the thickness of the shoulder of
the adapter insert. Tighten clamping screws to hold tubing
Figure 9-8. Correct and incorrect tubing bends.
securely. Insert pilot of correctly sized adapter into tubing.
Slip yoke over the flaring bars and center over adapter.
flare is produced when tubing is clamped flush with the top
Advance the cone downward until the shoulder of the adapter
of the die block. Insert tubing between the segments of the
rests on the flaring bar. This bells out the end of the tubing.
die block that correspond to the size of the tubing to be flared.
Next, back off the cone just enough to remove the adapter.
Advance the clamp screw against the end segment and tighten
After removing the adapter, advance the cone directly into the
firmly. Move the yoke down over the top of the die holder
belled end of the tubing. This folds the tubing on itself and
and twist it clockwise to lock it into position. Turn the feed
forms an accurate double flare without cracking or splitting
screw down firmly, and continue until a slight resistance is
the tubing. To prevent thinning out of the flare wall, do not
felt. This indicates an accurate flare has been completed.
overtighten. [Figure 9-13]
Always read the tool manufacturer’s instructions, because
there are several different types of rolling-type flaring tools
Fittings
that use slightly different procedures.
Rigid tubing may be joined to either an end item (such as a
Double Flaring brake cylinder), another section of either rigid tubing, or to a
flexible hose (such as a drain line). In the case of connection
A double flare is used on soft aluminum alloy tubing 3⁄8"
to an end item or another tube, fittings are required, which
outside diameter and under. This is necessary to prevent
may or may not necessitate flaring of the tube. In the case of
cutting off the flare and failure of the tube assembly under
attachment to a hose, it may be necessary to bead the rigid
operating pressures. A double flare is smoother and more
tube so that a clamp can be used to hold the hose onto the tube.
concentric than a single flare and therefore seals better. It is
also more resistant to the shearing effect of torque.
Flareless Fittings
Double Flaring Instructions Although the use of flareless tube fittings eliminates all
tube flaring, another operation, referred to as presetting,
Deburr both the inside and outside of the tubing to be flared.
is necessary prior to installation of a new flareless tube
Cut off the end of the tubing if it appears damaged. Anneal
assembly. Flareless tube assemblies should be preset with the
brass, copper, and aluminum by heating to a dull red and cool
proper size presetting tool or operation. Figure 9-14 (steps

9-5
 37°

A. Single-flared end

Figure 9-11. Flaring tool.

3. Final tightening depends upon the tubing (step 3). For

aluminum alloy tubing up to and including 1⁄2" outside
diameter, tighten the nut from 1 to 11⁄6 turns. For steel
tubing and aluminum alloy tubing over 1⁄2" outside
diameter, tighten from 11⁄6 to 11⁄2 turns.

After presetting the sleeve, disconnect the tubing from the

fitting and check the following points: The tube should extend
3
⁄32" to 1⁄8" beyond the sleeve pilot; otherwise, blowoff may
occur. The sleeve pilot should contact the tube or have a
maximum clearance of 0.005" for aluminum alloy tubing or
0.015" for steel tubing. A slight collapse of the tube at the
sleeve cut is permissible. No movement of the sleeve pilot,
B. Double-flared end
except rotation, is permissible.

Figure 9-10. Cutaway view of single-flared (A) and double-

flared (B) tube ends.

1, 2, and 3) illustrates the presetting operation, which is

performed as follows:
1. Cut the tube to the correct length, with the ends
perfectly square. Deburr the inside and outside of
the tube. Slip the nut, then the sleeve, over the tube
(step 1), lubricate the threads of the fitting and nut
with hydraulic fluid.
2. Place the fitting in a vise (step 2), and hold the tubing
firmly and squarely on the seat in the fitting. (The
tube must bottom firmly in the fitting.) Tighten the
nut until the cutting edge of the sleeve grips the tube.
To determine this point, slowly turn the tube back
and forth while tightening the nut. When the tube no
longer turns, the nut is ready for tightening.
Figure 9-12. Hand flaring tool.

9-6
Beading lines, steel tags may be used in place of tape or decals.
Tubing may be beaded with a hand beading tool, with [Figure 9-17B] Paint is used on lines in engine compartments
machine beading rolls, or with grip dies. The method to be where there is the possibility of tapes, decals, or tags being
used depends on the diameter and wall thickness of the tube drawn into the engine induction system.
and the material from which it was made.
In addition to the above-mentioned markings, certain lines
The hand beading tool is used with tubing having ⁄4" to 1 may be further identified regarding specific function within a
1" outside diameter. [Figure 9-15] The bead is formed by system (e.g., drain, vent, pressure, or return). Lines conveying
using the beader frame with the proper rollers attached. The fuel may be marked FLAM [Figure 9-17]; lines containing
inside and outside of the tube is lubricated with light oil to toxic materials are marked TOXIC in place of FLAM. Lines
reduce the friction between the rollers during beading. The containing physically dangerous materials, such as oxygen,
sizes, marked in sixteenths of an inch on the rollers, are for nitrogen, or FreonTM, may be marked PHDAN.
the outside diameter of the tubing that can be beaded with
the rollers. Aircraft and engine manufacturers are responsible for the
original installation of identification markers, but the aviation
Separate rollers are required for the inside of each tubing size, mechanic is responsible for the replacement when it becomes
and care must be taken to use the correct parts when beading. necessary. Tapes and decals are generally placed on both
The hand beading tool works somewhat like the tube cutter in ends of a line and at least once in each compartment through
that the roller is screwed down intermittently while rotating which lines run. In addition, identification markers are placed
the beading tool around the tubing. In addition, a small vise immediately adjacent to each valve, regulator, filter, or other
(tube holder) is furnished with the kit. accessories within a line. Where paint or tags are used,
location requirements are the same as for tapes and decals.
Other methods and types of beading tools and machines are
available, but the hand beading tool is used most often. As a Fluid Line End Fittings
rule, beading machines are limited to use with large diameter Depending on the type and use, fittings have either pipe
tubing, over 115⁄16", unless special rollers are supplied. The threads or machine threads. Pipe threads are similar to those
grip-die method of beading is confined to small tubing. used in ordinary plumbing and are tapered, both internal and
external. External threads are referred to as male threads and
Fluid Line Identification internal threads are female threads.
Fluid lines in aircraft are often identified by markers made
up of color codes, words, and geometric symbols. These When two fittings are joined, a male into a female, the
markers identify each line’s function, content, and primary thread taper forms a seal. Some form of pipe thread lubricant
hazard. Figure 9-16 illustrates the various color codes and approved for particular fluid application should be used when
symbols used to designate the type of system and its contents. joining pipe threads to prevent seizing and high-pressure
leakage. Use care when applying thread lubricant so that the
Fluid lines are marked, in most instances, with 1" tape or lubricant does not enter and contaminate the system. Do not
decals. [Figure 9-17A] On lines 4" in diameter (or larger), use lubricants on oxygen lines. Oxygen reacts with petroleum
lines in oily environment, hot lines, and on some cold products and can ignite (special lubricants are available or
oxygen systems).

