Eaton E-Z Clip System Assembly Instructions

Transcription

1 Eaton E-Z Clip System Assembly Instructions

2 E-Z Clip System Eaton s E-Z Clip System is designed for assembly with Eaton multi-refrigerant hose GH134. It s engineered hose and fitting connection exceeds SAE J2064 and has been vibration and impulse tested. The benefits of E-Z Clip are virtually endless: No guess work No leaking crimps No power supply needed As easy to use as a pair of pliers Easy to use in confined areas Assembly Materials Checklist: Pliers (FT1357) Guillotine blade (T-135 or FT1356) or equivalent cutting tool Refrigerant oil compatible with refrigeration or A/C system GH134 multi-refrigerant hose Nipple assembly* Appropriately sized clips and cage *NOTE: The two black O-Rings on the nipple assembly are of a specific rubber compound and size. If replaced, part number IF40106 size must be used to ensure performance. 2 EATON E-Z Clip Instructions E-HOAC-II001-E March 2013

3 E-Z Clip System Components are Simple to Identify, Order and Use Ordering Information Aeroquip Weatherhead Hose Hose Clips 2 per Fitting Cage 1 per Fitting GH134-6 GH134-6W 1F C 1F C GH134-8 GH134-8W 1F C 1F C GH GH134-10W 1F C 1F C GH GH134-12W 1F C 1F C Identification Guide Aeroquip Weatherhead Hose Hose Clips Marking Cage Marking GH134-6 GH134-6W and 150 GH134-8 GH134-8W and 175 GH GH134-10W and 200 GH GH134-12W and 245 (hose) (clips) (cage) (cage groove) EATON E-Z Clip Instructions E-HOAC-II001-E March

4 E-Z Clip System Assembly Instructions Step 1: Cut the hose. Cut the hose to proper length with an appropriate cutting tool. The Eaton hand-held hose cutter has been specifically designed for cutting all non-wire reinforced hose, such as GH134 multi-refrigerant hose. Be sure the cut is made square to the hose length. Step 2: Slip on two clips. Install two proper-sized clips onto the cut end of the hose. Orientation of the clips does not affect the performance of the connection. However, for ease of assembly Eaton recommends both clips have the same orientation. NOTE: Failure to slide the clips over the hose at this time will require the clips to be stretched over the hose or fitting later. This may permanently damage the clip. Step 3: Oil the nipple. Lubricate the nipple with a generous amount of the refrigeration or A/C system s compressor lubricating oil. This MUST be done to lower the force of nipple insertion. 4 EATON E-Z Clip Instructions E-HOAC-II001-E March 2013

5 E-Z Clip System Assembly Instructions Step 4: Insert the nipple into the hose. To ensure that the nipple is fully inserted, check the gap between the cut end of the hose and the shoulder on the nipple. Care should be taken to avoid kinking or other damage to the hose during nipple insertion. NOTE: Be sure to wipe excess oil from the nipple and hose. Step 5: Snap on the cage. Snap the cage into the groove on the nipple. The arms should extend over the hose length. When the cage has been correctly installed in the cage groove, the cage will be able to rotate in the groove. This step MUST be performed to ensure: 1. The clips will be located over the O-Rings on the nipple. 2. The connection will be compatible with the connection s pressure rating. Step 6: Slide the clips. Slide the clips over the cage arms and into the channels on each arm. EATON E-Z Clip Instructions E-HOAC-II001-E March

6 E-Z Clip System Assembly Instructions Step 7: Close the Clips. Use the FT1357 pliers to close the clips. The pliers should be positioned squarely on the clip connection points and should remain square during the closing of the clip. correct The nose of the pliers should be firmly seated under the assembly bump and lock latch. incorrect For easiest assembly, the clasp should be closed between the cage arms. 6 EATON E-Z Clip Instructions E-HOAC-II001-E March 2013

