ASSEMBLY, INSERT – FLUID CONNECTION
PORTING, INSTALLATION AND REMOVAL TOOLS
| ROSAN ASSEMBLY NUMBER | ROSAN PORT NUMBER | PORTING TOOL | INSTALLATION TOOLS | ||
| O-RING INSTALLATION TOOL | WRENCH | LOCKRING DRIVE TOOL | |||
| RF8502-6 | PS10040-02 | RPT9502 | ORT95-437 | RF8502WA | RF8502DA |
| RF8503-6 | PS10040-03 | RPT9503 | ORT95-500 | RF8503WA | RF85035DA |
| RF8504-6 | PS10040-04 | RPT9504 | ORT95-562 | RF8504WA | RF8504DA |
| RF8505-6 | PS10040-05 | RPT9505 | ORT95-625 | RF8505WA | RF8505DA |
| RF8506-6 | PS10040-06 | RPT9506 | ORT95-687 | RF8506WA | RF8506DA |
| RF8508-6 | PS10040-08 | RPT9508 | ORT95-937 | RF8508WA | RF8508DA |
| RF8510-6 | PS10040-10 | RPT9510 | ORT95-1062 | RF851WA | RF8510A |
| RF8512-6 | PS10040-12 | RPT9512 | ORT95-1250 | RF8512WA | RF851DA |
| RF8516-6 | PS10040-16 | RPT9516 | ORT95-1500 | RF8516WA | RF8516DA |
| RF8520–6 | PS10040-20 | RPT9520 | ORT95-1875 | RF8520WA | RF8520DA |
| ROSAN ASSEMBLY NUMBER | REMOVAL DRILL SIZE | REMOVAL COUNTERBORE TOOL |
| RF8502-6 | 25/64 (.3906) | RF8502R |
| RF8503-6 | 15/32 (.4687) | RF8503R |
| RF8504-6 | 17/32 (.5312) | RF8504R |
| RF8505-6 | 19/32 (.5937) | RF8505R |
| RF8506-6 | 21/32 (.6562) | RF8506R |
| RF8508-6 | 7/8 (.8750) | RF8508R |
| RF8510-6 | 1 (1.0000) | RF8510R |
| RF8512-6 | 1-7/32 (1.2188) | RF8512R |
| RF8515-6 | 1-7/16 (1.4375) | RF8516R |
| RF8520-6 | 1-13/16 (1.8125) | RF8520R |
PORT PREPARATION, INSERT INSTALLATION AND REMOVAL TOLLS
1. PORT PREPARATION
1.1 Prepare boss and port per PS10040 page 5. Drill through or to depth specified on applicable drawing. Use a drill
with a diameter .015-.030 smaller than the required thread minor diameter specified in standard PS10040 prior to
finishing part using RPT9500 series porting tool.
2. LOCKRING INSTALLATION
2.1 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.
3. O-RING INSTALLATION
3.1 Place the O-ring installation tool over the outside thread of the insert. Submerge the insert the lockring the
O-ring and the O- ring too in the fluid to be used in the working system or a lubricant compatible with the system
fluid.
3.2 Slide the O-ring over the O-ring tool and onto the insert. Be sure that the O-ring is not twisted and is properly
seated in the groove of the insert. See Figure 1.
3.3 Remove the O-ring installation tool.
4. INSERT INSTALLATION
4.1 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 contact area on the insert or in the
port.
4.2 Screw the drive wrench into the thread of the insert until the plastic collar touches the surface of the insert.
See Figure 2.
4.3 Screw the insert assembly into the port by hand using a clockwise rotation until the assembly 1s firmly set (See
Figure 2).
CAUTION: Be sure that the lockring internal serrations are engaged wit the insert serrations.To avoid possible O-ring
damage the insert should not berotated in a counterclockwise direction. If this has beendone replace the O-ring.
4.4 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 I on page 19. Remove the torque wrench and not the drive wrench.
4.5 Apply enough Zinc Chromate primer (TT-P-1757) with a brush or small 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.
.Figure 1
Figure 2
INSTALLATION AND REMOVAL, RF8500 SERIES FLUID INSERT
4.6 While the Zinc Chromate (or other primer) is still wet, 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 lockring
into the surface of port counterbore until the face of the lockring drive tool touches the port surface. See Figure 4.
NOTE: Depending upon he component configuration it may be necessary to support the port in order not to deform the
internal configuration of the component.
4.7 Remove the tools and excess Zinc Chromate (or other primer) that has formed on the surface of port and lockring.
TABLE I
| ROSAN ASSEMBLY NUMBER | ROSAN PORT NUMBER
REF |
O-RING NUMBER
REF |
INSTALLATION TORQUE lbf-in | |
| MIN | MAX | |||
| RF8502-6 | PS10040-02 | AS568-012 | 40 | 50 |
| RF8503-6 | PS10040-03 | AS568-013 | 65 | 84 |
| RF8504-6 | PS10040-04 | AS568-014 | 80 | 105 |
| RF8505-6 | PS10040-05 | AS568-015 | 120 | 150 |
| RF8506-6 | PS10040-06 | AS568-016 | 145 | 185 |
| RF8508-6 | PS10040-08 | AS568-019 | 350 | 400 |
| RF8510-6 | PS10040-10 | AS568-021 | 500 | 600 |
| RF8512-6 | PS10040-12 | AS568-024 | 700 | 800 |
| RF8516-6 | PS10040-16 | AS568-028 | 1200 | 1300 |
| RF8520-6 | PS10040-20 | AS568-132 | 1800 | 200 |
5. PRESSURE TESTING
5.1 A proof pressure test of unit may be conducted at this point. Place a pressure plug in the insert. Pressurize the
unit from another location on the unit to 1.5 times the operating pressure for three (3) minutes. There shall be
leakage.
