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Alcoa Fastening Systems

FLUID BOSS ADAPTERS AND INSERTS TOOLING

· PORT PREPARATION TOOLS · INSTALLATION TOOLS · REMOVAL TOOLS

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

Alcoa Fastening Systems

INDEX

ALPHABETICAL TOOL INDEX WEBSITE INFORMATION 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 -20 21 22 23 24 25 26 27 -29 30 31 32 33 34 35 36 -37 38 39 40 41 42 43 44 45 46 -47 48 -49 50 -51 52 -53 54 -55 56 -57

SECTION 1 - PORT SERRATION TOOLS, FLUID BOSS ADAPTER

PS10035-( ) PORTING DIMENSONS PS10035-( ) PORTING TOOLS CHART RPT( ) SERIES PORTING TOOL RFOPB5000 SERIES HAND HELD BROACH TOOL RFOPB5000HDB SERIES NON-IMPACT BROACH TOOL RFOPB5000ED2 SERIES ELECTRICAL DISCHARGE MACHINING BROACH (EDM) RFOPB5000ED3 SERIES ELECTRICAL DISCHARGE MACHINING BROACH (EDM) RFOPB5000WBA SERIES BROACH TOOL WOBBLE BROACH MACHINING RFOPB5000WB SERIES BROACH TOOL WOBBLE BROACH MACHINING RF( )CRP SERIES CHIP REMOVAL TOOL RFOPB( )PSG SERIES PORT SERRATION GAGE

SECTION 2 - INSTALLATION AND REMOVAL TOOLS, FLUID BOSS ADAPTER

INSTALLATION AND REMOVAL TOOLS CHART, FLUID BOSS ADAPTERS INSTALLATION AND REMOVAL INSTRUCTION, FLUID BOSS ADAPTERS ORT( ) O-RING INSTALLATION TOOL RF5000DW SERIES COMBINATION DRIVE TOOL AND WRENCH RF6900W WRENCH ASSEMBLY RF9800DEK LOCK RING DRIVE TOOL RF( )LPDE SERIES LOCK RING REMOVAL TOOL, LIFT TYPE ADAPTER/LOCKRING REMOVAL INSTRUCTIONS TOOL KITS

SECTION 3 - PORT SERRATION TOOLS, FLUID BOSS INSERTS

PS10040-( ) PORTING DIMENSIONS RPT9500 SERIES PORTING TOOL RFPBT9500 SERIES HAND HELD BROACH TOOL RFPBT9500HDB SERIES NON-IMPACT BROACH TOOL

SECTION 4 - INSTALLATION AND REMOVAL TOOLS, FLUID BOSS INSERTS

INSERT INSTALLATION AND REMOVAL INSTRUCTIONS ORT95-( ) O-RING INSTALLATION TOOL RF8500WA SERIES WRENCH ASSY RF9500DA SERIES LOCKRING DRIVE TOOL RF8500DA SERIES LOCKRING DRIVE TOOL RF9500LPD SERIES LOCKRING REMOVAL TOOL RF8500R SERIES INSERT REMOVAL TOOL, DRILL TYPE TOOL KITS, INSERT PORT PREPERATION, INSTALLATION AND REMOVAL

SECTION 5 - FLUID BOSS ADAPTERS AND INSERTS

RF5000-13 SERIES ADAPTER FLUID CONNECTION ASSY, BEAM SEAL, 5000 PSI RFK9800-13 SERIES ADAPTER FLUID CONNECTION ASSY, FLARED TUBE END AS4395 RFK9900-13 SERIES ADAPTER FLUID CONNECTION ASSY, FLARELESS TUBE END MS33514 OR AS4375 RF9800-13 SERIES ADAPTER, REDUCER, FLARED TUBE END AS4395 RF9900-13 SERIES ADAPTER, REDUCER, FLARELESS TUBE END, MS33514 OR AS4375 RF9500-6 SERIES INSERT ASSY 3000 PSI, MS33649 INTERNAL CONFIGURATION

2

Alcoa Fastening Systems

ALPHABETICAL TOOL INDEX

PART NUMBER ORT( ) O-RING INSTALLATION TOOL ORT95-( ) O-RING INSTALLATION TOOL PS10035-( ) PORTING DIMENSONS PS10035-( ) PORTING TOOLS CHART PS10040-( ) PORTING DIMENSIONS RF( )CRP SERIES CHIP REMOVAL TOOL RF( )LPDE SERIES LOCK RING REMOVAL TOOL, LIFT TYPE RF5000DW SERIES COMBINATION DRIVE TOOL AND WRENCH RF6900W WRENCH ASSEMBLY RF8500DA SERIES LOCKRING DRIVE TOOL RF8500R SERIES INSERT REMOVAL TOOL, DRILL TYPE RF8500WA SERIES WRENCH ASSY RF9500DA SERIES LOCKRING DRIVE TOOL RF9500LPD SERIES LOCKRING REMOVAL TOOL RF9800DEK LOCK RING DRIVE TOOL RFOPB( )PSG RFOPB5000 SERIES HAND HELD BROACH TOOL RFOPB5000ED2 SERIES ELECTRICAL DISCHARGE MACHINING BROACH (EDM) RFOPB5000ED3 SERIES ELECTRICAL DISCHARGE MACHINING BROACH (EDM) RFOPB5000HDB SERIES NON-IMPACT BROACH TOOL RFOPB5000WB SERIES BROACH TOOL WOBBLE BROACH MACHINING RFOPB5000WBA SERIES BROACH TOOL WOBBLE BROACH MACHINING RFPBT9500 SERIES HAND HELD BROACH TOOL RFPBT9500HDB SERIES NON-IMPACT BROACH TOOL RPT( ) SERIES PORTING TOOL RPT9500 SERIES PORTING TOOL TOOL KITS, FLUID BOSS ADAPTERS, INSTALLATION AND REMOVAL TOOL KITS, INSERT PORT PREPERATION, INSTALLATION AND REMOVAL PAGE 21 38 6 7 31 15 25 22 23 41 43 39 40 42 24 16 9 11 12 10 14 13 33 34 8 32 27 - 29 44

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4

Alcoa Fastening Systems

SECTION 1

FLUID BOSS ADAPTER PORT PREPARATION AND SERRATION TOOLS

· PORTING TOOLS · BROACH TOOLS · CHIP REMOVAL TOOL

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

5

Alcoa Fastening Systems

PS10035-( )

PORT ­ ROSAN FLUID CONNECTION TYPE, INTERNAL STRAIGHT THREAD

PORT NUMBER

AS I.D. NUMBER

T THREAD, MIL-S-8879 A

B C D E F

G

H

J

K

PS10035-02 AS1300-02 PS10035-03 AS1300-03 PS10035-04 AS1300-04 PS10035-05 AS1300-05 PS10035-06 AS1300-06 PS10035-08 AS1300-08 PS10035-10 AS1300-10 PS10035-12 AS1300-12 PS10035-14 AS1300-14 PS10035-16 AS1300-16 PS10035-20 AS1300-20 PS10035-24 AS1300-24 PS10035-32 AS1300-32

CLASS 3B MIN DIA DIA THREAD CONTROLLED BOSS +.003 +.002 SIZE MINOR DIA DIA -.000 -.000 .2160-28 .1857 .50 .381 .254 UNJF .1827 .2500-28 .2197 .62 .448 .286 UNJF .2167 .3125-24 .2764 .68 .495 .339 UNJF .2734 .3750-24 .3389 .79 .601 .401 UNJF .3359 .4375-20 .3933 .85 .464 UNJF .3903 .675 .5625-18 .5129 1.04 .582 UNJF .5099 .784 .6875-24 .6514 1.17 .725 UNJF .6484 1.015 .8125-20 .7683 1.42 .899 UNJF .7653 1.139 .9375-20 .8933 1.54 1.030 UNJF .8903 1.311 1.1250-18 1.0744 1.67 1.162 UNJF 1.0714 1.427 1.2629 1.3125-18 1.98 1.750 1.387 UNJF 1.2599 2.005 1.6250-18 1.5754 1.664 2.23 2.000 UNJF 1.5724 2.521 2.1250-16 2.0657 2.202 2.86 2.516 UNJF 2.0627

MIN FULL DIA NUMBER +.010 +.005 +.005 THREAD MIN OF -.000 -.000 -.000 DEPTH TEETH MIN .088 .088 .088 .088 .103 .103 .103 .103 .103 .103 .130 .130 .130 .153 .153 .153 .153 .168 .168 .168 .168 .168 .168 .195 .195 .195 .296 .296 .296 .296 .311 .311 .311 .343 .343 .343 .375 .375 .416 .507 .568 .568 .594 .631 .673 .693 .763 .800 .806 .838 .877 .1050 .408 .478 .524 .635 .710 .826 1.052 1.182 1.354 1.471 1.795 2.045 2.561 24 26 30 36 36 40 38 40 50 36 56 81 102 .061 .061 .061 .061 .073 .073 .073 .073 .073 .073 .093 .093 .093

6

Alcoa Fastening Systems

PORT AND SERRATION PREPARATION TOOLS PS10035 (AS1300) PORT

PORT PREPARATION 1 Tools in the table below are for preparation of ports for Adapter series RFK9800-13, RFK9802-13 and `'''''' `''''''RF5000-13 as well as all products requiring PS10035 (AS1301) port preparation 2 Prepare boss and port per specifications on previous page. Drill thru or to depth specified on applicable `'''''drawing using a drill with a diameter .015-.030 smaller than that specified as the minor diameter. Follow `'''''with the RPT Porting Tool to finish the minor diameter of the port thread to the sizes required for piloting of `'''''the broach tool. 3 Use Broach Tool selected from table below to achieve the proper serrations to complete the port. 4 After serrations are broached, chip removal is required using RF( )CRP tool from table below.

PORT NUMER

TUBING O.D. (REF)

PORTING TOOL

SERRATION BROACH TOOLS (1 REQUIRED ONLY) HAND HELD RFOPB5002 RFOPB5003 RFOPB5004 RFOPB5005 RFOPB5006 RFOPB5008 RFOPB5010 RFOPB5012 RFOPB5014 RFOPB5016 RFOPB5020 RFOPB5024 RFOPB5032 NON IMPACT 5 RFOPB5002HDB RFOPB5003HDB RFOPB5004HDB RFOPB5005HDB RFOPB5006HDB RFOPB5008HDB RFOPB5010HDB RFOPB5012HDB RFOPB5014HDB RFOPB5016HDB RFOPB5020HDB RFOPB5024HDB RFOPB5032HDB EDM RFOPB5002ED3 OR RFOPB5002ED2 RFOPB5003ED3 OR RFOPB5003ED2 RFOPB5004ED3 OR RFOPB5004ED2 RFOPB5005ED3 OR RFOPB5005ED2 RFOPB5006ED3 OR RFOPB5006ED2 RFOPB5008ED3 OR RFOPB5008ED2 RFOPB5010ED3 OR RFOPB5010ED2 RFOPB5012ED3 OR RFOPB5012ED2 RFOPB5014ED3 OR RFOPB5014ED2 RFOPB5016ED3 OR RFOPB50016ED2 RFOPB5020ED3 OR RFOPB5020ED2 RFOPB5024ED3 OR RFOPB50024ED2 RFOPB5032ED3 OR RFOPB5032ED2 WOBBLE 6 RFOPB5002WB or RFOPB5002WBA RFOPB5003WB or RFOPB5003WBA RFOPB5004WB or RFOPB5004WBA RFOPB5005WB or RFOPB5005WBA RFOPB5006WB or RFOPB5006WBA RFOPB5008WB or RFOPB5008WBA RFOPB5010WB or RFOPB5010WBA RFOPB5012WB or RFOPB5012WBA RFOPB5014WB or RFOPB5014WBA RFOPB5016WB or RFOPB5016WBA RFOPB5020WB or RFOPB5020WBA -----------------------------

CHIP REMOVAL TOOL NUMBER RF02CRP RF03CRP RF04CRP RF05CRP RF06CRP RF08CRP RF10CRP RF12CRP RF14CRP RF16CRP RF20CRP RF24CRP RF32CRP

PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1-1/4 1-1/2 2

RPT02 RPT03 RPT04 RPT05 RPT06 RPT08 RPT10 RPT12 RPT14 RPT16 RPT20 RPT24 RPT32

7

Alcoa Fastening Systems

RPT( )

SERIES

STANDARD PORT CONTOUR CUTTER SHORT SERIES ­ CARBIDE TIPPED PS10035 (AS1300) PORT

PORTING TUBING TOOL OD NUMBER REF RPT02* 1/8 RPT03* 3/16 RPT04* 1/4 RPT05 5/16 RPT06 3/8 RPT08 1/2 RPT10 5/8 RPT12 3/4 RPT14 7/8 RPT16 1 RPT20 1-1/4 RPT24 1-1/2 RPT32 2