7 Note If the pliers are not kept square during closing of the clip, the clasp may have an offset. Use the pliers to correct the clasp alignment. E-Z Clip components should not be reused. incorrect correct Caution: Failure to follow these assembly instructions and/or the use of Eaton hose with fittings supplied by other manufacturers may result in unreliable and unsafe hose assemblies, which may result in sudden or unintended escape of refrigerant gases. Personal injury and/or violations of the EPA regulations may occur as a consequence. Eaton recommends adherence to all guidelines, including EPA guidelines, concerning the services of refrigerant systems. EATON E-Z Clip Instructions E-HOAC-II001-E March

8 Aluminum E-Z Clip Lifesaver Instructions Introduction The Aluminum E-Z Clip Lifesaver System The Aluminum E-Z Clip Lifesaver system is designed to rework failed OEM aluminum air conditioning tubing and hose assembles in sizes 10mm to 18mm (-6 to -12). The system allows the installer to reuse unique OEM terminal connections while replacing the failed OEM hose, with a braze-on E-Z Clip Lifesaver nipple, GH134 veneer hose and the E-Z Clip attachment system. Note: The E-Z Clip System can only be used with Aeroquip or Weatherhead GH134 hose and metric aluminum tubing. Figures 1 and 2 illustrate the E-Z Clip Lifesaver concept: Before Figure 1. Failed Hose Assembly. Note crimp fittings. After Figure 2. Completed hose assembly. Note E-Z Clip Fittings. There are three (3) main advantages to using the Aluminum E-Z Clip System for A/C repairs. First, the technician avoids the cost and lead-time associated with ordering OEM air conditioning lines, and secondly, the system provides the end-user with a proven, high-quality replacement part. Finally, the E-Z Clip components are assembled by hand, using a patented assembly system that provides a suitable replacement connection. If you are unfamiliar with the Aluminum E-Z Clip system, be certain to review this instruction booklet and the E-Z Clip System Assembly Instructions (Doc. No. A-HC-T E or W-HOAC-T1001-S) before beginning any work on the hoses. The system is nonetheless intended for professional A/C service personnel who have experience with torch brazing aluminum. If you lack the proper skills and certification, then it is best to leave this type of work for specialists. Before After

9 Aluminum E-Z Clip Lifesaver Instructions Step 1 Evaluating the Failed Assembly Preparation Remove the failed A/C assembly from the vehicle. Remove all deposits from the tubing and hose with a stiff nylon brush and suitable solvent. Note all failure locations. Be certain to inspect the tubing carefully since aluminum can corrode, especially under steel brackets. Next, add a scribe line on the tube, approximately 5mm (3/16 inch) from where the hose interfaces with the tube assembly. Add a second scribe line on the opposite tube assembly. Record the distance between the primary scribe lines. This is the overall length which will be used in Step 7. For a hose assembly containing bent tubes on both ends, add a secondary scribe line perpendicular to the initial scribe line at one end of the tube (see Figure 3). Place a second perpendicular scribe mark in line with the first line at the other end of the hose assembly. This will assist in determining the phase angle needed in final assembly in Step 7. Next, measure and record the hose and tube size. Typically the hose inside diameter (ID) is labeled on the hose. If this is not the case, then the hose must be cut in half and the hose ID directly measured (see Figure 4). The tube outside diameter (OD) must also be measured according to Figure 4, however, don t cut the tube at this time. Calipers are the preferred method of measurement for both components. Finally, confirm whether the OEM has used standard tube-sized fittings for the hose assembly by referencing the below chart. For example, a standard size 8 hose assembly will have a metric tube OD size of 12mm with a corresponding hose ID of 11mm. TABLE 1 STANDARD CONFIGURATIONS Size * Tube OD Hose ID mm (in) mm (in) (.39) 8 (.32) (.47) 11 (.42) (.63) 13 (.51) (.71) 16 (.64) *Note: This (-) size label will be referenced throughout the instructions. Step 2 Cutting the Tube Assembly Cut one side of the tubing with a tube cutter or hacksaw along the primary scribe line. Attempt to keep as much tubing as possible in case rework is necessary (see Rework section, page 4). If using a hacksaw, attempt to create a square cut. Also, be certain that there is at least 7mm (1/4 inch) of straight, undistorted tubing between the cut and the next tube bend. This is important since this length is needed for attaching the nipple. Repeat the above procedure for the opposite tube assembly. Step 3 Preparing the Tube for Brazing Remove any burrs from the cut tube. Avoid removing excess material on the outside of the tube as this could compromise the braze joint integrity. Attempt to create a flat and square surface at the cut. Regardless of the cutting tool used, a round file Figure 3 - Adding Scribe Lines will be needed in order to remove internal burrs. Next, clean the outside of the tube assembly with a residue-free degreasing agent. Finally, blow out all tube assemblies with compressed air. Avoid exposing the tube to oil and other contaminates as they tend to reduce the effectiveness of the flux and could lead to leaks at the braze joint. Step 4 Part Selection Standard Sizes Nipple and Braze Ring Use the size designation found in Step 1 and Figure 4 to determine the proper nipple and braze ring. TABLE 2 Braze Ring Hose Part Number Size GA GA GA GA Secondary Scribe Line Initial Scribe Line Figure 4 - Hose and Tube Measurement Hose Tube