Figure 9-13. Double flare tool.

9-7
 STEP 1
Machine threads have no sealing capability and are similar
Fitting Sleeve Tube nut to those used on common nuts and bolts. This type of fitting
is used only to draw connections together or for attachment
Sleeve pilot Tube through bulkheads. A flared tube connection, a crush washer,
or a synthetic seal is used to make the connection fluid tight.
Machine threads have no taper and do not form a fluid-tight
seal. The size of these fittings is given in dash numbers, which
equal the nominal outside diameter in sixteenths of an inch.
Universal Bulkhead Fittings
When a fluid line passes through a bulkhead, and it is desired
Sleeve cutting edge to secure the line to the bulkhead, a bulkhead fitting should be
used. The end of the fitting that passes through the bulkhead
is longer than the other end(s), which allows a locknut to be
installed, securing the fitting to the bulkhead.
STEP 2

Fittings attach one piece of tubing to another or to system

units. There are four types: (1) bead and clamp, (2) flared
fittings, (3) flareless fittings, and (4) permanent fittings
(Permaswage™, Permalite™, and Cyrofit™). The amount
of pressure that the system carries and the material used are
usually the deciding factors in selecting a connector.

The beaded type of fitting, which requires a bead and a section

of hose and hose clamps, is used only in low- or medium-
pressure systems, such as vacuum and coolant systems. The
flared, flareless, or permanent-type fittings may be used as
connectors in all systems, regardless of the pressure.

AN Flared Fittings
A flared tube fitting consists of a sleeve and a nut.
[Figure 9-18] The nut fits over the sleeve and, when
tightened, draws the sleeve and tubing flare tightly against
a male fitting to form a seal. Tubing used with this type of
fitting must be flared before installation. The male fitting has
a cone-shaped surface with the same angle as the inside of
the flare. The sleeve supports the tube so that vibration does
not concentrate at the edge of the flare and distributes the
STEP 3 shearing action over a wider area for added strength.
Fitting combinations composed of different alloys should
3/ "
32 to 1/8" be avoided to prevent dissimilar metal corrosion. As with
all fitting combinations, ease of assembly, alignment, and
proper lubrication should be assured when tightening fittings
during installation.

Standard AN fittings are identified by their black or blue color.

All AN steel fittings are colored black, all AN aluminum
Slight deformation permissible fittings are colored blue, and aluminum bronze fittings are
.005" maximum aluminum alloy tubing cadmium plated and natural in appearance. A sampling of
.015" maximum corrosion-resistant steel tubing
AN fittings is shown in Figure 9-19. Figure 9-20 contains

Figure 9-14. Presetting flareless tube assembly.

9-8
Figure 9-15. To use the hand beading tool, cut with tube cutter (1), deburr (2), oil (3), and revolve tool around tube while tightening
handle (4).

additional information on sizes, torques, and bend radii. AN connection that is virtually maintenance free. Swaged
flared fittings are different from MS flareless fittings and fittings are used to join hydraulic lines in areas where routine
they are not interchangeable. AN flared fittings are easily disconnections are not required and are often used with
recognized, because they have a cone at the end of the fitting titanium and corrosion-resistant steel tubing. The fittings are
while the MS flareless fitting has a straight end. [Figure 9-21] installed with portable hydraulically-powered tooling, which
is compact enough to be used in tight spaces. [Figure 9-24]
MS Flareless Fittings If the fittings need to be disconnected, cut the tubing with a
MS flareless fittings are designed primarily for high-pressure tube cutter. Special installation tooling is available in portable
(3,000 psi) hydraulic systems that may be subjected to severe kits. Always use the manufacturer’s instructions to install
vibration or fluctuating pressure. [Figure 9-22] Using this swaged fittings. Typical Permaswage™ fittings are shown
type of fitting eliminates all tube flaring, yet provides a safe in Figure 9-25.
and strong, dependable tube connection. The fitting consists
of three parts: a body, a sleeve, and a nut. [Figure 9-23] The One of the latest developments is the Permalite™ fitting.
internal design of the body causes the sleeve to cut into the Permalite™ is a tube fitting that is mechanically attached to
outside of the tube when the body and nut are joined. The the tube by axial swaging. Permalite™ works by deforming
counterbore shoulder within the body is designed with a the fitting into the tube being joined by moving a ring, a
reverse angle of 15° for steel connectors and 45° for aluminum component of the Permalite™ fitting, axially along the fitting
fittings. This reverse angle prevents inward collapse of the length using a Permaswage™ Axial swage tool. Typical
tubing when tightened and provides a partial sealing force Permalite™ fittings are shown in Figure 9-26.
to be exerted against the periphery of the body counterbore.
Cryofit Fittings
Swaged Fittings Many transport category aircraft use Cryofit fittings to join
A popular repair system for connecting and repairing hydraulic lines in areas where routine disconnections are not
hydraulic lines on transport category aircraft is the use of required. Cryofit fittings are standard fittings with a cryogenic
Permaswage™ fittings. Swaged fittings create a permanent sleeve. The sleeve is made of a shape memory alloy, Tinel™.