*SOLID CARBIDE

A

DIA +.0000 -.0003 .3748 .3748 .4998 .4998 .4998 .4998 .4998 .4998 .7498 .7498 .7498 .7498 .9998

B

DIA +.0000 -.0003 .1842 .2182 .2749 .3374 .3918 .5114 .6499 .7668 .8918 1.0729 1.2614 1.5739 2.0642

C

DIA +.0000 -.0003 .3818 .4488 .4958 .6018 .6758 .7848 1.0158 1.1398 1.3118 1.4278 1.7508 2.0008 2.5185

D

+.005 .610 .670 .700 .725 .785 .850 .810 .950 .987 1.015 1.090 1.205 1.480

E

+.030 4.000 4.000 4.000 3.475 3.535 3.850 3.810 4.200 4.240 4.265 4.520 4.560 4.765

PORT TO PRODUCE THREAD CONTOUR MIL-S-8879 FOR PORT CLASS 3B NUMBER REF .2160-28UNJF PS10035-02 .2500-28UNJF PS10035-03 .3125-24UNJF PS10035-04 .3750-24UNJF PS10035-05 .4375-20UNJF PS10035-06 .5625-18UNJF PS10035-08 .6875-24UNJEF PS10035-10 .8125-20UNJEF PS10035-12 .9375-20UNJEF PS10035-14 1.125-18UNJEF PS10035-16 1.3125-18UNJEF PS10035-20 1.6250-18UNJEF PS10035-24 2.1250-16UNJ PS10035-32

APPLICATION: This tool counterbores, countersinks, provides a radius and produces a tap drill diameter in one pass. Countours are ground to insure concentricity. Cutter geometry permits the use of these tools with most common materials

8

Alcoa Fastening Systems

RFOPB5000

SERIES

BROACH TOOL ­ HAND HELD PS10035 PORT SERRATIONS

BROACH TOOL NUMBER RFOPB5002 RFOPB5003 RFOPB5004 RFOPB5005 RFOPB5006 RFOPB5008 RFOPB5010 RFOPB5012 RFOPB5014 RFOPB5016 RFOPB5020 RFOPB5024 RFOPB5032

CUTTER NUMBER 1 RFOPB5002-3 RFOPB5003-3 RFOPB5004-3 RFOPB5005-3 RFOPB5006-3 RFOPB5008-3 RFOPB5010-3 RFOPB5012-3 RFOPB5014-3 RFOPB5016-3 RFOPB5020-3 RFOPB5024-3 RFOPB5032-3

A

DIA +.015 .600 .730 .790 .920 .980 1.070 1.290 1.420 1.600 1.730 2.040 2.300 2.810

B

DIA +.0000 -.0010 .1822 .2162 .2729 .3354 .3898 .5094 .6479 .7648 .8898 1.0719 1.2594 1.5719 2.0647

C

REF 5.32 5.32 5.32 5.34 5.42 5.46 5.48 5.54 5.61 5.62 5.64 5.65 5.65

D

HEX REF .62 .75 .81 .94 1.00 1.12 1.31 1.44 1.62 1.75 2.25 2.50 2.88

E

'+.015 -.000 .063 .063 .063 .063 .075 .075 .075 .075 .075 .075 .095 .095 .095

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED `1 Replacement cutters may be purchased individually

`2 Inspection of noted runout and use of controlled minor diameter per Rosan PS10035 port spicspecification will provide an allowable maximum runout of .009 between serration major diameter and and controlled minor diameter after broaching. APPLICATION: This broach tool, when used in arbor, hydraulic presses or manually, is designed to produce serrations in the counterbore wall of ports prepared per PS10035. The tool will broach aluminum, magnesium, and many steels with hardness of 32 HRC or less. Successful broaching of harder or tougher material may be accomplished, but tool cutter wear is to be expected. METHOD: The pilot is inserted into the tap drill hole of PS10035 port, and sufficient force applied to the top of the mandrel to allow the cutter to broach into the counterbore. When the external shoulder of the mandrel contacts the internal shoulder of the body*, broaching is complete. If cutter sticks in counterbore, turn the nut in a clockwise direction to extract the cutter. Caution: nut is for cutter removal only and is not a stop. Always back off nut when broaching. Hole can be tapped before or after broaching.

9

Alcoa Fastening Systems

RFOPB5000HDB

SERIES

BROACH TOOL ­ NON-IMPACT PS10035 PORT SERRATIONS (FOR MATERAL UP TO 40 HRC)

THREAD MIL-S-8879 CLASS 3A RFOPB5002HDB RFOPB5002HDB5 RFOPB5002HDB4 AXK0619TN .2160-28UNJF RFOPB5003HDB RFOPB5003HDB5 RFOPB5003HDB4 AXK0821TN .2500-28UNJF RFOPB5004HDB RFOPB5004HDB5 RFOPB5004HDB4 K81102TN .3125-24UNJF RFOPB5005HDB RFOPB5005HDB5 RFOPB5005HDB4 K81103TN .3750-24UNJF RFOPB5006HDB RFOPB5006HDB5 RFOPB5006HDB4 K81104TN .4375-20UNJF RFOPB5008HDB RFOPB5008HDB5 RFOPB5008HDB4 K81105TN .5625-18UNJF RFOPB5010HDB RFOPB5010HDB5 RFOPB5010HDB4 K81206TN .6875-24UNJEF RFOPB5012HDB RFOPB5012HDB5 RFOPB5012HDB4 K81206TN .8125-20UNJEF RFOPB5014HDB RFOPB5014HDB5 RFOPB5014HDB4 K81208TN .9375-20UNJEF RFOPB5016HDB RFOPB5016HDB5 RFOPB5016HDB4 K81208TN 1.125-18UNJEF RFOPB5020HDB RFOPB5020HDB5 RFOPB5020HDB4 K81208TN 1.3125-18UNJEF RFOPB5024HDB RFOPB5024HDB5 RFOPB5024HDB4 K89407TN 1.6250-18UNJEF RFOPB5032HDB RFOPB5032HDB5 RFOPB5032HDB4 K89408TN 2.1250-16UNJ

BROACH TOOL NUMBER

CUTTER NUMBER 2 3

STUD PART NUMBER 4

THRUST BEARING PART NUMBER

A

B

HEX REF .500 .625 .750 .750 1.000 1.000 1.000 1.125 1.250 1.500 1.625 1.750 2.000

C

HEX REF .125 .172 .218 .250 .312 .375 .500 .625 .750 .875 1.062 1.000 1.125

D

DIA MAX 1.04 1.14 1.41 1.53 1.85 2.04 2.32 2.32 3.01 3.01 3.01 3.44 3.88

E

+.03 3.10 3.58 3.86 4.00 4.71 4.96 4.54 4.73 5.51 5.76 5.94 6.11 6.61

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED `1 Usage of tool is described in TSB52273. This tool will broach serrations into most materials with ` ` `'ardhardness up to 40 HRC. `2 Two extra cutters are provided with each tool. `3 Replacement cutters may be purchased individually `4 Replacement studs may be purchased individually `5 Use of this tool will provide an allowable maximum runout of .009 between serration major diameter and `'' `'''''controlled minor diameter (REF: PS10035) after broaching.

10

Alcoa Fastening Systems

RFOPB5000ED2

SERIES

BROACH TOOL ­ POCO GRAPHITE ELECTRICAL DISCHARGE MACHINING PS10035 PORT SERRATIONS

BROACH TOOL NUMBER RFOPB5002ED2 RFOPB5003ED2 RFOPB5004ED2 RFOPB5005ED2 RFOPB5006ED2 RFOPB5008ED2 RFOPB5010ED2 RFOPB5012ED2 RFOPB5014ED2 RFOPB5016ED2 RFOPB5020ED2 RFOPB5024ED2 RFOPB5032ED2

A

DIA +.002 -.004 .399 .468 .514 .624 .699 .814 1.040 1.170 1341 1.456 1.782 2.032 2.548

NUMBER OF TEETH 24 26 30 36 36 40 38 40 50 36 56 81 102

B

DIA +.002 .312 .375 .375 .500 .500 .500 .500 .750 .750 .750 1.000 1.500 1.500

C

DIA +.010 .109 .125 .125 .156 .156 .156 .156 .156 .156 .156 .156 .156 .156

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED `1 MATERIAL: UNION POCO GRADE EDM-3 GRAPHITE, with option of alloy steel shank. `2 This tool is designed to provide approximately 10 times the life of tools made from brass (RFOPB5000ED `'''''Series). `3 When using this tool, the machine should be set to produce a burn which is .009 to .011 larger on the `'''''diameter than "A". This will allow the lockring to fit into the serration produced with about .004 to .005 `'''''clearance. The applicable lockring may be used to gage the port serration CAUTION: Care must be taken when machining to provide the following requirements: A maximum runout of `'''''''''''''''''''.009 must be maintained between serration major dia and controlled minor dia (specified in `'''''''''''''''''''Rosan®PS10035 port specification) after machining.

11

Alcoa Fastening Systems

RFOPB5000ED3

SERIES

BROACH TOOL ­ COPPER TUNGSTEN ELECTRICAL DISCHARGE MACHINING PS10035 PORT SERRATIONS

BROACH TOOL NUMBER RFOPB5002ED3 RFOPB5003ED3 RFOPB5004ED3 RFOPB5005ED3 RFOPB5006ED3 RFOPB5008ED3 RFOPB5010ED3 RFOPB5012ED3 RFOPB5014ED3 RFOPB5016ED3 RFOPB5020ED3 RFOPB5024ED3 RFOPB5032ED3

A

DIA +.002 -.004 .411 .480 .526 .637 .712 .826 1.054 1.184 1.356 1.473 1.797 2.047 2.563

NUMBER OF TEETH 24 26 30 36 36 40 38 40 50 36 56 81 102

B

DIA +.002 .312 .375 .375 .500 .500 .500 .500 .500 .500 .500 .500 .500 .500

C

DIA +.010 .109 .125 .125 .156 .156 .156 .156 .156 .156 .156 .156 .156 .156

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED `1 MATERIAL: COPPER TUNGSTEN, with option of alloy steel shank. `2 When using this tool, the machine should be set to produce a burn which is .002 to .003 larger on the `'''''diameter than "A" Dia. This will allow the lockring to fit into the serration produced with about .004 to .005 `'''''clearance. The applicable lockring may be used to gage the port serration. CAUTION: Care must be taken when machining to provide the following requirements: A maximum runout of `'''''''''''''''''''.009 must be maintained between serration major dia and controlled minor dia (specified in Rosan `'''''''''''''''''''PS10035 port specification) after machining.

12

Alcoa Fastening Systems

RFOPB5000WBA

SERIES

BROACH TOOL WOBBLE BROACH MACHINING PS10035 PORT SERRATIONS

BROACH TOOL NUMBER RFOPB5002WBA RFOPB5003WBA RFOPB5004WBA RFOPB5005WBA RFOPB5006WBA RFOPB5008WBA RFOPB5010WBA RFOPB5012WBA RFOPB5014WBA RFOPB5016WBA RFOPB5020WBA RFOPB5024WBA RFOPB5032WBA

CUTTER AND SCREW COMBINATION NUMBER 2 RFOPB5002WBA23 RFOPB5003WBA23 RFOPB5004WBA23 RFOPB5005WBA23 RFOPB5006WBA23 RFOPB5008WBA23 RFOPB5010WBA23 RFOPB5012WBA23 RFOPB5014WBA23 RFOPB5016WBA23 RFOPB5020WBA23 RFOPB5024WBA23 RFOPB5032WBA23

A

NUMBER OF TEETH 24 26 30 36 36 40 38 40 50 36 56 81 102

B

DIA +.002 .412 .481 .527 .638 .713 .827 1.055 1.185 1.357 1.474 1.798 2.048 2.564

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED `1 Wobbling Drift Hold is ordered separately using part number W37601.00 `2 Cutter and Screw combination can be ordered separately for spares or replacement `3 USAGE: These tools are designed to broach serrations into counterbore of ports PS10035 (AS1300) and `'''''PS10048 with parent material hardness up to 40HRC. For harder materials, electrical discharge broach `'''''tools are available.

13

Alcoa Fastening Systems

RFOPB5000WB

SERIES

BROACH TOOL WOBBLE BROACH MACHINING PS10035 PORT SERRATIONS

BROACH TOOL NUMBER RFOPB5002WB RFOPB5003WB RFOPB5004WB RFOPB5005WB RFOPB5006WB RFOPB5008WB RFOPB5010WB RFOPB5012WB RFOPB5014WB RFOPB5016WB RFOPB5020WB

A

NUMBER OF TEETH 24 26 30 36 36 40 38 40 50 36 56

B

DIA +.002 .412 .481 .527 .638 .713 .824 1.055 1.185 1.357 1.474 1.798

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20

NOTES: UNLESS OTHERWISE SPECIFIED `1 Wobbling Drift Hold is ordered separately using part number W37601.00

`CAUTION: Care must be taken when machining to provide the following requirements: A maximum runout of `'''''''''''''''''''''.009 must be maintained between serration major dia and controlled minor dia (specified in `'''''''''''''''''''''Rosan PS10035 port specification) after broaching.