10 Aluminum E-Z Clip Lifesaver Instructions Step 4 Part Selection (continued) Hose Match the failed hose ID (Step 1) to the replacement hose. Table 3 provides characteristics needed to match the hoses: Table 3. HOSE SELECTION. Aeroquip or ID ID Size Weatherhead Hose (inch) (mm) -6 GH / GH / GH / GH /8 16 Figure 5 - Braze ring installation Step 5 Brazing the nipple to the tube Figure 6 - Adding flux Aluminum Brazing Tips Unlike steel brazing, aluminum brazing occurs just below the melting point of the aluminum-base metal. As previously noted on page 1, if you are not an experienced aluminum brazer, defer this work to the Auto Service Industry Expert. Brazing Procedures using Braze Rings Place the tube assembly into a vise or other suitable device (be certain not to over-tighten the jaws). As shown in Figure 5, insert the braze ring into the nipple counterbore, making sure the ring seats against the bottom of the counterbore. Using a brush, add aluminum brazing flux (corrosive type) to both the inside and outside of the nipple counterbore. Next add the flux to the outside of the tube as shown in Figure 6. Finally insert the nipple onto the cut tube. The nipple should fit loosely over the tube. Use a torch according to the manufacturer s instructions. Attempt to heat the nipple and tube so that both regions reach brazing temperature simultaneously. Bear in mind that the counterbore area of the nipple will require more heat than the tube (see Figure 7). As the ring melts, the nipple should fall on the tube and a fillet of brazing alloy should appear around the tube (see Figure 7). The nipple may cock as the ring melts. This means the ring is not completely melted and heat must be applied to the canted region. Be sure to remove the flame as soon as a uniform braze fillet appears and the nipple is straight. Allow the nipple and tube assembly to cool for 5 to 10 seconds. Then, while wearing gloves and using pliers, place the fitting into a clean container of water. Be sure that the fitting is completely immersed in water. Caution! Steam may be directed through the fitting ends causing severe burns! Once the unit is sufficiently cool enough to handle, use a stiff nylon brush or scratch pad to remove all flux and other debris. Flux removal is much easier if the assembly is still warm. Removal is essential since flux left on the tube/nipple will eventually corrode the aluminum and could lead to potential A/C system failure. Braze Joint Inspection: First, lightly bend and twist the nipple and tubing by hand. A poor quality braze joint will result in breakage. Second, inspect the braze joint. A successful braze joint will display a uniform fillet without deep voids. Figure 7 - Brazing Figure 8 - Completed tube assemblies