9-9
 FUEL LUBRICATION PNEUMATIC X HYDRAULIC
X FUEL FLAM
FUEL LUBRICATION PNEUMATIC X HYDRAULIC FUEL FLAM
FUEL
X
LUBRICATION
PNEUMATIC X HYDRAULIC
FUEL LUBRICATION X
PNEUMATIC X HYDRAULIC A
FUEL LUBRICATION X
PNEUMATIC X HYDRAULIC
FUEL LUBRICATION X
PNEUMATIC X HYDRAULIC
FUEL LUBRICATION X

COOLANT AIR ELECTRICAL

CONDITION CONDUIT WATER
COOLANT
ELECTRICAL WATER
AIR CONDUIT FUEL
COOLANT CONDITION WATER FLAM
ELECTRICAL
COOLANT CONDUIT
AIR WATER
COOLANT CONDITION ELECTRICAL
B
CONDUIT WATER
COOLANT
AIR ELECTRICAL WATER Figure 9-17. Fluid line identification using: tape and decals (A)
COOLANT CONDITION CONDUIT and metal tags (B).

COMPRESSED INSTRUMENT BREATHING

OXYGEN
FIRE
PROTECTION
Rigid Tubing Installation and Inspection
GAS AIR
INSTRUMENT BREATHING FIRE Before installing a line assembly in an aircraft, inspect the line
COMPRESSED
GAS AIR OXYGEN PROTECTION carefully. Remove dents and scratches, and be sure all nuts
COMPRESSED INSTRUMENT BREATHING FIRE and sleeves are snugly mated and securely fitted by proper
GAS AIR OXYGEN PROTECTION
BREATHING FIRE flaring of the tubing. The line assembly should be clean and
COMPRESSED INSTRUMENT
GAS AIR OXYGEN PROTECTION free of all foreign matter.
COMPRESSED INSTRUMENT BREATHING FIRE
GAS AIR OXYGEN PROTECTION
Connection & Torque
INERTING Never apply compound to the faces of the fitting or the
DE-ICING VACUUM
FLUID flare, as it destroys the metal-to-metal contact between the
DE-ICING VACUUM INERTING
FLUID fitting and flare, a contact which is necessary to produce
DE-ICING VACUUM
INERTING the seal. Be sure that the line assembly is properly aligned
DE-ICING VACUUM
FLUID before tightening the fittings. Do not pull the installation
INERTING
FLUID
into place with torque on the nut. Correct and incorrect
DE-ICING VACUUM
INERTING
methods of installing flared tube assemblies are illustrated in
DE-ICING VACUUM FLUID Figure 9-28. Proper torque values are given in Figure 9-20.
WARNING Remember that these torque values are for flared-type fittings
SYMBOL
only. Always tighten fittings to the correct torque value when
Figure 9-16. Identification of aircraft fluid lines. installing a tube assembly. Overtightening a fitting may badly

The sleeve is manufactured 3 percent smaller, frozen in

liquid nitrogen, and expanded to 5 percent larger than the AN819 sleeve
line. During installation, the fitting is removed from the
liquid nitrogen and inserted onto the tube. During a 10 to 15
second warming up period, the fitting contracts to its original
size (3 percent smaller), biting down on the tube, forming
a permanent seal. Cryofit fittings can only be removed by
cutting the tube at the sleeve, though this leaves enough
room to replace it with a swaged fitting without replacing
the hydraulic line. It is frequently used with titanium tubing.
The shape memory technology is also used for end fittings, Tubing
flared fittings, and flareless fittings. [Figure 9-27]
AN818 nut

Figure 9-18. Flared tube fitting.

9-10
 AN744 to AN932
Material:
Aluminum alloy........................................................................................................................................... (code D)
Steel ........................................................................................................................................................... (code, absence of letter)
Brass .......................................................................................................................................................... (code B)
Aluminum bronze ....................................................................................................................................... (code Z–for AN819 sleeve)

Size:
The dash number following the AN number indicates the size of the tubing (or hose) for which the fitting is made in 16ths of an inch.
This size measures the outer diameter of tubing and the inner diameter of hose. Fittings that have pipe threads are coded by a dash
number, indicating the pipe size in 8ths of an inch. The material code letter, as noted above, follows the dash number.

BOLT AN774 BOLT AN775 ELBOW AN776 ELBOW AN777 ELBOW AN778 TEE AN779

PLUG AN806 UNION AN815

NUT AN817 SLEEVE AN819

TEE AN804 PLUG AN814 ADAPTOR AN807 NIPPLE AN816 NUT AN818 CAP AN820

ELBOW AN821 ELBOW AN823 TEE AN825

CROSS AN827 UNION AN832

ELBOW AN822 TEE AN824 TEE AN826

ELBOW AN838 ELBOW AN839

ELBOW AN833 TEE AN834

ELBOW AN837

Figure 9-19. AN standard fittings.