14

Alcoa Fastening Systems

RF( )CRP

SERIES

CHIP REMOVAL TOOL PS10035 PORT

CHIP REMOVAL TOOL NUMBER 2 3 RF02CRP RF03CRP RF04CRP RF05CRP RF06CRP RF08CRP RF10CRP RF12CRP RF14CRP RF16CRP RF20CRP RF24CRP RF32CRP

CUTTER PART NUMBER

A

DIA +.010 .688 .750 .750 .875 .875 1.000 1.250 1.375 1.500 1.625 2.000 2.250 2.750

B

DIA +000 -.005 .183 .217 .274 .337 .391 .511 .649 .766 .891 1.072 1.261 1.573 2.063

C

DIA +.002 -.010 .371 .438 .485 .591 .665 .774 1.005 1.129 1.301 1.417 1.740 1.990 2.506

D

REF 5.35 5.35 5.35 5.4 5.4 5.5 6.00 6.10 6.10 6.10 6.15 6.20 6.35

E

MIN .077 .077 .077 .077 .092 .092 .092 .092 .092 .092 .119 .119 .119

F

MAX .490 .508 .535 .562 .606 .656 .676 .746 .782 .788 .820 .860 1.032

G

DIA +.010 .375 .375 .375 .375 .375 .375 .500 .500 .500 .500 .500 .500 .500

H

+.015 1.75 1.75 1.75 1.75 1.75 1.75 2.25 2.25 2.25 2.25 2.25 2.25 2.25

RF0206CRP-1 RF0206CRP-1 RF0206CRP-1 RF0206CRP-1 RF0206CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1 RF0832CRP-1

NOTES: UNLESS OTHERWISE SPECIFIED `1 Usage of tool is described in bulletin TSB91-0128 `2 Cutter is replaceable and can be ordered separately for spares. One spare cutter is supplied with each `'''''''tool assembly. `3 The RF( )CRA (sizes 04, 06 and 08) or RF( )CR (sizes 02 thru 32) may also be used to clear chips from `''''''PS10035 Port. For further information refer to bulletins TSB89-0606 (CRA Series) or TSB85-0228 (CR `''''''Series)

15

Alcoa Fastening Systems

RFOPB( )PSG

SERIES

PORT SERRATION GAGE PS10035 PORT

BROACH TOOL NUMBER RFOPB02PSG RFOPB03PSG RFOPB04PSG RFOPB05PSG RFOPB06PSG RFOPB08PSG RFOPB10PSG RFOPB12PSG RFOPB14PSG RFOPB16PSG RFOPB20PSG RFOPB24PSG RFOPB32PSG

FOR CHECKING PORT SERRATIONS PS10035-02 PS10035-03 PS10035-04 PS10035-05 PS10035-06 PS10035-08 PS10035-10 PS10035-12 PS10035-14 PS10035-16 PS10035-20 PS10035-24 PS10035-32

NOTES: UNLESS OTHERWISE SPECIFIED 1 2 3 Tool is a Go/No-Go Gage Go end should fit snugly into serrations, otherwise they are undersize No-Go end should not be able to fit into serrations, otherwise they are oversize

16

Alcoa Fastening Systems

SECTION2

FLUID BOSS ADAPTER INSTALLATION & REMOVAL TOOLS

· O-RING INSTALLATION TOOL · WRENCHES AND DRIVE TOOLS · LOCKRING REMOVAL TOOL

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

17

Alcoa Fastening Systems

FLUID BOSS ADAPTER INSTALLATION AND REMOVAL

TABLE I

FLUID BOSS ADAPTER NUMBERS RF5000 SERIES --------------RF5005-04-13 RF5006-04-13 RF5006-05-13 RF5008-04-13 RF5008-05-13 RF5008-06-13 RF5010-04-13 RF5010-06-13 RF5010-08-13 RF5012-04-13 RF5012-05-13 RF5012-06-13 RF5012-08-13 RF5012-10-13 --------------RF5016-04-13 RF5016-10-13 RF5016-12-13 RF5020-04-13 RF5020-12-13 RF5020-16-13 RF5024-16-13 RF5024-20T13 RFK9800 SERIES RF9804-02-13 RF9804-03-13 RF9805-04-13 RF9806-04-13 RF9806-05-13 RF9808-04-13 RF9808-05-13 RF9808-06-13 RF9810-04-13 RF9810-06-13 RF9810-08-13 RF9812-04-13 RF9812-05-13 RF9812-06-13 RF9812-08-13 RF9812-10-13 RF9814-10-13 RF9816-04-13 RF9816-10-13 RF9816-12-13 RF9820-04-13 RF9820-12-13 RF9820-16-13 RF9824-16-13 RF9824-20-13 1 CHOICE OF INDIVIDUAL WRENCH AND DRIVE TOOL COMBINATION TOOL 2 ROSAN O-RING LOCKRING TOOL LOCKRING PORT INSTALLATION COMBINATION REMOVAL KIT WRENCH PART DRIVE TOOL NUMBER TOOL WRENCH TOOL PART NUMBER PART AND NUMBER NUMBER NUMBER (REF) DRIVE TOOL 3 PS10035-04 PS10035-05 PS10035-06 PS10035-08 ORT312 ORT375 ORT437 ORT562 RF6904W RF6905W RF6906W RF6908W RF9804DEK RF9805DEK RF9806DEK RF9808DEK RF9804DW RF9805DW RF9806DW RF9808DW RF04LPDE RF05LPDE RF06LPDE RF08LPDE KM18 KM29 KM30 KM13

RFK9900 SERIES RF9904-02-13 RF9904-03-13 RF9905-04-13 RF9906-04-13 RF9906-05-13 RF9908-04-13 RF9908-05-13 RF9908-06-13 RF9910-04-13 RF9910-06-13 RF9910-08-13 RF9912-04-13 RF9912-05-13 RF9912-06-13 RF9912-08-13 RF9912-10-13 --------------RF9916-04-13 RF9916-10-13 RF9916-12-13 RF9920-04-13 RF9920-12-13 RF9920-16-13 RF9924-16-13 RF9924-20-13

PS10035-10

ORT687

RF6910W

RF9810DEK

RF9810DW

RF10LPDE

KM19

PS10035-12

ORT812

RF6912W

RF9812DEK

RF9812DW

RF12LPDE

KM31

PS10035-14 PS10035-16

ORT937 ORT1125

RF6914W RF6916W

RF9814DEK RF9816DEK

RF9814DW RF9816DW

RF14LPDE RF16LPDE

KM32 KM14

PS10035-20 PS10035-24

ORT1312 ORT1625

RF6920W RF6924W

RF9820DEK RF9824DEK

RF9820DW RF9824DW

RF20LPDE RF24LPDE

KM15 KM28

NOTES UNLESS OTHERWISE SPECIFIED: `''1 Adapters shown are a sampling of common standard Adapters. For assistance in selecting tools for `'''''''''''''''other Adapter or Inserts contact Alcoa Customer Support or visit our website. `''2 `''3 Select from individual Wrench and Lockring Drive Tool or a Combination Wrench and 'Drive Tool. Kits consist of one of each tool specified on the common line in Table I.

18

Alcoa Fastening Systems

FLUID BOSS ADAPTER INSTALLATION AND REMOVAL

PORT PREPARATION 1. Prepare boss and port per PS10035 specifications and instructions.

O-RING INSTALLATION 2. Place the O-Ring Installation Tool over the port end thread of the adapter. Submerge the tool and O-Ring in the fluid to be used in the working system, or a lubricant compatible with the system fluid. Slide the O-Ring over the tool and onto the adapter. Insure that the O-Ring is not twisted and is properly seated in the groove of the adapter. See figure 1. Remove the O-Ring installation tool.

3.

ADAPTER INSTALLATION 4. 5. 6. Lubricate the internal surfaces of the port and the entire adapter assembly using same fluid or lubricant as in note 2. Scratches, nicks or rough spots are not allowed in O-Ring contact area on the adapter or in the port. Insert the O-Ring end of the adapter into port by hand in a clockwise direction until the adapter is seated. To avoid possible O-Ring damage, the adapter should not be rotated in a counterclockwise direction. Using the applicable Combination Wrench or Wrench, engage the serrations of the tool with the external serrations of the adapter lockring per figure 2. Place a torque wrench of the proper size over the hex of the wrench and apply a torque equal to the minimum value specified by the applicable size in Table I or II on the following page. Note the relationship of the serration of the lockring with respect to the pre-broached serrations in the port. If they match, proceed to step 7. If the serrations do not match, continue to slowly torque the adapter toward the maximum value allowed in Table I and II until the serrations of the lockring match the port serrations. This will normally take between 3o and 8o of turning and the maximum torque value need not be reached if the serrations align themselves prior to that value. Do not exceed the maximum torque values.

Continued-

19

Alcoa Fastening Systems

FLUID BOSS ADAPTER INSTALLATION AND REMOVAL

-continuedTABLE 1: RF5000-13 SERIES ADAPTER INSTALLATION TORQUE VALUES INSTALLATION ADAPTER O-RING TORQUE BASIC NUMBER in-lb NUMBER (REF) MIN MAX RF5002 AS568-007 15 20 RF5003 AS568-008 29 36 RF5004 AS568-010 50 65 RF5005 AS568-011 100 125 RF5006 AS568-012 140 200 RF5008 AS568-014 270 375 RF5010 AS568-016 620 700 RF5012 AS568-116 855 945 RF5014 AS568-118 995 1105 RF5016 AS568-120 1140 1260 RF5020T AS568-123 1520 1680 RF5024T AS568-128 1900 2100

TABLE 2: RFK9800-13 & RFK9900-13 SERIES ADAPTER INSTALLATION TORQUE VALUES ADAPTER O-RING INSTALLATION BASIC NUMBER TORQUE NUMBER in-lb (REF) MIN MAX RFK9802 and RFK9902 AS568-007 15 20 RFK9803 and RFK9903 AS568-008 29 36 RFK9804 and RFK9904 AS568-010 50 65 RFK9805 and RFK9905 AS568-011 100 125 RFK9806 and RFK9906 AS568-012 140 200 RFK9808 and RFK9908 AS568-014 270 375 RFK9810 and RFK9910 AS568-016 620 700 RFK9812 and RFK9912 AS568-116 855 945 RFK9814 and RFK9914 AS568-118 995 1105 RFK9816 and RFK9916 AS568-120 1140 1260 RFK9820 and RFK9920 AS568-123 1520 1680 RFK9824 and RFK9924 AS568-128 1900 2100

7.

Degrease and apply enough Zinc Chromate Primer (TT-P-1757) with a brush or small syringe to the counterbore area of the port and below the adapter lockring so primer will be extruded out between external serrations of the lockring and the serrations in the port when lockring is installed. Note: Using design activity may specify another primer in place of or in addition to zinc chromate. If using a Combination Wrench, apply zinc chromate or sealant per item 7, install the lockring by rotating the threaded end of the Combination Wrench clockwise on the adapter assembly until it touches the lockring. Place an open end or socket wrench on the tool, turn the tool in a clockwise direction until it bottoms on the boss surface as shown in Figure 3 on the previous page. Observe that the tool has bottomed. (DO NOT OVER TORQUE ­ PORT DAMAGE CAN RESULT!) CAUTION: Any sudden increase in torque prior to bottoming may indicate that the lockring serrations and the port serrations are not aligned. If this occurs, remove the wrench by turning counterclockwise. Lift the lockring per lockring removal instructions . Torque the adapter clockwise per Item 6 until serrations in port and the external serrations on the lockring are aligned. Again attempt to install lockring. Remove excess sealant on surface of boss and lockring. If using the separate Wrench and Lockring Drive Tool, place the proper size Drive Tool over the end of the adapter. When it is properly located it will rest on the lockring. A hammer, arbor or hydraulic press may be used to press the lockring into the boss. Installation is complete when the tool bottoms on the surface of the boss. Remove excess sealant on surface of boss and lockring.

8.

PRESSURE TESTING 9. A proof pressure test of the unit may be conducted at this point. Place a pressure cap on the adapter. Pressurize the unit from another location on the unit to 1.5 times the operation pressure for three (3) minutes. There should be no leakage. NOTE: Using design activity may require testing other than shown.

