Rosan Fluid Assemblies and related installation tools (AS1958)
PORTING, INSTALLATION AND REMOVAL TOOLS
| ROSAN ASSEMBLY NUMBER | ROSAN PORT NUMBER | PORTING TOOL | INSTALLATION TOOLS | LOCKRING REMOVAL TOOL | INSERT REMOVAL TOOL | ||
| O-RING INSTALLATION TOOL | WRENCH | LOCKRING DRIVE TOOL | |||||
| RF9502-6 | PS10040-02 | RPT9502 | ORT95-437 | RF8502WA | RF9502DA | RF9502LPD | RF9502RT |
| RF9503-6 | PS10040-03 | RPT9503 | ORT95-500 | RF8503WA | RF9503DA | RF9503LPD | RF9503RT |
| RF9504-6 | PS10040-04 | RPT9504 | ORT95-562 | RF8504WA | RF9504DA | RF9504LPD | RF9504RT |
| RF9505-6 | PS10040-05 | RPT9505 | ORT95-625 | RF8505WA | RF9505DA | RF9505LPD | RF9505RT |
| RF9506-6 | PS10040-06 | RTP9506 | ORT95-687 | RF8506WA | RF9506DA | RF9506LPD | RF9506RT |
| RF9508-6 | PS10040-08 | RPT9508 | ORT95-937 | RF8508WA | RF9508DA | RF9508LPD | RF9508RT |
| RF9510-6 | PS10040-10 | RPT9510 | ORT95-1062 | RF8510WA | RF9510DA | RF9510LPD | RF9510RT |
| RF9512-6 | PS10040-12 | RPT9512 | ORT95-1250 | RF8512WA | RF9512DA | RF9512LPD | RF9512RT |
| RF9516-6 | PS10040-16 | RPT9516 | ORT95-1500 | RF8516WA | RF9516DA | RF9516LPD | RF9516RT |
| RF9520-6 | PS10040-20 | RPT9520 | ORT95-1875 | RF8520WA | RF9520DA | RF9520LPD | RF9520RT |
TOOL KIT
| ROSAN ASSEMBLY NUMBER | ROSAN KIT NUMBER | KIT CONTENTS | ||||||
| PORTING TOOL | BOTTOMING TAP | O-RING INSTALLATION TOOL | WRENCH | LOCKRING DRIVE TOOL | LOCKRING REMOVAL TOOL | INSERT REMOVAL TOOL | ||
| RF9502-6 | KM52RF9502 | RPT95002 | PS40-02BT | ORT95-437 | RF8502WA | RF9502DA | RF9502LPD | RF9502RT |
| RF9503-6 | KM52RF9503 | RPT9503 | PS40-03BT | ORT95-500 | RF8503WA | RF9503DA | RF9503LPD | RF9503RT |
| RF9504-6 | KM52RF9504 | RPT9504 | PS40-04BT | ORT95-562 | RF8504WA | RF9504DA | RF9504LPD | RF9504RT |
| RF9505-6 | KM52RF9505 | RPT9505 | PS40-05BT | ORT95-625 | RF8505WA | RF9505DA | RF9505LPD | RF9505RT |
| RF9506-6 | KM52RF9506 | RPT9506 | PS40-06BT | ORT95-687 | RF8506WA | RF9506DA | RF9506LPD | RF9506RT |
| RF9508-6 | KM52RF9508 | RPT9508 | PS40-08BT | ORT95-937 | RF8508WA | RF9508DA | RF9508LPD | RF9508RT |
| RF9510-6 | KM52RF9510 | RPT9510 | PS40-10BT | ORT95-1062 | RF8510WA | RF9510DA | RF9510LPD | RF9510RT |
| RF9512-6 | KM52RF9512 | RPT9512 | PS40-12BT | ORT95-1250 | RF8512WA | RF9512DA | RF9512LPD | RF9512RT |
| RF9516-6 | KM52RF9516 | RPT9516 | PS40-16BT | ORT95-1500 | RF8516WA | RF9516DA | RF9516LPD | RF9516RT |
| RF9520-6 | KM52RF9520 | RPT9520 | PS40-20BT | ORT95-1875 | RF8520WA | RF9520DA | RF9520LPD | RF9520RT |
PORT PREPARATION, INSERT INSTALLATION AND REMOVAL TOOLS AND TOOL KITS
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 port 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 tool 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 is firmly set (See
Figure 2).
CAUTION: Be sure that the lockring internal serrations are engaged with the insert serrations.To avoid possible O-ring
damage, the insert should notbe rotated in a counterclockwise direction. If this has been done, 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 8. Remove the torque wrench and not the drive wrench.
4.5 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.
