1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there
2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2015 SAE International All rights reserved. No part of this p
3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497
4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS4202A AEROSPACE STANDARD AS4202 REV. A Issued 1992-06 Revised 1998-01 Reaffirme
5、d 2015-06 Superseding AS4202 Adapter - Port Connection, Ring Locked Design, Installation and Removal of 8000 psi Systems RATIONALE AS4202A has been reaffirmed to comply with the SAE five-year review policy. 1. SCOPE:1.1 This SAE Aerospace Standard (AS) provides the essential minimum design, installa
6、tion and removal standard for AS4200 adapter and is applicable when specified on engineering drawings, or in procurement documents.2. REFERENCES:The following publications form a part of this document to the extent specified herein. The latest issue of SAE publications shall apply. The applicable is
7、sue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations
8、unless a specific exemption has been obtained.2.1 SAE Publications:Available from SAE, 400 Commonwealth Drive, Warrendale, PA 15096-0001.AS568 Aerospace Size Standard for O-ringsAS4200 Adapter Assembly - Port Connection Ring Locked to Beam Seal Fitting 8000 psiAS4201 Port - Ring Locked Fluid Connect
9、ion Type 8000 psi Standard Dimensions For2.2 U.S. Government Publications:Available from DODSSP, Subscription Services Desk, Building 4D, 700 Robbins Avenue, Philadelphia, PA 19111-5094.TT-P-1757 Primer Coating, Zinc Chromate, Low-Moisture-SensitivitySAE INTERNATIONAL AS4202A Page 2 of 10 3. GENERAL
10、 DESIGN INFORMATION:3.1 These adapters provide a semi-permanent male fitting for use in 8000 psi (24,000 psi burst pressure) fluid systems compatible with titanium, at -65 to +450 F temperature range.3.2 Adapters per AS4200 and installed per this document into ports per AS4201 shall have a stand-off
11、 dimension “P” per Figure 1 and Table 1.3.3 O-ring size per Table 1 and per AS568 must be used. The O-ring compound shall be specified by the using design activity and shall be selected based on system fluid and temperature.3.4 The lockring is driven into the mating port serrations after the adapter
12、 has been torqued. This prevents the adapter from rotating in the port during coupling nut assembly and disassembly and also eliminates the necessity of lock wiring the adapter. Only one wrench is required to install or remove the coupling nut.3.5 Adapter removal is accomplished by lifting the lockr
13、ing out of the port using a removal tool per Table 2.4. DESIGN REQUIREMENTS:4.1 Minimum data to be specified on engineering drawing or specification.4.1.1 Port diameter to be at least the minimum specified in AS4201.4.1.2 Location of port.4.1.3 Specific port size per AS4201. If tap drill depth is no
14、t through, then specify control dimensions.4.1.4 Specific adapter size per AS4200.4.1.5 Specific O-ring size and compound (see 3.3).4.1.6 Install adapter per this document.4.1.7 Corrosion protection is specified in 5.2.4. If materials or fluids require primer different from zinc chromate primer or i
15、f an additional sealant is required, so specify.4.1.8 Pressure testing of individual units is specified in 6.1. Testing other than that shown shall be specified.4.1.9 The port material for 8000 psi systems must have a minimum shear strength of 20 ksi to resist the axial load being generated from 24,
16、000 psi burst pressure (based on thread minimum shear engagement area shown in Table 3).SAE INTERNATIONAL AS4202A Page 3 of 10 FIGURE 1 - Installed AdapterTABLE 1 - Installation DimensionsAS4201PortDashNumberAS4200AdapterDashNumberO-RingSizeSee 3.3P/1/.020RMax02 02 AS568-007 .331 .12403 03 AS568-008
17、 .362 .12404 04 AS568-010 .404 .12405 05 AS568-011 .404 .12406 06 AS568-012 .430 .13007 07 AS568-013 .443 .13008 08 AS568-014 .443 .13009 09 AS568-015 .507 .13010 10 AS568-016 .507 .13011 11 AS568-017 .557 .140/1/ “P” and “R” dimensions are for design purposes only and represent final stand-off dime
18、nsions. Do not use as installation dimensions.SAE INTERNATIONAL AS4202A Page 4 of 10 TABLE 2 - ToolingAS4200AdapterDashNumberPortingToolNumberBasicBroachToolNumberO-ringToolNumberCombinationWrenchand DriveToolInstallationTorquelbf.inRemovalTool02 RPT02 RFOPB5002 ORT216 RF5002DW 21- 36 RF02LPDE03 RPT
19、03 RFOPB5003 ORT250 RF5003DW 45 - 60 RF03LPDE04 RPT04 RFOPB5004 ORT312 RF5004DW 70-100 RF04LPDE05 RPT05 RFOPB5005 ORT375 RF5005DW 140-170 RF05LPDE06 RPT06 RFOPB5006 ORT437 RF6006DW 210-270 RF06LPDE07 RPT07 RFOPB5007 ORT500 RF5007DW 320-400 RF07LPDE08 RPT08 RFOPB5008 ORT562 RF5008DW 430-540 RF08LPDE0
20、9 RPT09 RFOPB5009 ORT625 RF5009DW 560-660 RF09LPDE10 RPT10 RFOPB5010 ORT687 RF5010DW 625-750 RF10LPDE11 RPT11 RFOPB5011 ORT750 RF5011DW 700-820 RF11LPDENOTE: These adapters require special tooling for proper installation. Tooling is available from Rosan Products, Santa Ana, CA - CAGE CODE 83324.SAE
21、INTERNATIONAL AS4202A Page 5 of 10 TABLE 3 - Axial LoadPortNumber/1/TotalThreadMinimumShearEngagementAreain2Port“D” MaxPerAS4201in/2/Axial Loadon AdapterDeveloped by24,000 psiBurstPressurelbfAS4201-02 .0618 .256 1235AS4201-03 .0782 .288 1563AS4201-04 .1096 .341 2192AS4201-05 .1531 .403 3061AS4201-06
22、 .2047 .466 4093AS4201-07 .2598 .525 5195AS4201-08 .3214 .584 6429AS4201-09 .4130 .662 8261AS4201-10 .4981 .727 9963AS4201-11 .5661 .775 11,322/1/ Minimum shear engagement area shown is the assembled dimensional value for the overall engaged area of mating port threads (port threads full depth of ad