20

Alcoa Fastening Systems

ORT( )

SERIES

O-RING INSTALLATION TOOL

O-RING INSTALLATION TOOL NUMBER ORT216 ORT250 ORT312 ORT375 ORT437 ORT562 ORT687 ORT812 ORT937 ORT1125 ORT1312 ORT1625 ORT2125

A

+.06 .71 .79 .83 .86 .90 .98 1.05 1.12 1.19 1.25 1.82 1.94 1.94

B

+.05 -.01 .19 .23 .23 .25 .28 .33 .39 .49 .55 .58 .69 .78 1.02

C

DIA MAX .283 .322 .385 .445 .505 .635 .755 .885 1.010 1.205 1.395 1.715 2.215

D

DIA MIN .218 .252 .315 .377 .440 .565 .690 .815 .940 1.127 1.315 1.627 2.127

E

DIA +.040 .100 .130 .109 .250 .310 .435 .550 .670 .795 .920 .920 1.420 1.975

NOTES: UNLESS OTHERWISE SPECIFIED `1 MATERIAL: Teflon or Nylon

21

Alcoa Fastening Systems

RF5000DW

SERIES

TOOL - COMBINATION DRIVE AND WRENCH

COMBINATION WRENCH AND DRIVE TOOL NUMBER RF5002DW RF5003DW RF5004DW RF5005DW RF5006DW RF5008DW RF5010DW RF5012DW RF5014DW RF5016DW RF5020DW RF5020TDW RF5024DW RF5024TDW

A

THREAD MIL-S-8879 CLASS 3B .3125-32UNJEF .3750-28UNJS .4375-24JUNJS .5000-24UNJS .5625-20UNJS .7188-20UNJS .8438-18UNJS 1.0000-16UNJ 1.1250-16UNJ 1.2500-14UNJS 1.5156-14UNJS 1.5781-14UNJS 1.7812-14UNJS 1.8438-14UNJS

B

DIA +.015 .680 .750 .800 .900 .980 1.100 1.320 1.450 1.580 1.740 2.070 2.070 2.340 2.340

C

DIA +.010 .427 .496 .542 .652 .727 .842 1.070 1.200 1.373 1.490 1.820 1.820 2.070 2.070

D

+.007 -.002 .109 .109 .109 .109 .115 .115 .115 .130 .130 .130 .130 .130 .130 .130

E

+.015 1.000 1.000 1.000 1.000 1.120 1.120 1.250 1.380 1.450 1.500 1.500 1.500 1.600 1.600

F

HEX REF .75 .75 .81 .94 1.00 1.12 1.38 1.50 1.62 1.75 2.12 2.12 2.50 2.50

G

ACROSS CORNERS REF .866 .866 9.38 1.082 1.155 1.299 1.588 1.732 1.876 2.021 2.454 2.454 2.886 2.886

NOTES: UNLESS OTHERWISE SPECIFIED `1 This tool is used for standard RF5000 Series adapters only. `

22

Alcoa Fastening Systems

RF6900W

SERIES

WRENCH ­ FLUID ADAPTER ASSEMBLY

WRENCH PART NUMBER RF6902W RF6903W RF6904W RF6905W RF6906W RF6908W RF6910W RF6912W RF6914W RF6916W 1 RF6920W RF6924W RF6932W 1

A

DIA MAX .572 .698 .760 .760 .885 1.010 1.198 1.385 1.635 1.760 2.010 2.260 2.885

B

+.03 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.50 1.75

C

HEX .56 .69 .75 .75 .88 1.00 1.19 1.38 1.62 1.75 2.00 2.25 2.88

SERRATION ACROSS NUMBER OF CORNERS TEETH REF .649 24 .794 26 .866 30 .866 36 1.010 36 1.155 40 1.371 38 1.588 40 1.876 50 2.021 36 2.309 56 2.598 81 3.320 102

D

NOTES: UNLESS OTHERWISE SPECIFIED `1 Part number RF5332W will also be marked on RF6932W wrench; part number RF6915W will also be `''''''marked on RF6916W wrench. `2 These wrenches may be used to wrench in RF5000, RFH5000, RF75000, RFH7500, RF7700, RF9800, `'''''''RFK9800, RF9900, RFH9900, RFK9900 series, as well as other adapters and check valves.

23

Alcoa Fastening Systems

RF9800DEK

SERIES

DRIVE TOOL - LOCKRING LIFT TYPE, ADAPTER

LOCKRING DRIVE TOOL NUMBER RF9802DEK RF9803DEK RF9804DEK RF9805DEK RF9806DEK RF9808DEK RF9810DEK RF9812DEK RF9814DEK RF9816DEK 4 RF9820DEK RF9824DEK RF9832DEK

A

DIA +.010 -.020 .562 .625 .750 .875 1.000 1.125 1.375 1.500 1.750 1.875 2.125 2.375 2.875

B

DIA +.007 -.001 .324 .386 .442 .537 .595 .755 .880 1.067 1.218 1.327 1.630 1.880 2.505

C

DIA +.006 -.001 .412 .481 .527 .637 .712 .827 1.053 1.183 1.354 1.469 1.795 2.045 2.561

D

+.05 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.00 4.00

E

+.1 -.0 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2 2.2

F

+.007 -.002 .109 .109 .109 .109 .115 .115 .115 .130 .130 .130 .130 .130 .130

NOTES: UNLESS OTHERWISE SPECIFIED `1 `2 Lockring drive tool RF9800DEK supersedes RF9800D, RF9800DE and RF5000-02D Part Number RF9815DEK will also be on RF9816DEK drive tool

24

Alcoa Fastening Systems

RF( )LPDE

SERIES

REMOVAL TOOL LOCKRING LIFT TYPE

LOCKRING REMOVAL TOOL NUMBER RF02LPDE RF03LPDE RF04LPDE RF05LPDE RF06LPDE RF08LPDE RF10LPDE RF12LPDE RF14LPDE RF16LPDE 4 RF20LPDE RF24LPDE RF32LPDE

A

DIA MAX .812 .812 .812 .937 1.000 1.125 1.375 1.500 1.688 1.812 2.250 2.500 3.125

B

MAX 2.24 2.24 2.24 2.41 2.48 2.63 2.80 2.93 3.19 3.34 3.60 4.02 4.81

C

MAX 3.91 3.91 3.91 4.31 4.44 4.73 5.12 5.47 5.82 6.18 6.72 7.35 8.83

D

MAX 3.98 3.98 3.98 4.31 4.46 4.72 4.98 5.26 5.68 6.01 6.52 7.18 8.76

E

HEX NOM .438 .438 .438 .562 .562 .625 .938 1.125 1.312 1.312 1.312 1.312 1.312 MIN .183 .183 .183 .191 .209 .209 .214 .214 .224 .224 .204 .225 .245

F

2 MAX 1.470 1.470 1.470 1.634 1.705 1.792 1.875 2.010 2.124 2.238 2.490 2.795 3.545

NOTES: UNLESS OTHERWISE SPECIFIED `1 `2 Puller halves will engage lockring groove when expanded to "A"diameter. Range of adapter stand-off that removal tool will accommodate

`3 RF( )LPDE series supersedes RF9800LPD series and will remove all basic adapters, reducers, restrictors, `'''''''filters and quick disconnects. `4 Part number RF15LPDE will also be on RF16LPDE removal tool.

25

Alcoa Fastening Systems

ADAPTER REMOVAL

`1 `2 If a sealant has been used to cover lockring, carefully remove sealant to expose lockring Select the proper size lockring removal tool for your Adapter

`3 Spread the puller halves apart by retracting the sleeve from the tool until the pin bottoms in the groove of `'''''''the sleeve as shown below. Holding the puller halves apart, place the tool over the protruding adapter. `'''''''Release the puller halves and locate in the groove of the lockring. Adjustment up or down is achieved by `'''''''turning the bolt head. Slide the sleeve over the puller halves and check for proper engagement of the `'''''''puller halves in the lockring groove.

`4 Place the wrench on the bolt head of the removal tool and turn in a clockwise direction while holding the ` `'''''''sleeve with your other hand. This action will cause the lockring to be jacked out of the port counterbore. `'''''''When the external serrations of the lockring are clear of the boss surface, the turning may be stopped. `'''''''Remove the tool from the adapter by loosening the bolt and lifting the sleeve to free the puller halves. `5 Select the proper size drive wrench or combination wrench and drive tool from the installation tool `'''''''section of this catalog. Engage the serrations of the wrench with those of the lockring. Using an open `'''''''end or socket wrench over the wrench hex, turn in a counterclockwise direction to disengage the adapter `'''''''from the boss port. Plug the port minor diameter when cleaning out the cavity to avoid contamination of `'''''''the fluid system.

26

Alcoa Fastening Systems

ADAPTER, TOOL KITS

RF5000 SERIES

KIT AND NATIONAL STOCK NUMBER KIT CONTENTS (1 EACH) KIT COMBINATION ADAPTER KIT NATIONAL O-RING WRENCH AND LOCKRING PART PART STOCK INSTALLATION DRIVE REMOVAL NUMBER NUMBER NUMBER TOOL TOOL TOOL REF (NSN) NUMBER NUMBER RF5004-13 KM9RF5004 5180-00-785-5062 ORT312 RF5004DW RF5004LPD RF5005-13 RM9RF5005 -------------ORT375 RF5005DW RF5005LPD RF5006-13 RM9RF5006 5180-00-785-5063 ORT437 RF5006DW RF5006LPD RF5008-13 RM9RF5008 5180-00-785-5068 ORT562 RF5008DW RF5008LPD RF5010-13 RM9RF5010 5180-00-785-5069 ORT687 RF5010DW RF5010LPD RF5012-13 RM9RF5012 5180-00-785-5073 ORT812 RF5012DW RF5012LPD RF5014-13 RM9RF5014 -------------ORT937 RF5014DW RF5014LPD RF5016-13 RM9RF5016 5180-00-785-5080 ORT1125 RF5016DW RF5016LPD RF5020T13 RM9RF5020T 5180-00-782-7033 ORT1312 RF5020TDW RF5020LPD RF5024T13 RM9RF5024T -------------ORT1625 RF5024TDW RF5024LPD KIT WEIGHT APPROX. (lbs) 1.00 1.06 1.12 1.25 1.50 1.75 2.06 2.25 3.00 3.75

RFK9800 and RFK9900

KIT AND NATIONAL STOCK NUMBER KIT CONTENTS (1 EACH) KIT COMBINATION ADAPTER KIT NATIONAL O-RING WRENCH AND LOCKRING PART PART STOCK INSTALLATION DRIVE REMOVAL NUMBER NUMBER NUMBER TOOL TOOL TOOL REF (NSN) NUMBER NUMBER RFK9804-13 KM9RF9804 5180-00-008-5657 ORT312 RF9804DW RF04LPDE RFK9904-13 RFK9805-13 KM9RF9805 5180-00-293-4647 ORT375 RF9805DW RF05LPDE RFK9905-13 RFK9806-13 KM9RF9806 5180-00-008-5658 ORT437 RF9806DW RF06LPDE RFK9906-13 RFK9808-13 KM9RF9808 5180-00-008-5659 ORT562 RF9808DW RF08LPDE RFK9908-13 RFK9810-13 KM9RF9810 5180-00-008-5660 ORT687 RF9810DW RF10LPDE RFK9910-13 RFK9812-13 KM9RF9812 5180-00-008-5661 ORT812 RF9812DW RF12LPDE RFK9912-13 RFK9914-13 KM9RF9814 -------------ORT937 RF9814DW RF14LPDE RFK9816-13 KM9RF9816 5180-00-008-5637 ORT1125 RF9816DW RF16LPDE RFK9916-13 RFK9820-13 KM9RF9820 5180-01-247-7341 ORT1312 RF9820DW RF20LPDE RFK9920-13 RFK9824-13 KM9RF9824 --------------ORT1625 RF9824DW RF24LPDE RFK9924-13 KIT WEIGHT APPROX. (lbs) 1.00 1.06 1.13 1.25 1.63 1.94 ---------2.38 -------------------

27

Alcoa Fastening Systems

GENERAL USAGE INSTALLATION AND REMOVAL TOOL KITS FOR USE WITH ADAPTERS, CHECK VALVES, FILTERS, QUICK DISCONNECTS AND REDUCERS

ROSAN PORT END SIZE -02 -03 -04 -05 -06 -08 -10 -12 -14 -16 -20 -24 -32 3 3 KIT PART NUMBER KM35 KM36 KM18 KM29 KM30 2 KM22-640-2 KM13 2 KM22-660-2 KM19 2 KM22-680-2 KM31 KM32 KM14 2 KM22-612-2 KM15 2 KM22-616-2 KM28 KM33 KM34 KM57 KIT NATIONAL O-RING STOCK INSTALLATION NUMBER TOOL (NSN) NUMBER 5180-01-075-5690 ORT216 5180-01-077-1577 ORT250 5180-00-283-6999 ORT312 5180-01-075-0765 ORT375 5180-01-075-0766 ORT437 5180-00-163-6640 5180-00-283-6993 ORT562 5180-00-163-6637 5180-00-283-6989 ORT687 5180-00-163-6633 5180-01-077-1578 ORT812 5180-01-075-0767 ORT937 5180-00-283-6992 ORT1125 5180-00-179-0067 5180-00-283-6991 ORT1312 5180-00-163-6638 5180-01-075-0768 ORT1625 5180-01-075-5689 ORT2125 5180-01-263-9173 WRENCH PART NUMBER RF6902W RF6903W RF6904W RF6905W RF6906W RF6908W RF6910W RF6912W RF6914W RF6916W RF6920W LOCKRING DRIVE TOOL NUMBER RF9802DEK RF9803DEK RF9804DEK RF9805DEK RF9806DEK RF9808DEK RF9810DEK RF9812DEK RF9814DEK RF9816DEK RF9820DEK LOCKRING REMOVAL TOOL NUMBER RF02LPDE RF03LPDE RF04LPDE RF05LPDE RF06LPDE RF08LPDE RF10LPDE RF12LPDE RF14LPDE RF16LPDE RF20LPDE RF24LPDE RF32LPDE