11 Rework If the fillet area contains deep voids, then it should be reworked. To rework, clean the braze area with a scratch pad and water. Add more flux around the braze joint. Reheat to brazing temperature and attempt to create a uniform fillet. Additional braze alloy is unnecessary providing none was lost during the initial brazing process. Step 6 - Nipple O-ring Installation Select the proper nipple o-ring according to Table 5. Add a few drops of A/C system lubricant (e.g. PAG oil) to the o-rings (2). Install the first o-ring by pushing it over the cone-shaped portion of the nipple. The first o-ring assembly is complete when the o-ring snaps into the groove nearest the point of assembly. The second o-ring will slide over the first o-ring and will fit into the second groove. The completed o-ring assembly is shown in Figure 9 below: TABLE 5 O-RING AND NIPPLE CROSS-REFERENCE Size O-Ring Nipple -6 1F GW AL -8 1F GW AL -10 1F GW AL -12 1F GW AL If the o-rings were inadvertently installed prior to brazing, then these o-rings must be removed and any residue on the nipple must be cleaned with a suitable solvent. A smooth, debris free nipple surface is essential for proper sealing and a leak-free connection. Don t scratch the nipple surface during o-ring removal. Finally, replace the o-rings according to Table 5. Step 7 - Hose Assembly Fabrication Cut the GH134 hose approximately 150mm (6 inches) longer than the overall length calculated in Step 1. Install one reworked tube assembly onto the hose according to the E-Z Clip System Assembly Instructions (Doc. No. A-HC-T E). Determine the necessary phase angle (secondary scribe lines should line-up) of the remaining piece of tubing, and install the final tube assembly according the E-Z Clip System Assembly Instructions. Figure 9 - O-rings Only the o-rings supplied in the kit, part number FF13727 or o-ring part number 1F40106-size, can be used, along with the proper A/C system oil. Improper o-rings or improper lube of the o-ring, could result in refrigerant leakage and A/C system failure. Figure 9 - Finished tube assemblies with o-rings

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13 Materials Needed Eaton FF9075 silver braze rings or 1/16- inch diameter 45% silver alloy braze wire Water soluble flux Brazing outfit capable of +1200ºF (propane or mapp gas) Small files - rattail and flat Spray paint (quick drying) Water (to cool joint) Needle nose pliers Tape measure Emery paper Hacksaw Pliers Pair of diagonals (or other tool to cut silver wire) Residue-free degreasing agent Wire brush Existing hose socket for reusables Eaton crimp nipple/socket for crimp Tube Size O.D. Part Number (Inches) FF FF FF FF FF FF FF FF

14 Lifesaver Fittings Brazing and assembling Lifesaver reusable fittings is a simple process Eaton Lifesaver hose fittings are designed to simplify the replacement of failed hose lines which have unusual, steel end configurations, compound tubes, or thread styles. Refer to your master catalog for available sizes and hose configurations. The process involves removing the old configuration, silver brazing it to an unused Lifesaver nipple and assembling the fitting onto the hose in the usual manner. A few Lifesaver fittings, some bulk hose, the appropriate hand tools and accessories plus basic silver brazing equipment are all that is necessary to make up hose assemblies anywhere. Be sure to follow all applicable safety procedures when brazing Lifesaver fittings. STEP 2 Cutting Using a hacksaw or tubing cutter, cut the tube at the juncture of the tube and the hose socket. It s important to cut the tube so there is at least 1/4 inch length of straight, un-bent tubing in order for it to properly enter into the counter bore of the Lifesaver nipple. STEP 1 Measuring Measure and record the length of the old assembly. For elbow assemblies, scribe a very light mark 5/16 inch or more from juncture of the tube and the existing hose socket. The distance from the scribe mark to the end of the other fitting should be recorded as the fabrication length. In the case of double elbows, make the scribe marks in line with one another so that you can duplicate the phase angle later. Record the distance between the two scribe marks as the fabrication length. STEP 3 Preparing the tube for brazing Avoid touching the tube, oily or greasy surfaces tend to repel the flux and silver material leaving voids and inclusions. Clean the tube thoroughly using a residuefree degreasing agent, or hot caustic soda. Using a flat file, remove the burrs on the outside of the tube and use a rattail file to remove the burrs on the inside. Polish the tube end on the outside with an emery cloth to remove the plating down to the base metal. It is important to remove oil and grease first because abrasives tend to scrub the oil into the surface and/or impregnate it with a fine abrasive powder, resulting in further contamination. Remem