9-11
 Aluminum Hose End Fittings and Minimum Bend
Steel
Tubing Alloy Tubing, Hose Assemblies Radii (inches)
Tubing, Bolt
Outer Diameter Fitting Bolt Bolt, Fitting, MS28740 or Equivalent
Fitting, or Alum. Alloy
(inches) or Nut Size or Nut End Fitting
Nut Torque 1100-H14 Steel
Torque
(in–lb) Minimum Maximum 5052-0
(in–lb)
1¹⁄8 –2 20–30 ³⁄8
³⁄16 –3 30–40 90–100 70 120 ⁷⁄16 ²¹⁄32
¹⁄4 –4 40–65 135–150 100 250 ⁹⁄16 ⁷⁄8
⁵⁄16 –5 60–85 180–200 210 420 ³⁄4 1¹⁄8
³⁄8 –6 75–125 270–300 300 480 ¹⁵⁄16 1⁵⁄16
¹⁄2 –8 150–250 450–500 500 850 1¹⁄4 1³⁄4
⁵⁄8 –10 200–350 650–700 700 1,150 1¹⁄2 2³⁄16
³⁄4 –12 300–500 900–1,000 1³⁄4 2⁵⁄8
⁷⁄8 –14 500–600 1,000–1,100
1 –16 500–700 1,200–1,400 3 3¹⁄2
1¹⁄4 –20 600–900 1,200–1,400 3³⁄4 4³⁄8
1¹⁄2 –24 600–900 1,500–1,800 5 5¹⁄4
1³⁄4 –28 850–1,050 7 6¹⁄8
2 –32 950–1,150 8 7

Figure 9-20. Flared fitting data.

Figure 9-21. AN flared (left) and MS flareless fitting (right).

damage or completely cut off the tube flare, or it may ruin the commence at the point where the nut just begins to bottom.
sleeve or fitting nut. Failure to tighten sufficiently also may Use a wrench and turn the nut one-sixth turn (one flat on a
be serious, as this condition may allow the line to blow out hex nut). Use a wrench on the connector to prevent it from
of the assembly or to leak under system pressure. The use of turning while tightening the nut. After the tube assembly
torque wrenches and the prescribed torque values prevents is installed, the system should be pressure tested. It is
overtightening or undertightening. If a tube fitting assembly is permissible to tighten the nut an additional one-sixth turn
tightened properly, it may be removed and retightened many (making a total of one-third turn), should a connection leak.
times before reflaring is necessary. If leakage still occurs after tightening the nut a total of one-
third turn, remove the assembly and inspect the components
Flareless Tube Installation for scores, cracks, presence of foreign material, or damage
Tighten the nut by hand until an increase in resistance to from overtightening. Several aircraft manufacturers include
turning is encountered. Should it be impossible to run the nut torque values in their maintenance manuals to tighten the
down with the fingers, use a wrench, but be alert for the first flareless fittings.
signs of bottoming. It is important that the final tightening

9-12
 SLEEVE UNION ELBOW
MS20819 MS21902 MS21904

ADAPTER ADAPTER UNION CROSS ELBOW

MS21900 MS21901 MS21903 TEE MS21905 MS21906 MS21907

ELBOW TEE MS21909 TEE MS21910 TEE MS21911

MS21908

PLUG BUSHING NUT SLEEVE

MS21913 MS21915 MS21917 MS21922

TEE CAP REDUCER NUT ADAPTER UNION

MS21912 MS21914 MS21916 MS21921 MS21923 MS21924

MS 21900 –4 D

Material: aluminum alloy

Size of fitting in 16ths inch – 4⁄16 inch

Design part number: adapter, flareless tube to AN flared tube

Prefix: military specification

ELBOW ELBOW
MS21925 MS21926

Figure 9-22. Typical MS flareless tube fittings.

9-13
 Body Nut Lower die/holder assembly

Sleeve

Figure 9-23. Flareless fitting.

The following notes, cautions, and faults apply to the

installation of rigid tubing.

Note: Overtightening a flareless tube nut drives the cutting

edge of the sleeve deeply into the tube, causing the tube to be
weakened to the point where normal in-flight vibration could Head assembly
cause the tube to shear. After inspection (if no discrepancies
are found), reassemble the connections and repeat the
pressure test procedures.
Power unit

Caution: Never tighten the nut beyond one-third turn (two

flats on the hex nut); this is the maximum the fitting may be Hydraulic Tubing
tightened without the possibility of permanently damaging Waged Fitting
the sleeve and nut.

Common faults: Flare distorted into nut threads; sleeve

cracked; flare cracked or split; flare out of round; inside of
flare rough or scratched; and threads of nut or union dirty,
damaged, or broken.

Rigid Tubing Inspection & Repair

Minor dents and scratches in tubing may be repaired.
Scratches or nicks not deeper than 10 percent of the wall
thickness in aluminum alloy tubing, which are not in the
heel of a bend, may be repaired by burnishing with hand
tools. The damage limits for hard, thin-walled corrosion-
resistant steel and titanium tubing are considerably less
than for aluminum tubing and might depend on the aircraft
manufacturer. Consult the aircraft maintenance manual for
damage limits. Replace lines with severe die marks, seams,
or splits in the tube. Any crack or deformity in a flare is
unacceptable and is cause for rejection. A dent of less than Disconnect
20 percent of the tube diameter is not objectionable, unless
it is in the heel of a bend. To remove dents, draw a bullet of
proper size through the tube by means of a length of cable, Figure 9-24. Swaged fitting tooling.
or push the bullet through a short straight tube by means of
a dowel rod. In this case, a bullet is a ball bearing or slug

9-14
Figure 9-25. PermaswageTM fitting.