RF6924W RF9824DEK RF6932W RF9832DEK See Following Page See Following Page

NOTES: UNLESS OTHERWISE SPECIFIED `1 Tools in these kits are universal since they will install and remove RF5000, RFH5000, RF5700, RF7500, `''''''RFH7500, RF7700, RF9800, RFK9800, RF9900, RFK9900 and RFH9000 series adapters, reducers, check `''''''valves, filters and quick disconnects. `2 Kits are identical and interchangeable except for part numbers and National Stock Numbers. `3 KM34 is a multi use kit containing tooling for port end sizes -04 thru -32. KM57 is for port end sizes 05 thru 12

28

Alcoa Fastening Systems

KM34

Multi Use Installation and Removal Tool Kit Port Sizes -04 thru -32

KM57

Specialty Use Installation and Removal Tool Kit Port Sizes -05 thru -12

29

Alcoa Fastening Systems

SECTION 3

FLUID BOSS INSERTS PORT SERRATION TOOLS

· PORTING TOOLS · BROACH TOOLS

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

30

Alcoa Fastening Systems

PS10040-( )

PORT ­ INSERT FLUID CONNECTION TYPE (AS1598)

ADAPTER NUMBER

AS I.D. NUMBER AS1598-02 AS1598-03 AS1598-04 AS1598-05 AS1598-06 AS1598-08 AS1598-10 AS1598-12 AS1598-16 AS1598-20

A

THREAD MIL-S-8879 CLASS 3B .4375-28UNJEF .5000-28UNJEF .5625-24UNJEF .6250-24UNJEF .6875-24UNJEF .9375-20UNJEF 1.0625-18UNJEF 1.2500-18UNJEF 1.5000-18UNJEF 1.8750-16UNJ

B

5 MIN .80 .84 .92 .98 1.03 1.40 1.60 1.83 2.20 2.80

C

+.005 -.000 .670 .733 .795 .858 .905 1.155 1.280 1.499 1.765 2.155

D

+.002 -.000 .473 .540 .603 .666 .728 .958 1.083 1.271 1.521 1.922

E

5 MIN .550 .520 .565 .590 .620 .745 .830 .950 .950 1.000

F

+.005 .225 .225 .225 .225 .225 .225 .225 .225 .225 .265

PS10040-02 PS10040-03 PS10040-04 PS10040-05 PS10040-06 PS10040-08 PS10040-10 PS10040-12 PS10040-16 PS10040-20

NOTES UNLESS OTHERWISE SPECIFIED: 1. 2. 3. 4. 5. Recommended minimum full thread depth. The drill and porting tool method of preparing the machined cavity is recommended. Refer to the RPT9500 series port contour cutter for available sizes. When installing RF9500 series inserts into stainless steel or titanium or hardened ferrous materials the use of the RFPBT9500 or RFPBT9500HDB series broach tool is required. When using the hand held piloted broach tool, the drill and porting method of preparing the machined cavity is mandatory. The minimum port diameter "B" and port depth "E" are satisfactory for use in materials that exhibit a minimum shear strength of 14 KSI.

31

Alcoa Fastening Systems

RPT9500

SERIES

STANDARD PORT CONTOUR CUTTER SHORT SERIES ­ CARBIDE TIPPED PS10035 (AS1300) PORT

PORTING TOOL NUMBER RPT9502 RPT9503 RPT9504 RPT9505 RPT9506 RPT9508 PRT9510 RPT9512 RPT9516 RPT9520

A

DIA +.0000 -.0003 .4998 .4998 .4998 .4998 .4998 .7498 .7498 .7498 .7498 .7498

B

DIA +.0005 .4057 .4682 .5249 .5874 .6499 .8918 1.0114 1.1989 1.4489 1.8172

C

DIA +.0003 .6725 .7355 .7975 .8605 .9075 1.1575 1.2825 1.5015 1.7675 2.1575

D

+.005 .700 .645 .750 .750 .800 1.005 1.120 1.240 1.240 1.330

E

+.030 3.450 3.645 3.750 3.750 3.800 4.255 4.370 7.740 4.740 4.830

PORT TO PRODUCE THREAD CONTOUR MIL-S-8879 FOR PORT CLASS 3B NUMBER REF .4375-28UNJEF PS10040-02 .5000-28UNJEF PS10040-03 .5625-24UNJEF PS10040-04 .6250-24UNJEF PS10040-05 .6875-24UNJEF PS10040-06 .9375-20UNJEF PS10040-08 1.0625-18UNJEF PS10040-10 1.2500-18UNJEF PS10040-12 1.5000-18UNJEF PS10040-16 1.875-16UNJ PS10040-20

APPLICATION: This tool counterbores, countersinks, provides a radius and produces a tap drill diameter in one pass. Contours are ground to insure concentricity. Cutter geometry permits the use of these tools with most common materials

32

Alcoa Fastening Systems

RFPBT9500

SERIES

BROACH TOOL ­ HAND HELD PS10040 PORT SERRATIONS

BROACH TOOL NUMBER RFPBT9502 RFPBT9503 RFPBT9504 RFPBT9505 RFPBT9506 RFPBT9508 RFPBT9510 RFPBT9512 RFPBT9516 RFPBT9520

CUTTER NUMBER 1 RFPBT9502-3 RFPBT9503-3 RFPBT9504-3 RFPBT9505-3 RFPBT9506-3 RFPBT9508-3 RFPBT9510-3 RFPBT9512-3 RFPBT9516-3 RFPBT9520-3

A

+.015 -.000 .600 .730 .790 .920 .980 1.070 1.290 1.420 1.730 2.040

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10040-02 PS10040-03 PS10040-04 PS10040-05 PS10040-06 PS10040-08 PS10040-10 PS10040-12 PS10040-16 PS10040-20

NOTES: UNLESS OTHERWISE SPECIFIED `1 Replacement cutters may be purchased individually

`2 Inspection of noted runout and use of controlled minor diameter per Rosan PS10040 port spicspecification will provide an allowable maximum runout of .009 between serration major diameter and and controlled minor diameter after broaching. APPLICATION: This broach tool, when used in arbor, hydraulic presses or manually, is designed to produce serrations in the counterbore wall of ports prepared per PS10035. The tool will broach aluminum, magnesium, and many steels with hardness of 32 HRC or less. Successful broaching of harder or tougher material may be accomplished, but tool cutter wear is to be expected. METHOD: The pilot is inserted into the tap drill hole of PS10040 port, and sufficient force applied to the top of the mandrel to allow the cutter to broach into the counterbore. When the external shoulder of the mandrel contacts the internal shoulder of the body*, broaching is complete. If cutter sticks in counterbore, turn the nut in a clockwise direction to extract the cutter. Caution: nut is for cutter removal only and is not a stop. Always back off nut when broaching. Hole can be tapped before or after broaching.

33

Alcoa Fastening Systems

RFPBT9500HDB

SERIES

BROACH TOOL ­ NON-IMPACT PS10040 PORT SERRATIONS (FOR MATERAL UP TO 40 HRC)

BROACH TOOL NUMBER RFPBT9502HDB RFPBT9503HDB RFPBT9504HDB RFPBT9505HDB RFPBT9506HDB RFPBT9508HDB RFPBT9510HDB RFPBT9512HDB RFPBT9516HDB RFPBT9520HDB

STUD PART NUMBER 3 RFPBT9502HDB4 RFPBT9503HDB4 RFPBT9504HDB4 RFPBT9505HDB4 RFPBT9506HDB4 RFPBT9508HDB4 RFPBT9510HDB4 RFPBT9512HDB4 RFPBT9516HDB4 RFPBT9520HDB4

STUD CUTTER NUMBER 4 RFPBT9502HDB5 RFPBT9503HDB5 RFPBT9504HDB5 RFPBT9505HDB5 RFPBT9506HDB5 RFPBT9508HDB5 RFPBT9510HDB5 RFPBT9512HDB5 RFPBT9516HDB5 RFPBT9520HDB5

THRUST BEARING PART NUMBER K81104TN K81105TN K81105TN K81206TN K81206TN K81208TN K81208TN K81208TN K81208TN K89408TN

TO PRODUCE SERRATIONS FOR PORT NUMBER PS10040-02 PS10040-03 PS10040-04 PS10040-05 PS10040-06 PS10040-08 PS10040-10 PS10040-12 PS10040-16 PS10040-20

NOTES: UNLESS OTHERWISE SPECIFIED `1 This tool will broach serrations into most materials with hardness up to 40 HRC. `2 Two extra cutters are provided with each tool. `3 Replacement studs may be purchased individually `4 Replacement cutters may be purchased individually `5 Use of this tool will provide an allowable maximum runout of .009 between serration major diameter `''''''and controlled minor diameter (REF: PS10040) after broaching.

34

Alcoa Fastening Systems

SECTION 4

FLUID BOSS INSERTS INSTALLATION AND REMOVAL TOOLS

· INSTALLATION TOOLS · LOCKRING REMOVAL TOOL

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

35

Alcoa Fastening Systems

INSTALLATION AND REMOVAL RF9500 SERIES FLUID INSERTS

PORT PREPARATION 1. 2. Prepare port per PS10040-( ) details Slide the lockring over the insert thread and engage into insert serration such that the pilot of the lockring faces the thread. See Figure 1. Place the O-ring installation tool over the outside thread of the insert. Submerge the insert, the lockring, the O-ring and the Oring tool in the fluid to be used in the working system or a lubricant compatible with the system fluid. Slide the O-ring over the O-ring tool and on to the insert. Be sure that the O-ring is not twisted and is properly seated in the seat. Remove the O-ring installation tool.'''''''''''''''''''''''''''''''''''''''''''''''' Caution: To avoid possible O-ring damage, the insert should never be rotated in a counterclockwise direction. If this is done, replace the O-ring. Lubricate the internal surfaces of the port and the entire insert assembly using the same fluid or lubricant as specified in paragraph 3. Scratches, nicks or rough spots are not allowed in O-Ring Screw the drive wrench into the thread of the insert until the plastic collar touches the surface of the insert. See figure 2 Screw the insert assembly into the port by hand using clockwise rotation until the assembly is firmly set. See figure 2 Place the torque wrench of the proper size into the square of the drive wrench and apply a torque equal to the value specified in Table 1 on the following page. Remove the torque wrench and not the drive wrench. Apply enough Zinc Chromate primer (TT-P-1757) with a brush or small syringe to the counterbore area of the port by lifting the lockring slightly by hand so primer will be extruded out between external serrations of the lockring and the port counterbore when lockring is installed. NOTE: Design activity may specify another primer in place of or in addition to Zinc Chromate. LOCKRING INSTALLATION

O-RING INSTALLATION 3.

4.

5.

INSERT INSTALLATION 6.

7. 8. 9. 10.

-continued-

36

Alcoa Fastening Systems

INSTALLATION AND REMOVAL RF9500 SERIES FLUID INSERTS

11. While the primer is still wet, place the lockring drive tool over the drive wrench and let it rest on the lockring top surface, see figure 3. Apply a sufficient downward force to drive the lockring into the surface of the port counterbore until the face of the lockring drive tool touches the port surface, see figure 4. NOTE: Depending upon the component configuration, it may be necessary to support the port in order not to deform the internal configuration of the component. Remove the tools and excess primer that has formed on the surface of the port and lockring See lockring removal instructions.

12. 13.