FIGURE 1
FIGURE 2
INSTALLATION AND REMOVAL, RF9500 SERIES FLUID INSERT
4.6 While the Zinc Chromate (or other 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 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 the 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 | |||
| RF9502-6 | PS10040-02 | AS568-012 | 40 | 50 |
| RF9503-6 | PS10040-03 | AS568-013 | 65 | 84 |
| RF9504-6 | PS10040-04 | AS568-014 | 80 | 105 |
| RF9505-6 | PS10040-05 | AS568-015 | 120 | 150 |
| RF9506-6 | PS10040-06 | AS568-016 | 145 | 185 |
| RF9508-6 | PS10040-08 | AS568-019 | 350 | 400 |
| RF9510-6 | PS10040-10 | AS568-021 | 500 | 600 |
| RF9512-6 | PS10040-12 | AS568-024 | 700 | 800 |
| RF9516-6 | PS10040-16 | AS568-028 | 1200 | 1300 |
| RF9520-6 | PS10040-20 | AS568-132 | 1800 | 2000 |
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 no
leakage.
Note: Using design activity may require testing other than shown.
6. LOCKRING REMOVAL
6.1 If a sealant has been used to cover lockring, carefully remove sealant to expose lockring.
6.2 Select the proper size lockring removal tool from page 6.
6.3 Spread the puller halves apart by retracting the sleeve from the tool until the pin bottoms in the groove of the
sleeve per Figure 5. Holding the puller halves apart, place tool over protruding insert so the nylon pad rests on the
top surface of the insert. Release the puller halves and locate in the groove of the lockring. Adjustment up or down is
achieved by rotating the bolt head. Slide the sleeve over the puller halves and check for proper engagement of the
puller halves in the lockring groove. See Figure 6.
6.4 Place wrench on the bolt head of the removal tool and turn in a clockwise direction while holding the sleeve with
other hand. This action will cause the lockring to be jacked out of the port counterbore. When the external serra- tions
of the lockring are clear of the boss surface, the turning may be stopped. Remove the tool from the insert assembly by
loosening the bolt and lifting the sleeve to free the puller halves.
7. INSERT REMOVAL
7.1 If the insert is damaged and will not be used again, place shims between the lockring and the port surface. Drive a
screw extractor into the internal threads and remove the insert.
7.2 If the insert is not damaged and it will be reinstalled:
– Screw the insert removal tool into the insert thread such that the thread is below the top surface of the insert.
– Assemble the left hand thread nut onto the tool stud. The hexagon drive socket in the stud should be held to prevent
the stud from backing out. Place shims between the lockring and the port surface to prevent lockring from dropping back
down into the port serration.
– Seat the nut firmly against the top surface of the insert by turning in a counter-clockwise direction. Continue to
tighten nut. The insert will break away from its seat at approximately half the installation torque value. See Figure 7.
FIGURE 7
8. REINSTALLATION OF INSERT AND LOCKRING:
8.1 Reinstall lockring as described in paragraph 2.
8.2 Reinstall O-ring as described in paragraph 3. using a new O-ring per Table I, page 8.
8.3 Reinstall insert assembly into port as described in paragraph 4. 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. 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 until the serrations of the lockring
aligns with the port serrations, then remove shim before driving lockring.
INSTALLATION AND REMOVAL, RF9500 SERIES FLUID INSERT
RF8500 AND RF9500 SERIES, ASSEMBLY MATERIAL CODE
TABLE I
| ASSEMBLY MATERIAL CODE RF8500-( ) RF9500-( ) | INSERT MATERIAL CODE RF8500-( ) RF9500-( ) | LOCKRING MATERIAL CODE RL8500-( ) RLT9500-( ) |
| 2 [1] | 502 | 21 |
| 4 [1] | 502 | 22 |
| 5 | 503 | 21 |
| 6 | 504 | 24 |
| 7 [1] | 505 | 24 |
MATERIAL, HEAT TREAT AND FINISH, INSERT
TABLE II
| INSERT MATERIAL CODE | MATERIAL | SPECIFICATION | HEAT TREAT | FINISH |
| -502 [1] | CRES, 17-4PH | AMS5643 | COND H1200 | PASSIVATE PER QQ-P-35 |
| -503 | 4130 STEEL ALTERNATE: 4140 STEEL | MIL-S-6758 COND F MIL-S-5626 COND F | 125,000 PSI UTS MIN | CAD PLATE PER QQ-P-416, TY II, CL 3 |
| -504 | CRES, A286 | AMS5731, AMS5732 AMS5734 OR AMS5737 | 130,000 PSI UTS MIN | PASSIVATE PER QQ-P-35 |
| -505 [1] | TITANIUM, 6AI-4V | AMS4965 OR AMS4967 | 140,000 PSI UTS MIN | DRY FILM LUBRICANT ON ALL SURFACES |
MATERIAL, HEAT TREAT AND FINISH, LOCKRING
TABLE III
| LOCKRING MATERIAL CODE | MATERIAL | SPECIFICATION | HEAT TREAT | FINISH |
| -21 | STEEL, 1117 | ASTM A108 | CASE HARDEN | CAD PLATE PER |
| 36-45 HRC | QQ-P-416. TY II, CL 3 | |||
| -22 [1] | CRES, 17-4PH | AMS5643 | COND H900 | PASSIVATE PER QQ-P-35 |
| -24 | CRES, A286 | AMS5731, AMS5732 AMS5734 OR AMS5737 | 130,000 PSI UTS MIN | PASSIVATE PER QQ-P-35 |
NOTES:
[1]RF8500 series are not available in noted materials.