Figure 9-26. Permalite™ fitting.

normally made of steel or some other hard metal. In the case

of soft aluminum tubing, a hard wood slug or dowel may even
be used as a bullet. [Figure 9-29] A severely damaged line
should be replaced. However, the line may be repaired by
cutting out the damaged section and inserting a tube section of
the same size and material. Flare both ends of the undamaged
and replacement tube sections and make the connection by
using standard unions, sleeves, and tube nuts. Aluminum
6061-T6, corrosion-resistant steel 304-1/8h and Titanium
3AL-2.5V tubing can be repaired by swaged fittings. If
the damaged portion is short enough, omit the insert tube
and repair by using one repair union. [Figure 9-30] When
repairing a damaged line, be very careful to remove all chips
and burrs. Any open line that is to be left unattended for a
Figure 9-27. Cryofit fittings. period of time should be sealed, using metal, wood, rubber,

Do not deflect into place. Incorrect—will damage

Replace tube assembly. flare or threads, or cause
sleeve to crack under
vibration if tightened

Incorrect—may pull off or

distort flare if tightened

Correctly fitted and

tightened
.025 clearance between flare
and shoulder before tightening

Figure 9-28. Correct and incorrect methods of tightening flared fittings.

9-15
or plastic plugs or caps. Buna-S. Do not use for phosphate ester base hydraulic fluid
(Skydrol™).
When repairing a low-pressure line using a flexible fluid
connection assembly, position the hose clamps carefully Neoprene
to prevent overhang of the clamp bands or chafing of the Neoprene is a synthetic rubber compound that has an
tightening screws on adjacent parts. If chafing can occur, acetylene base. Its resistance to petroleum products is not
the hose clamps should be repositioned on the hose. as good as Buna-N, but it has better abrasive resistance. Do
Figure 9-31 illustrates the design of a flexible fluid connection not use for phosphate ester base hydraulic fluid (Skydrol™).
assembly and gives the maximum allowable angular and
dimensional offset. Butyl
Butyl is a synthetic rubber compound made from petroleum
When replacing rigid tubing, ensure that the layout of the new raw materials. It is an excellent material to use with phosphate
line is the same as that of the line being replaced. Remove the ester base hydraulic fluid (Skydrol™). Do not use with
damaged or worn assembly, taking care not to further damage petroleum products.
or distort it, and use it as a forming template for the new part.
If the old length of tubing cannot be used as a pattern, make Flexible rubber hose consists of a seamless synthetic rubber
a wire template, bending the pattern by hand as required for inner tube covered with layers of cotton braid and wire braid
the new assembly. Then bend the tubing to match the wire and an outer layer of rubber-impregnated cotton braid. This
pattern. Never select a path that does not require bends in type of hose is suitable for use in fuel, oil, coolant, and
the tubing. A tube cannot be cut or flared accurately enough hydraulic systems. The types of hose are normally classified
so that it can be installed without bending and still be free by the amount of pressure they are designed to withstand
from mechanical strain. Bends are also necessary to permit under normal operating conditions: low, medium, and high.
the tubing to expand or contract under temperature changes
and to absorb vibration. If the tube is small (under 1⁄4") and • Low pressure—below 250 psi. Fabric braid
can be hand formed, casual bends may be made to allow reinforcement.
for this. If the tube must be machine formed, definite bends • Medium pressure—up to 3,000 psi. One wire braid
must be made to avoid a straight assembly. Start all bends a reinforcement. Smaller sizes carry up to 3,000 psi.
reasonable distance from the fittings because the sleeves and Larger sizes carry pressure up to 1,500 psi.
nuts must be slipped back during the fabrication of flares and
• High pressure—all sizes up to 3,000 psi operating
during inspections. In all cases, the new tube assembly should
pressures.
be so formed prior to installation that it is not necessary to
pull or deflect the assembly into alignment by means of the
Flexible hoses used for brake systems have sometimes a
coupling nuts.
stainless steel wire braid installed over the hose to protect
the hose from damage. [Figure 9-32]
Flexible Hose Fluid Lines
Flexible hose is used in aircraft fluid systems to connect Hose Identification
moving parts with stationary parts in locations subject to Lay lines and identification markings consisting of
vibration or where a great amount of flexibility is needed. It lines, letters, and numbers are printed on the hose.
can also serve as a connector in metal tubing systems. [Figure 9-33] Most hydraulic hose is marked to identify
its type, the quarter and year of manufacture, and a 5-digit
Hose Materials & Construction
code identifying the manufacturer. These markings are in
Pure rubber is never used in the construction of flexible fluid contrasting colored letters and numerals that indicate the
lines. To meet the requirements of strength, durability, and
workability, among other factors, synthetics are used in place
of pure rubber. Synthetic materials most commonly used in Dent Cable
the manufacture of flexible hose are Buna-N, neoprene, butyl,
ethylene propylene diene rubber (EPDM) and Teflon™.
While Teflon™ is in a category of its own, the others are
synthetic rubber.

Buna-N Bullet

Buna-N is a synthetic rubber compound that has excellent

Figure 9-29. Dent removal using a bullet.
resistance to petroleum products. Do not confuse with

9-16
 Type of Failure Repair Method

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

Not to exceed 0.30" b. Swage 1 tube-to-tube union in tube section under repair.