TABLE I

INSERT ASSEMBLY NUMBER RF9502-6 RF9503-6 RF9504-6 RF9505-6 RF9506-6 RF9508-6 RF9510-6 RF9512-6 RF9516-6 RF9520-6 PORT NUMBER REF PS10040-02 PS10040-03 PS10040-04 PS10040-05 PS10040-06 PS10040-08 PS10040-10 PS10040-12 PS10040-16 PS10040-20 O-RING NUMBER REF AS568-012 AS568-013 AS568-014 AS568-015 AS568-016 AS568-019 AS568-021 AS568-024 AS568-028 AS568-132 INSTALLATION TORQUE in-lb MIN MAX 40 50 65 84 80 105 120 150 145 185 350 400 500 600 700 800 1200 1300 1800 2000

37

Alcoa Fastening Systems

ORT95-( )

SERIES

O-RING INSTALLATION TOOL

O-RING INSTALLATION TOOL NUMBER ORT95-437 ORT95-500 ORT95-562 ORT95-625 ORT95-687 ORT95-937 ORT95-1062 ORT95-1250 ORT95-1500 ORT95-1875

A

+.06 .91 .88 .93 .97 1.02 1.34 1.44 1.56 1.60 1.63

B

+.05 -.01 .33 .30 .35 .38 .40 .53 .61 .73 .73 .75

C

DIA MAX .509 .572 .635 .697 .760 1.013 1.143 1.330 1.590 1.965

D

DIA MIN .440 .502 .565 .627 .690 .940 1.065 1.252 1.502 1.877

E

DIA +.040 .310 .472 .435 .495 .546 .731 .856 1.043 1.290 1.661

NOTES: UNLESS OTHERWISE SPECIFIED `1 MATERIAL: Teflon or Nylon

38

Alcoa Fastening Systems

RF8500WA

SERIES

WRENCH

INSTALLATION WRENCH NUMBER

WASHER PART NUMBER 1

A

THREAD MIL-S-7742 CLASS-3A .3125-24 UNF .3750-24UNF .4375-20UNF .5000-20UNF .5625-18UNF .7500-16UNF .8750-14UNF 1.0625-12UN 1.3125-12UN 1.6250-12UN

B

MAX .617 .680 .745 .805 .870 1.057 1.180 1.430 1.680 1.995

C

MAX 1.47 1.67 1.72 1.72 1.77 1.90 2.02 2.16 2.50 2.55

D

NOMINAL .25 .25 .25 .38 .38 .38 .50 .50 .75 .75

RF8502WA RF8503WA RF8504WA RF8505WA RF8506WA RF8508WA RF8510WA RF8512WA RF8516WA RF8520WA

RF8502WA1 RF8503WA1 RF8504WA1 RF8505WA1 RF8506WA1 RF8508WA1 RF8510WA1 RF8512WA1 RF8516WA1 RF8520WA1

NOTES: UNLESS OTHERWISE SPECIFIED `1 Nylon Washer can be purchased separately and must be used to insure tool can be removed freely

39

Alcoa Fastening Systems

RF9500DA

SERIES

DRIVE TOOL - LOCKRING

LOCKRING DRIVE TOOL NUMBER RF9502DA RF9503DA RF9504DA RF9505DA RF9506DA RF9508DA RD9510DA RF9512DA RF9516DA RF9520DA

A

DIA +.005 -.002 .627 .690 .753 .815 .872 1.065 1.190 1.440 1.690 2.025

B

DIA +.010 -.030 1.18 1.25 1.31 1.37 1.42 1.73 1.86 2.08 2.34 2.73

C

+.05 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.50 3.50 3.50

D

+.010 .805 .870 .930 .990 1.040 1.290 1.420 1.640 1.900 2.290

E

MIN 1.39 1.39 1.39 1.39 1.39 1.39 1.45 1.45 1.79 1.79

NOTES: UNLESS OTHERWISE SPECIFIED `1 For use with RF9500 Series Fluid Inserts only

40

Alcoa Fastening Systems

RF8500DA

SERIES

DRIVE TOOL - LOCKRING

LOCKRING DRIVE TOOL NUMBER RF8502DA RF8503DA RF8504DA RF8505DA RF8506DA RF8508DA RD8510DA RF8512DA RF8516DA RF8520DA

A

DIA +.005 -.002 .627 .690 .753 .815 .872 1.065 1.190 1.440 1.690 2.025

B

DIA +.010 -.030 1.00 1.06 1.12 1.18 1.25 1.50 1.62 1.88 2.12 2.50

C

+.05 3.00 3.00 3.00 3.00 3.00 3.00 3.00 3.50 3.50 3.50

D

MIN 1.27 1.27 1.27 1.27 1.27 1.27 1.33 1.33 1.67 1.67

NOTES: UNLESS OTHERWISE SPECIFIED `1 For use with RF8500 Series Fluid Inserts only

41

Alcoa Fastening Systems

RF9500LPD

SERIES

REMOVAL TOOL LOCKRING LIFT TYPE

LOCKRING REMOVAL TOOL NUMBER RF9502LPD RF9503LPD RF9504LPD RF9505LPD RF9506LPD RF9508LPD RF9510LPD RF9512LPD RF9516LPD RF9520LPD

A

DIA MAX 1.06 1.14 1.20 1.27 1.32 1.63 1.70 1.93 2.20 2.62

B

MAX 1.64 1.64 1.64 1.74 1.74 1.89 1.89 1.89 2.02 2.02

C

MAX 1.34 1.54 1.54 1.57 1.57 1.59 1.67 1.67 1.88 1.88

D

HEX MAX .438 .438 .438 .562 .562 .562 .562 .562 .562 .562 MIN .05 .05 .05 .05 .05 .05 .05 .05 .05 .05

E

2 MAX .26 .26 .26 .26 .26 .26 .27 .29 .29 .29

NOTES: UNLESS OTHERWISE SPECIFIED `'1 `'2 Puller halves will engage lockring groove when expanded to "A"diameter. Range of adapter stand-off that removal tool will accommodate

42

Alcoa Fastening Systems

RF8500R

SERIES

REMOVAL TOOL LOCKRING DRILL TYPE

LOCKRING REMOVAL TOOL NUMBER RF8502R RF8503R RF8504R RF8505R RF8506R RF8508R RF8510R RF8512R RF8516R RF8520R

A

+.005 .500 .500 .500 .500 .500 .625 .625 .750 .750 .750

B

+.03 3.75 3.75 4.12 4.12 4.12 4.38 4.5 4.75 4.75 4.75

C

+.030 .937 1.000 1.125 1.125 1.125 1.25 1.25 1.25 1.25 1.25

D

+.015 .500 .500 .500 .500 .500 .625 .750 .750 .750 .750

E

+.001 -.002 .404 .467 .524 .586 .649 .891 1.010 1.198 1.448 1.816

F

+.001 .635 .698 .760 .823 .870 1.120 1.245 1.464 1.730 2.120

43

Alcoa Fastening Systems

INSERT PORT PREPARATION, INSTALLATION AND REMOVAL TOOL KITS

INSERT ASSY NUMBER

KIT NUMBER

PORTING TOOL RPT9502 RPT9503 RPT9504 RPT9505 RPT9506 RPT9508 RPT9510 RPT9512 RPT9516 RPT9520

BOTTOMING TAP PS40-02BT PS40-03BT PS40-04BT PS40-05BT PS40-06BT PS40-08BT PS40-10BT PS40-12BT PS40-16BT PS40-20BT

KIT CONTENTS O-RING WRENCH INSTALLATION TOOL ORT95-437 ORT95-500 ORT95-562 ORT95-625 ORT95-687 ORT95-937 ORT95-1062 ORT95-1250 ORT95-1500 ORT95-1875 RF8502WA RF8503WA RF8504WA RF8505WA RF8506WA RF8508WA RF8510WA RF8512WA RF8516WA RF8520WA

LOCKRING DRIVE TOOL RF9502DA RF9503DA RF9504DA RF9505DA RF9506DA RF9508DA RF9510DA RF9512DA RF9516DA RF9520DA

LOCKRING REMOVAL TOOL RF9502LPD RF9506LPD RF9504LPD RF9505LPD RF9506LPD RF9508LPD RF9510LPD RF9512LPD RF9516LPD RF9520LPD

INSERT REMOVAL TOOL RF9502RT RF9503RT RF9504RT RF9505RT RF9506RT RF9508RT RF9510RT RF9512RT RF9516RT RF9520RT

RF9502-6 RF9503-6 RF9504-6 RF9505-6 RF9506-6 RF9508-6 RF9510-6 RF9512-6 RF9516-6 RF9520-6

KM52RF9502 KM52RF9503 KM52RF9504 KM52RF9505 KM52RF9506 KM52RF9508 KM52RF9510 KM52RF9512 KM52RF9516 KM52RF9520

44

Alcoa Fastening Systems

SECTION 5

FLUID BOSS ADAPTERS, REDUCERS AND INSERTS

· RF5000 FLUID BOSS ADAPTERS · RFK9800 & RFK9000 FLUID BOSS ADAPTERS · RF8500, RF9500, RFR9500 AND RFS9500 FLUID BOSS INSERTS

Assembly Tool Systems 801 South Placentia Avenue Fullerton, CA USA 92831 714-278-8908 Telephone 714-871-4821 FAX

45

Alcoa Fastening Systems

RF5000-13

SERIES

ADAPTER ­ FLUID CONNECTION ASSY BEAM SEAL, CAPTIVE LIFT TYPE LOCKRING 5000 PSI

ADAPTER NUMBER

AS I.D. NUMBER

TUBING OD

A

THREAD MIL-S-8879 CLASS 3A

B

THREAD MIL-S-8879 CLASS 3A .2160-28 UNJF .2500-28 UNJF .3125-24 UNJF .3750-24 UNJF .4375-20 UNJF .5625-18 UNJF .6875-24 UNJF .8125-20 UNJF .9375-20 UNJF

C

DIA

D

DIA REF

E

DIA +.010 -.005 .519 .550 .592 .592 .633 .646 .710 .760 .778 .808

F

+.000 -.015 .300 .355 .355 .381 .395 .430 .465 .527 .572 .564

G

+.007 .192 .192 .192 .192 .210 .210 .210 .220 .220 .220

H

DIA +.005 .400 .468 .514 .624 .700 .814 1.040 1.170 1.341 1.456

RF5002-13 RF5003-13 RF5004-13 RF5005-13 RF5006-13 RF5008-13 RF5010-13 RF5012-13 RF5014-13 RF5016-13

AS1986-02 AS1986-03 AS1986-04 AS1986-05 AS1986-06 AS1986-08 AS1986-10 AS1986-12 AS1986-14 AS1986-16

1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1

.3125-32UNJEF .3750-28UNJS .4375-24UNJS .5000-24UNJS .5625-20UNJS .7188-20UNJS .8438-18UNJS 1.0000-16UNJ 1.1250-16UNJ

.090-.096 .122-.128 .169-.175 .231-.237 .294-.300 .398-.408 .493-.503 .604-.614 .729-.739 .839-.851

.317 .349 .400 .491 .544 .670 .824 .981 1.118 1.251

1.2500-14UNJS 1.1250-18 UNJF

NOTES: UNLESS OTHERWISE SPECIFIED 1. 2. 3. 4. 5. MATERIAL: Adapter:6AI-4V titanium per AMS4928, AMS4965 or AMS4967, 130 KSI UTS min kljljljlkjlkjjjjj Lockring: A286 corrosion resistant steel per AMS5731 or AMS5734, 34-40 HRC. FINISH: Adapter: Anodic treatment per AMS2488, type 2 All interior packages are marked per MIL-STD-129 and durably marked with the complete Rosan® part number. Lockring retained on adapter by controlled interference fit. Sealing Surface, do not mar, take care in handling.

-continued-

46

Alcoa Fastening Systems

RF5000-13

SERIES-Continued

ADAPTER ­ FLUID CONNECTION ASSY BEAM SEAL, CAPTIVE LIFT TYPE LOCKRING 5000 PSI

RF5000-13 ADAPTER INSTALLED IN ROSAN PS10035 (AS1300) PORT PER AS1301 NOTES: (CONTINUED FROM PREVIOUS PAGE

ADAPTER NUMBER O-RING NUMBER 8 REF AS568-007 AS568-008 AS568-010 AS568-011 AS568-012 AS568-014 AS568-016 AS568-116 AS568-118 AS568-120 AS568-123 AS568-128

J

11 +.020 .358 .389 .431 .431 .457 .470 .534 .584 .602 .632 .629 .714

H

11 MAX .124 .124 .124 .124 .130 .130 .130 .140 .140 .140 .140 .140

6.

ADAPTER WEIGHT lbs/100 PCS APPROX 0.72 1.09 1.32 1.90 2.44 3.45 5.78 7.79 10.03 12.45 17.80 25.60

The RF5000-13 series provides a semi-permanent male adapter for use in any fluid system compatible with titanium. Adapters will qualify to a 3000 PSI, 4000PSI and 5000PSI working pressure hydraulic system (-65F to +275oF depending on the type of O-Ring selected). O-ring sizes per AS568 must be specified separately and shall be selected based on system fluid temperature and are not supplied by Alcoa Fastening Systems. These Adapters are installed in standard Rosan® ports per PS10035 or equivalent size. The Lockring is driven into the port counterbore after adapter has been torqued. The lockring eliminates adapter rotation in the port and prevents port damage at tubing installation due to torquing of nut. One wrench is used to install and remove coupling nuts.

7.

RF5002-13 RF5003-13 RF5004-13 RF5005-13 RF5006-13 RF5008-13 RF5010-13 RF5012-13 RF5014-13 RF5016-13 RF5020T-13 RF5024T-13

8.

9. 10.

11. 12. 13.

Dimensions are given for design purposes only; they are not to be used for installation verification. Adapter removal is accomplished by lifting the lockring out of the port using a simple tool lockring removal tool Dimensions and finish of tubing end are per MIL-F-85720/1 except for RF5002-13 and flow hole diameters.