2.Rosan fluid boss inserts and their corresponding mating lockringmay be ordered separately or by the assembly number.
EXAMPLE: RF9506-5 consistes of RF9506-503 and RLT9506-2J. RF8506-5 consistes of RF8506-503 and RL8506-21.
| ROSAN PART NUMBER | TUBE OD REF | A THREAD MIL-S-8879 CLASS-3B | B THREAD MIL-S-8879 CLASS-3A | C MAX | D MIN | E ±.003 | F ±.010 | G +.005 -.002 | H +.010 -.004 |
| RFR9503-02-504 | .125 | .3125-24UNJF | .5000-28UNJEF | .685 | .665 | .536 | .442 | .440 | .047 |
| RFR9504-03-504 | .188 | .3750-24UNJF | .5625-24UNJEF | .748 | .728 | 5.99 | .498 | .503 | .047 |
| RFR9505-04-504 | .250 | .4375-20UNJF | .6250-24UNJEF | .810 | .790 | .662 | .558 | .566 | .047 |
| RFR9506-05-504 | .312 | .5000-20UNJF | .6875-24UNJEF | .867 | .852 | .724 | .623 | .628 | .047 |
| RFR9508-06-504 | .375 | .5625-18UNJF | .9375-20UNJEF | 1.060 | 1.040 | .954 | .857 | .858 | .047 |
| RFR9510-08-504 | .500 | .7500-16UNJF | 1.0625-18UNJEF | 1.185 | 1.165 | 1.079 | .973 | .983 | .057 |
| RFR9512-10-504 | .625 | .8750-14UNJF | 1.2500-18UNJEF | 1.435 | 1.415 | 1.267 | 1.161 | 1.171 | .072 |
| RFR9516-12-504 | .750 | 1.0625-12UNJ | 1.5000-18UNJEF | 1.685 | 1.665 | 1.517 | 1.411 | 1.421 | .072 |
| RFR9520-16-504 | 1.000 | 1.3125-12UNJ | 1.8750-16UNJ | 2.020 | 1.978 | 1.918 | 1.775 | 1.760 | .072 |
| ROSAN PART NUMBER | J ±.010 | K +.010 -.005 | L ±.015 | M RAD |
| RFR9503-02-504 | .729 | .082 | .364 | .030-.045 |
| RFR9504-03-504 | .777 | .082 | .364 | .030-.045 |
| RFR9505-04-504 | .802 | .082 | .364 | .030-.045 |
| RFR9506-05-504 | .830 | .082 | .364 | .030-.045 |
| RFR9508-06-504 | .955 | .082 | .364 | .030-.045 |
| RFR9510-08-504 | 1.051 | .082 | .374 | .030-.045 |
| RFR9512-10-504 | 1.185 | .082 | .389 | .030-.045 |
| RFR9516-12-504 | 1.185 | .082 | .389 | .030-.045 |
| RFR9520-16-504 | 1.237 | .122 | .389 | .045-.065 |
NOTES:
1. MATERIAL: A286 Cres per AMS5731, AMS5732, AMS5734 or These parts are also available in other materials. Refer to
page 11, Table II.
2. HEAT TREAT: 130 KSI UTS min.
3. FINISH: Passivate per QQ-P-35.
[4] Insert internal configuration and “D” diameter per MS33649.
[5] Sealing surface: No visible defects. To be protected for shipment.
6. Break sharp edges .003-.015, except serration.
7. Fluorescent penetrant inspection per AMS2645 and AS3071.
8. All machined surfaces shall be smooth to 125 microinches Ra, serration 250 microinches Ra, and sealing surfaces 63
microinches Ra per ANSI/ASME B46.1.
9. Identification per AS478 class 35D. Manufacturer’s name, trademark or CAGE CODE, part number and lot number.