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

b. Remove damaged section and duplicate.

New section c. Swage replacement section into tubing under repair using 2
tube-to-tube unions.
Original tubing

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

b. Duplicate tubing sections for each branch.

c. Swage splice sections to tee or elbow.

d. Connect each splice section to tubing under repair using a

tube-to-tube union.

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

b. Swage appropriate end fitting to tube end.

c. Connect new end fitting to mating connection, torquing nut

as required.

Figure 9-30. Permaswage™ repair.

natural lay (no twist) of the hose and are repeated at intervals limitless. Teflon™ hose is flexible and designed to meet the
of not more than 9 inches along the length of the hose. Code requirements of higher operating temperatures and pressures
markings assist in replacing a hose with one of the same in present aircraft systems. Generally, it may be used in the
specifications or a recommended substitute. Hose suitable same manner as rubber hose. Teflon™ hose is processed and
for use with phosphate ester base hydraulic fluid is marked extruded into tube shape to a desired size. It is covered with
Skydrol™ use. In some instances, several types of hose stainless steel wire, which is braided over the tube for strength
may be suitable for the same use. Therefore, to make the and protection. Teflon™ hose is unaffected by any known
correct hose selection, always refer to the applicable aircraft fuel, petroleum, or synthetic base oils, alcohol, coolants,
maintenance or parts manual. or solvents commonly used in aircraft. Teflon™ hose has
the distinct advantages of a practically unlimited storage
Teflon™ is the DuPont trade name for tetrafluoroethylene time, greater operating temperature range, and broad usage
resin. It has a broad operating temperature range (−65 °F to (hydraulic, fuel, oil, coolant, water, alcohol, and pneumatic
+450 °F). It is compatible with nearly every substance or systems). Medium-pressure Teflon™ hose assemblies are
agent used. It offers little resistance to flow; sticky, viscous sometimes preformed to clear obstructions and to make
materials do not adhere to it. It has less volumetric expansion connections using the shortest possible hose length. Since
than rubber, and the shelf and service life is practically preforming permits tighter bends that eliminate the need for

9-17
 (A) MIL-H-8794 Type Hose
Clamps
¼" Min.
Two cotton braids—impregnated with synthetic compound

G. ref Hose number Hose size

MIL-H-8794: SIZE-6-2/90 Mfg Symbol

Fitting Hose Tubing

3° Max. angular deviation Single wire braid

Quarter and year of manufacturer Synthetic inner tube

" Max. offset

Minimum gap “G” shall be ½" or Tube OD/4 (B) MIL-H-6000 Type Hose
(Views showing opposite side of hose)
Figure 9-31. Flexible fluid connection assembly.
Hose size

MIL-H-6000-SIZE-3-4/90 Mfg Symbol

Quarter and year of manufacturer

(C) MIL-H-5593 Type Hose

Hose size Lay lines

MIL-H-5593-6-4/90 Mfg Symbol

Figure 9-32. Flexible hose with stainless braid.

Quarter and year of manufacturer

special elbows, preformed hose assemblies save space and

weight. Never straighten a preformed hose assembly. Use a
support wire if the hose is to be removed for maintenance. (D) MIL-H-27267 Type Hose (E) MIL-H-83797 Type Hose
[Figure 9-34]

Flexible Hose Inspection

Check the hose and hose assemblies for deterioration at each Figure 9-33. Hose identification markings.
inspection period. Leakage, separation of the cover or braid
from the inner tube, cracks, hardening, lack of flexibility, or equipped with reusable end fittings, a replacement line can be
excessive “cold flow” are apparent signs of deterioration and fabricated with the use of such tooling as may be necessary to
reason for replacement. The term “cold flow” describes the comply with the assembly instructions of the manufacturer.
deep, permanent impressions in the hose produced by the
pressure of hose clamps or supports. Fabrication & Replacement of Flexible Hose
To make a hose assembly, select the proper size hose and
When failure occurs in a flexible hose equipped with swaged end fitting. [Figure 9-35] MS-type end fittings for flexible
end fittings, the entire assembly must be replaced. Obtain a hose are detachable and may be reused if determined to be
new hose assembly of the correct size and length, complete serviceable. The inside diameter of the fitting is the same
with factory installed end fittings. When failure occurs in hose as the inside diameter of the hose to which it is attached.
[Figure 9-36]

9-18
 Support wire 1. Place hose in vise and cut 2. Locate length of hose to
to desired length using be cut off and slit cover
fine tooth hacksaw or cut with knife to wire braid,
off wheel. taking care to not damage
underlying materials. After
slitting cover, twist off with
pair of pliers. (See note
below.)

Figure 9-34. Suggested handling of preformed hose.

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

Flexible Hose Testing screw socket on hose and nipple threads liberally.
counterclockwise.
All flexible hose must be proof-tested after assembly and
applying pressure to the inside of the hose assembly. The NOTE: Hose assemblies
fabricated per MIL-H-8790
proof-test medium may be a liquid or gas. For example, must have the exposed wire
hydraulic, fuel, and oil lines are generally tested using braid coated with a special
sealant.
hydraulic oil or water, whereas air or instrument lines
are tested with dry, oil-free air or nitrogen. When testing NOTE: Step 2 applies to high-
with a liquid, all trapped air is bled from the assembly pressure hose only.

prior to tightening the cap or plug. Hose tests, using a gas, *CAUTION: Do not use any
are conducted underwater. In all cases, follow the hose petroleum product with hose
designed for synthetic fluids
manufacturer’s instructions for proof-test pressure and 5. Screw nipple into socket (Skydrol™ and/or HYJET
fluid to be used when testing a specific hose assembly. using wrench on hex of product). For a lubricant
nipple and leave .005" to
[Figure 9-37] .031" clearance between
during assembly, use a
vegetable soap liquid.
nipple hex and socket.
When a flexible hose has been repaired or overhauled using Disassemble in reverse order.
existing hardware and new hose material, and before the hose
is installed on the aircraft, it is recommended that the hose be Figure 9-35. Assembly of MS fitting to flexible hose.
tested to at least 1.5 system pressure. A hydraulic hose burst
test stand is used for testing flexible hose. [Figure 9-38] A
new hose can be operationally checked after it is installed in
the aircraft using system pressure.