23、apter). It does not represent a dimension of either of the members in an unassembled condition./2/ Axial load = Area x Burst Pressure = x 24,000D24-SAE INTERNATIONAL AS4202A Page 6 of 10 5. INSTALLATION OF ADAPTER AS4200 INTO PORT AS4201:5.1 O-ring Installation:5.1.1 Place the O-ring tool (per Table
24、 2) over the small thread of the fitting. Submerge the adapter,O-ring tool and O-ring in the fluid to be used in the working system, or a lubricant compatible with the system fluid and all components. Slide the O-ring over the O-ring tool and onto the fitting. Be sure that the O-ring is not twisted
25、and is properly seated in the groove of the fitting. See Figure 2.FIGURE 2 - O-ring InstallationSAE INTERNATIONAL AS4202A Page 7 of 10 5.1.2 Remove the O-ring tool.5.2 Install adapter assembly into port.5.2.1 Lubricate the internal surfaces of the port and the entire adapter assembly using the same
26、fluid or lubricant as specified in 5.1.1. Scratches, dings or rough spots are not allowed in O-ring contact area on the adapter or in the port.5.2.2 Insert the smaller thread of the adapter into port by hand using a clockwise rotation until the adapter is seated. To avoid possible O-ring damage, the
27、 adapter should not be rotated in a counterclockwise direction.5.2.3 Using the applicable combination wrench and drive tool in Table 2, engage the serrations of the tool with the external serrations of the lockring per Figure 3. Place a torque wrench of the proper size over the hex of the wrench and
28、 apply a torque equal to the minimum value specified in Table 2. Note the relationship of the lockring serrations with respect to the prebroached serrations in the port. If they match, proceed to 5.2.4. If the lockring serrations do not match the prebroached serrations in the port, continue to slowl
29、y torque the adapter toward the maximum value allowed in Table 2 until the serrations match. This will normally take between 3 and 8 of turning, the maximum value need not be reached if the serrations align themselves prior to that value. Do not exceed maximum torque values.FIGURE 3 - Torquing Adapt
30、er AssemblySAE INTERNATIONAL AS4202A Page 8 of 10 5.2.4 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 serrations in the port
31、 when lockring is installed.NOTE: Using design activity may specify another primer in place of, or in addition to, zinc chromate (see 4.1.7).5.2.5 While the zinc chromate (or other primer) applied per 5.2.4 is still wet, install the lockring by rotating the threaded end of the combination wrench and
32、 drive tool clockwise onto the adapter assembly until it touches the lockring. Using an open end or socket wrench on the tool, turn the tool in a clockwise direction until it bottoms on the port surface as shown in Figure 4. Visually observe that the tool has bottomed.CAUTION: Any sudden increase in
33、 torque prior to bottoming may indicate that the lockring serrations and the port serrations are not aligned. If this occurs, remove wrench and drive tool by turning counterclockwise. Lift the lockring per 7.2. Tighten adapter clockwise per 5.2.3 until serrations in port and the external serrations
34、on the lockring are aligned. Re-install lockring and remove excess primer from surface of port and lockring.FIGURE 4 - Lockring InstallationSAE INTERNATIONAL AS4202A Page 9 of 10 6. PRESSURE TESTING:6.1 A pressure test of unit may be conducted at this point. Place a pressure cap on the adapter. Pres
35、surize the unit to 1.5 times the operating pressure for 3 min. There shall be zero leakage.NOTE: The using design activity may require testing other than that shown. See 4.1.8.7. REMOVAL OF ADAPTER:7.1 If an additional sealant has been used to cover the lockring, carefully remove sealant to expose l
36、ockring.7.2 Lockring Retraction:7.2.1 Select the proper size removal tool from Table 2.7.2.2 Spread the puller halves apart by retractiing the sleeve from the tool until the pin bottoms in the grooves of the sleeve per Figure 5. Holding the puller halves apart, place tool over protruding adapter so
37、that the nylon pad rests on the top surface of the adapter. 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 gr
38、oove.7.2.3 Place wrench on the bolt head of the removal tool and turn in a clockwise direction while holding the sleeve with the 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 t
39、urning may be stopped. Remove the tool from the adapter by loosening the bolt and lifting the sleeve to free the puller halves.7.3 Remove adapter from port.7.3.1 Select the proper size combination wrench and drive tool from Table 2. Engage the serrations of the wrench with those of the lockring. Usi
40、ng an open end or socket wrench over hex on wrench, turn in a counterclockwise direction to disengage the adapter from the port. Plug the port minor diameter when cleaning out the cavity to avoid contamination of the fluid system.8. REINSTALLATION OF ADAPTER:8.1 Reinstall the adapter per Section 5 u
41、sing a new O-ring per Table 1 and 3.3.SAE INTERNATIONAL AS4202A Page 10 of 10 FIGURE 5 - Lockring Retraction9. NOTES:9.1 All dimensions are in inches.9.2 Key Words:Aerospace, adapters, hydraulic, installation, removalPREPARED BY SAE SUBCOMMITTEE G-3B, AEROSPACE FITTING OFCOMMITTEE G-3, AEROSPACE COUPLINGS, FITTINGS, HOSE, AND TUBING ASSEMBLIES