47

Alcoa Fastening Systems

RFK9800-13

SERIES

ADAPTER ­ FLUID CONNECTION ASSY FLARED TUBE END AS4395 CAPTIVE LIFT-TYPE LOCKRING

ADAPTER NUMBER

AS I.D. NUMBER AS1985-02 AS1985-03 AS1985-04 AS1985-05 AS1985-06 AS1985-08 AS1985-10 AS1985-12 AS1985-16 AS1985-20 AS1985-24 AS1985-32

TUBING OD

A

THREAD MIL-S-8879 CLASS 3A .3125-24UNJF .3750-24UNJF .4375-20UNJF .5000-20UNJF .5625-18UNJF .7500-16UNJF .8750-14UNJF 1.0625-12UNJ 1.3125-12UNJ 1.625-12UNJ 1.8750-12UNJ 2.5000-12UNJ

B

THREAD MIL-S-8879 CLASS 3A .2160-28 UNJF .2500-28 UNJF .3125-24 UNJF .3750-24 UNJF .4375-20 UNJF .5625-18 UNJF .6875-24 UNJEF .8125-20 UNJEF 1.1250-18 UNJEF 1.3125-18 UNJEF 1.6250-18 UNJEF 2.1250-16UNJ

C

DIA .058-.065 .121-.128 .168-.175 .230-.237 .293-.301 .387-.395 .480-.488 .604-.614 .839-.851 1.073-1.086 1.307-1.320 1.776-1.791

D

DIA REF .317 .349 .400 .491 .544 .670 .824 .981 1.251 1.466 1.768 2.311

E

DIA +.010 -.005 .743 .774 .845 .845 .872 .973 1.074 1.190 1.237 1.311 1.435 1.726

F

+.000 -.015 .300 .355 .355 .381 .395 .430 .465 .527 .564 .569 .608 .730

G

+.007 .192 .192 .192 .192 .210 .210 .210 .220 .220 .240 .240 .240

H

DIA +.005 .400 .468 .514 .624 .700 .814 1.040 1.170 1.456 1.782 2.031 2.548

RFK9802-13 RFK9803-13 RFK9804-13 RFK9805-13 RFK9806-13 RFK9808-13 RFK9810-13 RFK9812-13 RFK9816-13 RFK9820-13 RFK9824-13 RFK9832-13

1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 1 1-1/4 1-1/2 2

NOTES: UNLESS OTHERWISE SPECIFIED 1. 2. 3. 4. 5. MATERIAL: Adapter:6AI-4V titanium per AMS4928, AMS4965 or AMS4967, 130 KSI UTS min kljljljlkjlkjjjjj Lockring: A286 corrosion resistant steel per AMS5731, AMS5732, AMS5734 or AMS5737, 34-40 HRC. FINISH: Adapter: Anodic treatment per AMS2488, type 2 (Tiodize TY II or equivolent). L Lockring: Passivate per QQ-P-35. All interior packages are marked per MIL-STD-129 and durably marked with the complete Rosan® part number. Lockring retained on adapter by controlled interference fit. Sealing Surface, do not mar, take care in handling. -continued-

48

Alcoa Fastening Systems

RFK9800-13

SERIES-Continued

ADAPTER ­ FLUID CONNECTION ASSY FLARED TUBE END AS4395 CAPTIVE LIFT-TYPE LOCKRING

RFK9800-13 ADAPTER INSTALLED IN ROSAN PS10035 (AS1300) PORT PER AS1301 NOTES: (CONTINUED FROM PREVIOUS PAGE

ADAPTER NUMBER O-RING NUMBER 8 REF AS568-007 AS568-008 AS568-010 AS568-011 AS568-012 AS568-014 AS568-016 AS568-116 AS568-120 AS568-123 AS568-128 AS568-137

J

14 +.020 .577 .608 .679 .679 .691 .792 .893 1.009 1.056 1.103 1.228 1.478

K

14 MAX .124 .124 .124 .124 .130 .130 .130 .140 .140 .140 .140 .140

6.

ADAPTER WEIGHT lbs/100 PCS APPROX 0.9 1.3 1.7 2.2 2.7 4.6 7.6 10.9 16.2 24.4 28.1 61.1

The RFK9800-13 series provides a semi-permanent male adapter for use in any fluid system compatible with titanium. Adapters will qualify to a 3000 PSI and 4000 PSI working pressure hydraulic system (-65F to +450oF depending on the type of O-Ring selected). O-ring sizes per AS568 must be specified separately and shall be selected based on system fluid and temperature and are not supplied by Alcoa Fastening Systems. These Adapters are installed in standard Rosan® ports per PS10035 or equivalent size. The Lockring is driven into the port counterbore after adapter has been torqued. The lockring eliminates adapter rotation in the port and prevents port damage at tubing installation due to over torquing. One wrench is used to install and remove coupling nuts.

7.

RFK9802-13 RFK9803-13 RFK9804-13 RFK9805-13 RFK9806-13 RFK9808-13 RFK9810-13 RFK9812-13 RFK9816-13 RFK9820-13 RFK9824-13 RFK9832-13

8.

9. 10.

11. 12. 13. 14.

Dimensions are given for design purposes only; they are not to be used for installation verification. Coupling nuts (AN818) used with this adapter must have threads in accordance with MIL-S-8879 Adapter removal is accomplished by lifting the lockring out of the port using a simple lock ring removal tool Dimensions and finish of tubing end are per MIL-F-85720/1 except for RF5002-13 and flow hole diameters.

49

Alcoa Fastening Systems

RFK9900-13

SERIES

ADAPTER ­ FLUID CONNECTION ASSY FLARELESS TUBE END MS33514 OR AS4375 CAPTIVE LIFT-TYPE LOCKRING

ADAPTER NUMBER

AS I.D. NUMBER AS4099-02 AS4099-03 AS4099-04 AS4099-05 AS4099-06 AS4099-08 AS4099-10 AS4099-12 -------AS4099-16 AS4099-20 AS4099-24 AS4099-32

TUBING OD

A

THREAD MIL-S-8879 CLASS 3A .3125-24UNJF .3750-24UNJF .4375-20UNJF .5000-20UNJF .5625-18UNJF .7500-16UNJF .8750-14UNJF 1.0625-12UNJ 1.1875-12UNJ 1.3125-12UNJ 1.625-12UNJ 1.8750-12UNJ 2.5000-12UNJ

B

THREAD MIL-S-8879 CLASS 3A .2160-28 UNJF .2500-28 UNJF .3125-24 UNJF .3750-24 UNJF .4375-20 UNJF .5625-18 UNJF .6875-24 UNJEF .8125-20 UNJEF .9375-20UNJEF 1.1250-18 UNJEF 1.3125-18 UNJEF 1.6250-18 UNJEF 2.1250-16UNJ

C

DIA .090-.096 .122-.128 13 .231-.237 .294-.300 .419-.425 .497-.503 .653-.659 .715-.721 .872-.878 1.090-1.096 1.341-1.347 1.810-1.816

D

DIA REF .317 .349 .400 .491 .544 .670 .824 .981 1.118 1.251 1.466 1.768 2.311

E

DIA +.010 -.005 .674 .721 .752 .752 .789 .882 .945 1.018 1.018 1.018 1.045 1.045 1.086

F

+.000 -.015 .300 .355 .355 .381 .395 .430 .465 .527 .552 .564 .569 .608 .730

G

+.007 .192 .192 .192 .192 .210 .210 .210 .220 .220 .220 .240 .240 .240

H

DIA +.005 .400 .468 .514 .624 .700 .814 1.040 1.170 1.341 1.456 1.782 2.031 2.548

RFK9902-13 RFK9903-13 RFK9904-13 RFK9905-13 RFK9906-13 RFK9908-13 RFK9910-13 RFK9912-13 RFK9914-13 RFK9916-13 RFK9920-13 RFK9924-13 RFK9932-13

1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1 1-1/4 1-1/2 2

NOTES: UNLESS OTHERWISE SPECIFIED 1. 2. 3. 4. 5. MATERIAL: Adapter:6AI-4V titanium per AMS4928, AMS4965 or AMS4967, 130 KSI UTS min kljljljlkjlkjjjjj Lockring: A286 corrosion resistant steel per AMS5731, AMS5732, AMS5734 or AMS5737, 34-40 HRC. FINISH: Adapter: Anodic treatment per AMS2488, type 2 (Tiodize TY II or equivolent). L Lockring: Passivate per QQ-P-35. All interior packages are marked per MIL-STD-129 and durably marked with the complete Rosan® part number. Lockring retained on adapter by controlled interference fit. Sealing Surface, do not mar, take care in handling. -continued-

50

Alcoa Fastening Systems

RFK9900-13

SERIES -Continued

ADAPTER ­ FLUID CONNECTION ASSY FLARELESS TUBE END MS33514 OR AS4375 CAPTIVE LIFT-TYPE LOCKRING

RFK9800-13 ADAPTER INSTALLED IN ROSAN PS10035 (AS1300) PORT PER AS1301 NOTES: (CONTINUED FROM PREVIOUS PAGE

ADAPTER NUMBER O-RING NUMBER 8 REF AS568-007 AS568-008 AS568-010 AS568-011 AS568-012 AS568-014 AS568-016 AS568-116 AS568-118 AS568-120 AS568-123 AS568-128 AS568-137

J

15 +.020 .509 .556 .587 .587 .609 .702 .765 .838 .838 .838 .838 .838 .838

K

15 MAX .124 .124 .124 .124 .130 .130 .130 .140 .140 .140 .140 .140 .140

6.

ADAPTER WEIGHT lbs/100 PCS APPROX 0.8 1.2 1.4 2.1 2.5 3.8 6.3 8.3 11.3 12.8 18.8 24.7 41.0

The RFK9900-13 series provides a semi-permanent male adapter for use in any fluid system compatible with titanium. Adapters will qualify to a 3000 PSI and 4000 PSI working pressure hydraulic system (-65F to +450oF depending on the type of O-Ring selected). O-ring sizes per AS568 must be specified separately and shall be selected based on system fluid and temperature and are not supplied by Alcoa Fastening Systems. These Adapters are installed in standard Rosan® ports per PS10035 or equivalent size. The Lockring is driven into the port counterbore after adapter has been torqued. The lockring eliminates adapter rotation in the port and prevents port damage at tubing installation due to over torquing. One wrench is used to install and remove coupling nuts.

7.

RFK9902-13 RFK9903-13 RFK9904-13 RFK9905-13 RFK9906-13 RFK9908-13 RFK9910-13 RFK9912-13 RFK9914-13 RFK9916-13 RFK9920-13 RFK9924-13 RFK9932-13

8.

9. 10.

11. 12. 13. 14. 15.

Adapter removal is accomplished by lifting the lockring out of the port using a simple lock ring removal tool Coupling nuts (MS21921) used with this adapter must have threads in accordance with MIL-S-8879 Adapter "C" for RFK9904-13 is .184-.190 on MS33514 or AS4375 end and reduced to .169-.175 diameter on opposite end Dimensions meet the requirements of Military Specification MS33514 or AS4375. These Dimensions are for design purposes only. Do not use as installation data.