Size Designations
Hose is also designated by a dash number according to its
size. The dash number is stenciled on the side of the hose and
indicates the size tubing with which the hose is compatible.
It does not denote inside or outside diameter. When the dash
number of the hose corresponds with the dash number of
the tubing, the proper size hose is being used. [Figure 9-33]
Figure 9-36. MS-type end fitting.

9-19
 Single Wire Braid Fabric Covered

Tube Size Hose Size Hose Size Recomm. Min. Burst Max. Proof Min. Bend
MIL. Part No. OD ID OD Operating Pressure Pressure Radius
(inches) (inches) (inches) Pressure (PSI) (PSI) (PSI) (inches)

MIL-H-8794-3-L ³⁄16 ¹⁄8 .45 3,000 12,000 6,000 3.00

MIL-H-8794-4-L ¹⁄4 ³⁄16 .52 3,000 12,000 6,000 3.00
MIL-H-8794-5-L ⁵⁄16 ¹⁄4 .58 3,000 10,000 5,000 3.38
MIL-H-8794-6-L ³⁄8 ⁵⁄16 .67 2,000 9,000 4,500 4.00
MIL-H-8794-8-L ¹⁄2 ¹³⁄32 .77 2,000 8,000 4,000 4.63
MIL-H-8794-10-L ⁵⁄8 ¹⁄2 .92 1,750 7,000 3,500 5.50
MIL-H-8794-12-L ³⁄4 ⁵⁄8 1.08 1,750 6,000 3,000 6.50
MIL-H-8794-16-L 1 ⁷⁄8 1.23 800 3,200 1,600 7.38
MIL-H-8794-20-L 1¹⁄4 1¹⁄8 1.50 600 2,500 1,250 9.00
MIL-H-8794-24-L 1¹⁄2 1³⁄8 1.75 500 2,000 1,000 11.00
MIL-H-8794-32-L 2 1¹³⁄16 2.22 350 1,400 700 13.25
MIL-H-8794-40-L 2¹⁄2 2³⁄8 2.88 200 1,000 300 24.00
MIL-H-8794-48-L 3 3 3.56 200 800 300 33.00
Construction: Seamless synthetic rubber inner tube reinforced Operating Temperatures:
with one fiber braid, one braid of high tensile steel wire and Sizes 3 through 12: − 65 °F to + 250 °F
covered with an oil resistant rubber impregnated fiber braid. Sizes 16 through 48: − 40 °F to + 275 °F

Identification: Hose is identified by specification number, Note: Maximum temperatures and pressures should not be
size number, quarter year and year, hose manufacturer’s used simultaneously.
identification.

Uses: Hose is approved for use in aircraft hydraulic, pneumatic,

coolant, fuel, and oil systems.

Multiple Wire Braid Rubber Covered

Tube Size Hose Size Hose Size Recomm. Min. Burst Max. Proof Min. Bend
MIL. Part No. OD ID OD Operating Pressure Pressure Radius
(inches) (inches) (inches) Pressure (PSI) (PSI) (PSI) (inches)

MIL-H-8788- 4-L ¹⁄4 ⁷⁄32 .63 3,000 16,000 8,000 3.00

MIL-H-8788- 5-L ⁵⁄16 ⁹⁄32 .70 3,000 14,000 7,000 3.38
MIL-H-8788- 6-L ³⁄8 ¹¹⁄32 .77 3,000 14,000 7,000 5.00
MIL-H-8788- 8-L ¹⁄2 ⁷⁄16 .86 3,000 14,000 7,500 5.75
MIL-H-8788-10-L ⁵⁄8 ⁹⁄16 1.03 3,000 12,000 6,000 6.50
MIL-H-8788-12-L ³⁄4 ¹¹⁄16 1.22 3,000 12,000 6,000 7.75
MIL-H-8788-16-L 1 ⁷⁄8 1.50 3,000 10,000 5,000 9.63

Construction: Seamless synthetic rubber inner tube reinforced Uses: High pressure hydraulic, pneumatic, coolant, fuel and oil.
with one fiber braid, two or more steel wire braids, and Operating Temperatures: − 65 °F to + 200 °F
covered with synthetic rubber cover (for gas applications
request perforated cover).

Identification: Hose is identified by specification number,

size number, quarter year and year, hose manufacturer’s
identification.

Figure 9-37. Aircraft hose specifications.

9-20
 Spur

Nipple
Socket

Reinforcement Sheath

Figure 9-38. Hydraulic hose burst test stand.