NOTE: Using design activity may require testing other than shown.
6. INSERT REMOVAL, The removal of RF8500 series boss inserts is to be accomplished in a manner that will not damage the
parent material.
6.1 Obtain the proper drill size from table on page 17.
6.2 The drill must be centered to the insert internal threads. Set drill stop so that the drill diameter will
penetrate 160 inches below the parent material surface. Drill until insert has separated which will normally be about
.140 inches below the parent material surface.
NOTE: This drilling operation will separate the insert in the O-ring gland area thereby not touching the parent material
cavity or the lockring.
6.3 Lift the upper portion of the insert out.
6.4 Using a screw extractor or similar device unscrew the bottom half of the insert from the cavity. The lockring will
still be in the parent material.
CAUTION: Do not pry out lockring. This could damage the 20ù angle of the cavity sealing surface and also could enlarge
or damage parent material serrations and affect the security of a replacement lockring.
7. LOCKRING REMOVAL
7.1 If a sealant has been used to cover lockring carefully remove sealant to expose lockring.
7.2 Select the proper size removal counterbore too from table on page 17. This tool pilots in the minor diameter of
the cavity thread and bores into the lockring without touching the parent material serrations.
7.3 Bore into the lockring .050-.055 inches deep. This will leave a thin wall and externa serrations on lockring and
separates the lockring pilot.
7.4 Using a thin pointed punch collapse the remaining portion of the lockring radially inward being careful not to mar
the parent material remove lockring and lockring pilot.
7.5 Remove all loose and hanging burrs in counterbore area and clean cavity.
7.6 Purge unit or system.
8. REINSTALLATION OF INSERT AND LOCKRING:
8.1 Reinstall lockring as described in paragraph 2 page 18.
8.2 Reinstall O-ring as described in paragraph 3 page 18 using a new O-ring per Table I page 19.
8.3 Reinstall insert assembly into part as described in paragraph 4 page 18 except a shim shall be used between
lockring and the broached surface to prevent premature engagement of serrations.
Torque to the minimum value specified in Table I page 19. If the lockring serrations does not align with the port
serrations continue to slowly torque the insert towards the maximum value allowed in Table I page 19 until the
serrations of the lockring aligns with the port serrations then remove shim before driving lockring.
| PORTING TOOL NUMBER | øA +.0000 -.0003 | øB ±.0005 | øC ±.0003 | D ±.005 | E REF | PORT THREAD MIL-S-8879 CLASS-3B REF | TO PRODUCE CONTOUR FOR PORT NUMBER |
| RPT9502 | .4998 | .4057 | .6725 | .700 | 3.450 | .4375-28UNJEF | PS10040-02 |
| RPT9503 | .4998 | .4682 | .7355 | .645 | 3.645 | .5000-28UNJEF | PS10040-03 |
| RPT9504 | .4998 | .5249 | .7975 | .750 | 3.750 | .5625-24UNJEF | PS10040-04 |
| RPT9505 | .4998 | .5874 | .8605 | .750 | 3.750 | .6250-24UNCJEF | PS10040-05 |
| RPT9506 | .4998 | .6499 | .9075 | .800 | 3.800 | .6875-24UNJEF | PS10040-06 |
| RPT9508 | .7498 | .8918 | 1.1575 | 1.005 | 4.255 | .9375-20UNJEF | PS10040-08 |
| RPT9510 | .7498 | 1.0114 | 1.2825 | 1.120 | 4.370 | 1.0625-18UNJEF | PS10040-10 |
| RPT9512 | .7498 | 1.1989 | 1.5015 | 1.240 | 4.740 | 1.2500-18UNJEF | PS10040-12 |
| RPT9516 | .7498 | 1.4489 | 1.7675 | 1.240 | 4.740 | 1.5000-18UNJEF | PS10040-16 |
| RPT9520 | .7498 | 1.8172 | 2.1575 | 1.330 | 4.830 | 1.8750-16UNJ | PS10040-20 |
NOTES:
1.MATERIAL: Body – High Speed Steel. Cutting Edges – Carbide Inserts.
APPLICATION
This tool counterbores, countersinks, provides a radius and produces a perfect tap drill diameter in one pass. Contours
are ground to insure concentricity. Cutter geometry permits the use of these tools with most common materials.
METHOD
Drill through or to a depth specified on the applicable drawing using a drill with a diameter .015-.030 smaller than
that specified (ref: “fB”). This will allow Rosan “RPT9500” series porting tool to finish all diameters of the port
(PS10040) to the dimensions required. The user must set the cutting depth.