15 Lifesaver Fittings (cont...) ber, attempting to braze contaminated or improperly cleaned surfaces will generally result in an unsatisfactory joint. STEP 5 Fluxing Cover the counterbore, ring, outer hex and threads of the Lifesaver nipple and the outside of the tube with water soluble flux. STEP 4 Preparing the Lifesaver fitting for brazing Clean the nipple and tube end thoroughly. Place the tube into the counterbore (it should fit freely into it). Measure the diameter of the counterbore to determine the braze ring size needed. At this point, you have the option of selecting a readymade Eaton braze ring or making a ring for the application from bulk silver braze wire. To assemble, simply place the appropriate size Eaton FF9075 braze ring into the counterbore of the Lifesaver nipple. To make a braze ring, multiply the diameter of the counterbore by 3 to determine the length of silver wire needed. For example, if the counter-bore diameter measures 3/4 of an inch, a 2¼ inch length of wire would be needed (3/4 X 3 = 9/4 or 2¼ ) Now cut off a piece of sliver wire just short of 2¼ inches, so it is about 2 3 / 16 inches long. Using needle nose pliers, form the wire into a ring and, after wiping it off, place the ring into the counterbore of the Lifesaver nipple. STEP 6 Brazing Place the tube assembly into a vise. Place the nipple with the installed braze ring over the tube. Light the brazing torch and adjust the flame so that the base is blue with orange feather-like-flicks at the end. Try to heat both the nipple and the tube uniformly so they both reach the brazing temperature at the same time. Don t overheat the thin section. As the temperature increases, the flux will undergo several changes: At 212ºF or (100ºC) the water boils off. At 600ºF the flux becomes white puffyand starts to work (snow balling). At 800ºF it lays against the surface and has a milky appearance. At 1100ºF it is completely clear and active and has the appearance of water. At this point, a bright metal surface will appear underneath. The silver wire melts at 1125ºF (600ºC) and flows at 1145ºF (620ºC).

16 Lifesaver Fittings (cont...) CAUTION! Steam may be directed through the fitting ends. To prevent burns, handle the fitting carefully. Hot water will facilitate flux removal. CAUTION! Never heat the parts to a bright red color. When the silver alloy melts, the flux will draw it throughout the joint and a small fillet of silver alloy will appear around the tube. When this happens the braze is completed. Remove the heat source and allow the fitting to cool for five to ten seconds. Using pliers, place the fitting into water until it completely cools. STEP 8 Hose assembly or Shoulder To determine the required amount of new hose, measure the distance from the scribe mark on the tube (refer to step 1) to the shoulder hex of the Lifesaver nipple. Add this measurement to the Lifesaver D dimension (cut off dimension) found in the Fittings section of the Eaton Master Catalog. For each Lifesaver fitting, subtract this sum from the fabrication length previously recorded. Cut the hose to this length and install the fitting. Align the scribe marks to establish the phase angle. Spray paint brazed joints to prevent rusting. STEP 7 Removing Flux It is necessary to remove residual flux from the area since it is corrosive and presents an unclean appearance and condition. Simply rub the surface using hot water and a wire brush. The water should be at least 120ºF or hotter to be truly effective inside and out. Looking for dependable performance fuel system parts? Rely on Eaton for quality and long-lasting products.