Hose Fittings
Flexible hose may be equipped with either swaged fittings or Figure 9-39. Reusable fittings for medium-pressure hose.
detachable fittings, or they may be used with beads and hose
clamps. Hoses equipped with swaged fittings are ordered by stripe running along its length. This stripe should not spiral
correct length from the manufacturer and ordinarily cannot around the hose.
be assembled by the mechanic. They are swaged and tested
at the factory and are equipped with standard fittings. The
Bending
detachable fittings used on flexible hoses may be detached
To avoid sharp bends in the hose assembly, use elbow
and reused if they are not damaged; otherwise, new fittings
fittings, hose with elbow-type end fittings, or the appropriate
must be used. [Figure 9-39]
bend radii. Bends that are too sharp reduce the bursting
Installation of Flexible Hose Assemblies pressure of flexible hose considerably below its rated value.
[Figure 9-40]
Slack
Hose assemblies must not be installed in a manner that causes Clearance
a mechanical load on the hose. When installing flexible hose,
The hose assembly must clear all other lines, equipment, and
provide slack or bend in the hose line from 5 to 8 percent of
adjacent structure under every operating condition.
its total length to provide for changes in length that occurs
when pressure is applied. Flexible hose contracts in length
Flexible hose should be installed so that it is subject to a
and expands in diameter when pressurized. Protect all flexible
minimum of flexing during operation. Although hose must
hoses from excessive temperatures, either by locating the lines
be supported at least every 24 inches, closer supports are
so they are not affected or by installing shrouds around them.
desirable. Flexible hose must never be stretched tightly
between two fittings. If clamps do not seal at specified
Flex tightening, examine hose connections and replace parts as
When hose assemblies are subject to considerable vibration necessary. The above is for initial installation and should not
or flexing, sufficient slack must be left between rigid fittings. be used for loose clamps.
Install the hose so that flexure does not occur at the end
fittings. The hose must remain straight for at least two hose For retightening loose hose clamps in service, proceed as
diameters from the end fittings. Avoid clamp locations that follows:
restrict or prevent hose flexure.
• Non-self-sealing hose—if the clamp screw cannot
be tightened with the fingers, do not disturb unless
Twisting
leakage is evident. If leakage is present, tighten one-
Hoses must be installed without twisting to avoid possible fourth turn.
rupture of the hose or loosening of the attaching nuts. Use of
swivel connections at one or both ends relieve twist stresses. • Self-sealing hose—if looser than finger-tight, tighten
Twisting of the hose can be determined from the identification to finger-tight and add one-fourth turn. [Figure 9-41]

9-21
 Planning Hose Line Installations

Wrong

Wrong Right

Right

1. Provide slack or bend in the hose line to provide for changes 2. Observe linear stripe. The hose must not be twisted. High
in length that will occur when pressure is applied. pressures applied to a twisted hose may cause failure or
loosen the nut.

Wrong Right

Wrong

3. Relieve sharp bends, avoid strain or hose collapse, and make Right
cleaner installations by using Aeroquip elbows or other
adapter fittings. Provide as large a bend radius as possible.
Never use less than the recommended minimum bend
radius specified for the hose.
4. Provide additional bend radius when lines are subject to
flexing and remember that the metal end fittings are not
flexible. Place line support clamps so as not to restrict
hose flexing.

Figure 9-40. Flexible hose installation.

Clamps—
Initial Worm screw type radial and other
Installation clamp (10 threads type (28 threads
Hose Clamps Only per inch) per inch)
To ensure proper sealing of hose connections and to prevent
Self-sealing hose Finger-tight plus
breaking hose clamps or damaging the hose, follow the hose Finger-tight plus 2
approximately 2½ complete
clamp tightening instructions carefully. When available, use complete turns
15 in-lb turns
the hose clamp torque-limiting wrench. These wrenches All other
are available in calibrations of 15 and 25 in-lb limits. In the Finger-tight plus
aircraft hose Finger-tight plus 2
1¼ complete
absence of torque-limiting wrenches, follow the finger-tight- approximately
turns
complete turns
25 in-lb
plus-turns method. Because of the variations in hose clamp
design and hose structure, the values given in Figure 9-41 are Figure 9-41. Hose clamp tightening.
approximate. Therefore, use good judgment when tightening
hose clamps by this method. Since hose connections are subject [Figure 9-42] The plain clamp is used to secure lines in areas
to “cold flow” or a setting process, a follow-up tightening not subject to vibration.
check should be made for several days after installation.
A Teflon™-cushioned clamp is used in areas where the
Support clamps are used to secure the various lines to the deteriorating effect of Skydrol™, hydraulic fluid, or fuel
airframe or powerplant assemblies. Several types of support is expected. However, because it is less resilient, it does
clamps are used for this purpose. The most commonly not provide as good a vibration-damping effect as other
used clamps are the rubber-cushioned and plain. The cushion materials.
rubber-cushioned clamp is used to secure lines subject to
vibration; the cushioning prevents chafing of the tubing.

9-22
Use bonded clamps to secure metal hydraulic, fuel, or oil lines
in place. Unbonded clamps should be used only for securing
wiring. Remove any paint or anodizing from the portion of the
tube at the bonding clamp location. Make certain that clamps
are of the correct size. Clamps or supporting clips smaller
than the outside diameter of the hose may restrict the flow
of fluid through the hose. All fluid lines must be secured at
specified intervals. The maximum distance between supports
for rigid tubing is shown in Figure 9-43.

Support tube at least 1/4" from edge of hole

Grommet

Figure 9-42. Rubber-cushioned clamp.

Distance Between Supports (in.)

Tube OD (in.)
Aluminum Alloy Steel

¹⁄8 9¹⁄2 11¹⁄2

³⁄16 12 14
¹⁄4 13¹⁄2 16
⁵⁄16 15 18
³⁄8 16¹⁄2 20
¹⁄2 19 23
⁵⁄8 22 25¹⁄2
³⁄4 24 27¹⁄2
1 26¹⁄2 30

Figure 9-43. Maximum distance between supports for fluid tubing.

9-23