51

Alcoa Fastening Systems

RF9800-( )-13

SERIES

ADAPTER - REDUCER FLARED TUBE END AS4395 CAPTIVE LIFT-TYPE LOCKRING

ADAPTER NUMBER

A

THREAD MIL-S-8879 CLASS 3A .3125-24UNJF .3750-24UNJF .4375-20UNJF .3750-24UNJF .4375-20UNJF .5000-20UNJF .3750-24UNJF .4375-20UNJF .5000-20UNJF .5625-18UNJF .4375-20UNJF .5625-18UNJF .7500-16UNJF .4375-20UNJF .5000-20UNJF .5625-18UNJF .7500-16UNJF .8750-14UNJF .8750-14UNJF .4375-20UNJF .8750-14UNJF 1.0625-12UNJ .4375-20UNJF 1.0625-12UNJ 1.3125-12UNJ 1.3125-12UNJ 1.6250-12UNJ

B

THREAD MIL-S-8879 CLASS 3A .3125-24UNJF .3750-24UNJF .4375-20UNJF

C

DIA +.005 .185 .232 .295

D

DIA +.005 .514 .624 .700

E

+.007 .192 .192 .210

F

+.000 -.015 .866 .897 .979 .941 1.010 1.010 .941 1.010 1.010 1.018 1.010

G

+.000 -.015 .355 .381 .395

RF9804-02-13 RF9804-03-13 RF9805-04-13 RF9806-03-13 RF9806-04-13 RF9806-05-13 RF9808-03-13 RF9808-04-13 RF9808-05-13 RF9808-06-13 RF9810-04-13 RF9810-06-13 RF9810-08-13 RF9812-04-13 RF9812-05-13 RF9812-06-13 RF9812-08-13 RF9812-10-13 RF9814-10-13 RF9816-04-13 RF9816-10-13 RF9816-12-13 RF9820-04-13 RF9820-12-13 RF9820-16-13 RF9824-16-13 RF9824-20-13

.5625-18UNJF

.412

.814

.210

.430

.6875-24UNJEF

.498

1.040

.210

1.018 1.120 1.010 1.010 1.018 1.120 1.217 1.200 1.021 1.229 1.335 1.028 1.342 1.389 1.410 1.457

.465

.8125-20UNJEF

.633

1.170

.220

.527

.937520-UNJEF 1.1250-18UNJEF

.730 .861

1.341 1.456

.220 .220

.572 .564

1.3125-18UNJEF 1.6250-18UNJEF

1.057 1.297

1.782 2.031

.240 .240

.569 .608

-continued-

52

Alcoa Fastening Systems

RF9800-( )-13

SERIES-Continued

ADAPTER - REDUCER FLARED TUBE END AS4395 CAPTIVE LIFT-TYPE LOCKRING

RF9800-( )-13 ADAPTER INSTALLED IN ROSAN PS10035 (AS1300) PORT

ADAPTER NUMBER O-RING NUMBER 6 REF AS568-010 AS568-011 AS568-012

H

10 +.020 0.701 0.732 0.814 0.761 0.83 0.83 0.761 0.83 0.83 0.838 0.83

J

10 MAX .124 .124 .130

NOTES: UNLESS OTHERWISE SPECIFIED: 1. MATERIAL: Adapter: 6AI-4V titanium per AMS4928, AMS4965 or AMS4967, 130 KSI UTS min. llllllllllllllll "'''''''''''''''''''Lockring: A286 corrosion resistant steel per AMS5731, `''''''''''''''''''''AMS5732, AMS5734 or AMS5737, 34-40HRC Finish: Adapter: Anadonic treatment per AMS2488, Type 2 (Tiodize TY ii `''''''''''''or equivalent).''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' `''''''''''''Lockring: Passivate per QQ-P-35 Lockring retained on adapter by controlled interference fit. Sealing surface, do not mar, take care in handling. This end per AS4395 style "E". O-rings must be specified separately and shall be selected based on system fluid and temperature and are not supplied by Alcoa Fastening Systems. Dash numbers shown in the table conform to SAE standard (AS568) uniform dash numbering system. Port preparation per Rosan® PS10035 (Ref:AS1300) Coupling Nut (AN818)must have MIL-S-8879 thread. See installation instructions in this catalog These dimensions are for design purposes only. Do no use as installation data.

RF9804-02-13 RF9804-03-13 RF9805-04-13 RF9806-03-13 RF9806-04-13 RF9806-05-13 RF9808-03-13 RF9808-04-13 RF9808-05-13 RF9808-06-13 RF9810-04-13 RF9810-06-13 RF9810-08-13 RF9812-04-13 RF9812-05-13 RF9812-06-13 RF9812-08-13 RF9812-10-13 RF9814-10-13 RF9816-04-13 RF9816-10-13 RF9816-12-13 RF9820-04-13 RF9820-12-13 RF9820-16-13 RF9824-16-13 RF9824-20-13

2.

AS568-014

.130

3. 4. 5. 6.

AS568-016

0.838 0.94 0.83 0.83 0.838 0.94 1.037 1.02 0.841 1.049 1.155 0.821 1.135 1.182 1.203 1.25

.130

AS568-116

.140

7.

.140 .140

AS568-118 AS568-120

8. 9. 10.

AS568-123 AS568-128

.140 .140

53

Alcoa Fastening Systems

RF9900-( )-13

SERIES

ADAPTER - REDUCER FLARELESS TUBE END MS33514 OR AS4375 CAPTIVE LIFT-TYPE LOCKRING

ADAPTER NUMBER

A

THREAD MIL-S-8879 CLASS 3A

B

THREAD MIL-S-8879 CLASS 3A .3125-24UNJF .3750-24UNJF .4375-20UNJF

C

DIA +.005 .185 .232 .295

D

DIA +.005 .514 .624 .700

E

+.007 .192 .192 .210

F

+.010 -.005 .792 .840 .882 .884 .915 .915 .884 .915 .915 .931 .915

RF9904-02-13 .3125-24UNJF RF9904-03-13 .3750-24UNJF RF9905-04-13 .4375-20UNJF RF9906-03-13 .3750-24UNJF RF9906-04-13 .4375-20UNJF RF9906-05-13 .5000-20UNJF RF9908-03-13 .3750-24UNJF RF9908-04-13 .4375-20UNJF RF9908-05-13 .5000-20UNJF RF9908-06-13 .5625-18UNJF RF9910-04-13 .4375-20UNJF

.5625-18UNJF

.412

.814

.210

RF9910-06-13 .5625-18UNJF .6875-24UNJEF RF9910-08-13 RF9912-04-13 RF9912-05-13 RF9912-06-13 RF9912-08-13 RF9912-10-13 RF9916-04-13 RF9916-10-13 RF9916-12-13 RF9916-14-13 RF9920-04-13 RF9920-12-13 RF9920-16-13 RF9924-16-13 RF9924-20-13 .7500-16UNJF .4375-20UNJF .5000-20UNJF .5625-18UNJF .7500-16UNJF .8750-14UNJF .4375-20UNJF .8750-14UNJF 1.0625-12UNJ 1.1875-12UNJ .4375-20UNJF 1.0625-12UNJ 1.3125-12UNJ 1.3125-12UNJ 1.6250-12UNJ

.498

1.040

.210

.931 1.025 .915 .915 .931 1.025 1.084 .924 1.096 1.159 1.159 .931 1.166 1.166 1.187 1.187

.8125-20UNJEF

.633

1.170

.220

1.1250-18UNJEF

.861

1.456

.220

1.3125-18UNJEF 1.6250-18UNJEF

1.057 1.297

1.782 2.031

.240 .240

-continued-

54

Alcoa Fastening Systems

RF9900-( )-13

SERIES

ADAPTER - REDUCER FLARELESS TUBE END MS33514 OR AS4375 CAPTIVE LIFT-TYPE LOCKRING

ADAPTER NUMBER

O-RING NUMBER 6 REF AS568-010 AS568-011 AS568-012

H

9 +.020 .628 .675 .717 .704 .735 .735 .704 .735 .735 .751 .735

J

9 MAX .124 .124 .130

NOTES: UNLESS OTHERWISE SPECIFIED: 1. MATERIAL: Adapter: 6AI-4V titanium per AMS4928, AMS4965 or AMS4967, 130 KSI UTS min. llllllllllllllll "'''''''''''''''''''Lockring: A286 corrosion resistant steel per AMS5731, `''''''''''''''''''''AMS5732, AMS5734 or AMS5737, 34-40HRC Finish: Adapter: Anadonic treatment per AMS2488, Type 2 (Tiodize TY ii `''''''''''''or equivalent).''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''''' `''''''''''''Lockring: Passivate per QQ-P-35 Lockring retained on adapter by controlled interference fit. Sealing surface, do not mar, take care in handling. This end per MS33514 or AS4375, style "E" O-rings must be specified separately and shall be selected based on system fluid and temperature and are not supplied by Alcoa Fastening Systems. Dash numbers shown in the table conform to SAE standard (AS568) uniform dash numbering system. Port preparation per Rosan® PS10035 (Ref:AS1300). See installation instructions in this catalog. These dimensions are for design purposes only. Do no use as installation data.

RF9904-02-13 RF9904-03-13 RF9905-04-13 RF9906-03-13 RF9906-04-13 RF9906-05-13 RF9908-03-13 RF9908-04-13 RF9908-05-13 RF9908-06-13 RF9910-04-13 RF9910-06-13 RF9910-08-13 RF9912-04-13 RF9912-05-13 RF9912-06-13 RF9912-08-13 RF9912-10-13 RF9916-04-13 RF9916-10-13 RF9916-12-13 RF9916-14-13 RF9920-04-13 RF9920-12-13 RF9920-16-13 RF9924-16-13 RF9924-20-13

2.

AS568-014

.130

3. 4. 5. 6.

AS568-016

.751 .845 .735 .735 .751 .845 .904 .744 .916 .979 .979 .724 .959 .959 .980 .980

.130

AS568-116

.140

7.

.140

AS568-120

8. 9.

AS568-123 AS568-128

.140 .140

55

Alcoa Fastening Systems

RF9500-6

SERIES

INSERT ­ FLUID CONNECTION MS33649 INTERNAL CONFIGURATION 3000 PSI

INSERT TUBING ASSEMBLY OD NUMBER RF9502-6 RF9503-6 RF9504-6 RF9505-6 RF9506-6 RF9508-6 RF9510-6 RF9512-6 RF9516-6 RF9520-6 1/8 1/5 1/4 1/3 3/8 1/2 5/8 3/4 1 1 1/4

A

THREAD AS-8879 CLASS 3B

B

THREAD AS-8879 CLASS 3A

C

MAX .622 .685 .748 .810 .867

D

E

F

MIN .602 .665 .728 .790 .852

G

H

J

K

L

+.005 -.002 +.003 .373 .440 .503 .566 .628 .469 .536 .599 .662 .724

+.010 +.010 -.004 +.010 -.005 +.015 +.010 .047 .047 .047 .047 .047 .761 .729 .777 .802 .830 .955 .082 .082 .082 .082 .082 .082 .364 .364 .364 .364 .765 .830 .890 .950

INSERT WEIGHT lb/100 PIECES MAX APPROX

M

.3125-24UNJF .4375-28UNJEF .3750-24UNJF .5000-28UNJEF .4375-20UNJF .5625-24UNJEF .5000-20UNJF .6250-24UNJEF .5625-18UNJF .6875-24UNJEF

.630 .693 .755 .818

2.19 2.86 2.85 3.58 3.59 7.57 9.79 12.19 18.36 27.96

.364 1.000 .865 .364 1.250 1.113 .374 1.380 1.238 .389 1.600 1.455 .389 1.860 1.716 .389 2.250 2.111

.7500-16UNJF .9375-20UNJEF 1.060 .858

.954 1.040 .047

.8750-14UNJF 1.0625-18UNJEF 1.185 .983 1.079 1.165 .057 1.051 .082 1.0625-12UNJ 1.2500-18UNJEF 1.435 1.171 1.267 1.415 .072 1.185 .082 1.3125-12UNJ 1.5000-18UNJEF 1.685 1.421 1.517 1.665 .072 1.185 .082 1.6250-12UNJ 1.8750-16UNJ 2.020 1.760 1.918 1.978 .072 1.237 .122

Notes unless otherwise specified: 1. 2. 3. 4. 5. MATERIAL: A286 Cres per AMS5731, AMS5732, AMS5734 or AMS5737. These parts are also available in other """""""""materials. Contact technical support for other options. HEAT TREAT: 130 KSI UTS min. FINISH: Passivate per QQ-P-35 Insert internal configurations and "F" Diameter per MS33649. Sealing Surface: No visible defects. To be protected for shipment -continued-

56

Alcoa Fastening Systems

RF9500-6

SERIES

INSERT ­ FLUID CONNECTION MS33649 INTERNAL CONFIGURATION 3000 PSI

INSERT ASSEMBLY NUMBER RF9502-6 RF9503-6 RF9504-6 RF9505-6 RF9506-6 RF9508-6 RF9510-6 RF9512-6 RF9516-6 RF9520-6

INSERT NUMBER

LOCKRING NUMBER

PORT NUMBER

O-RING SIZE 7 REF AS568-012 AS568-013 AS568-014 AS568-015 AS568-016 AS568-019 AS568-021 AS568-024 AS568-128 AS568-132

A

8 .550 .520 .565 .590 .620 .745 .830 .950 .950 1.000

B

+.000 -.045 .255 .255 .255 .255 .255 .255 .265 .280 .280 .280

RF9502-504 RF9503-504 RF9504-504 RF9505-504 RF9506-504 RF9508-504 RF9510-504 RF9512-504 RF9516-504 RF9520-504

RLT9502-24 RLT9503-24 RLT9504-24 RLT9505-24 RLT9506-24 RLT9508-24 RLT9510-24 RLT9512-24 RLT9516-24 RLT9520-24

PS10040-02 PS10040-03 PS10040-04 PS10040-05 PS10040-06 PS10040-08 PS10040-10 PS10040-12 PS10040-16 PS10040-20

NOTES CONTINUED FROM PREVIOUS PAGE: 6. 7. 8. 9. 10. The RF9500-6 series provides a semi-permanent hydraulic port primarily for use in 3000 PSI fluid systems. O-rings must be specified separately and shall be selected based on system fluid and temperature and are not supplied by Alcoa Fastening Systems. O-ring size per AS568. Maximum insert installation depth or minimum recommended parent material thickness. Dimension "B" is for design purpose only. Do not use as installation data. These inserts and lockrings are installed in standard ports per PS10040 or equivalent size.

57

Alcoa Fastening Systems

For Sales, Parts and Service Contact: Alcoa Fastening Systems Assembly Tool Systems Division 801 S. Placentia Avenue Fullerton, CA 92831 714-278-8908 Telephone 714-871-4821 FAX

58

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