Additional Procedures

Transcription

1 Additional Procedures Reusing an Original Fitting Reusing a Bracket Fitting Installing Protective and Decorative Hose Guards Converting an Inverted Seat to a Drill Point Seat Using Universal Fittings Bending a Banjo Fitting Keep for future use.

2 Reusing an Original Fitting Tools Required Equipment required when reusing an original fitting: Small workbench with vice. Bench grinder or belt sander. Wire buff or blaster. MAPP Gas torch or Oxy welding equipment. Drill press with vice (or hand drill) Optional Equipment: Small metal lathe Compressed Air Loose Tools / Consumables: Hand tools Spray paint BQ1010 drill bit 45% + silver content brazing rods (BQ33) or similar. If you do not have the correct fitting in stock, you will need to reuse the customer s original fitting. This is achieved by the following procedures. 2

3 Types of Life Savers for Reusing the Original Fitting HF01 - Used for fittings with bulky material This also can be used when making 3/16 tube fittings. HF05 - Used for center support fittings. HF26 - Used for fittings with bulky material. This also can be used when making 1/4 tube fittings. HF27 - Used for tube style banjo fittings. HF120 - Used for solid shank banjo fittings. Removing the Original Crimp Shell Before cutting the original shell off, note orientation and ensure there is enough material for you to countersink the fitting for the lifesaver using HF01 or HF26. You may have to cut the original shell off up to 5mm (3/16 ) from fitting head. Using a hacksaw, or cutoff tool, cut off the original crimp shell approximately 5/8 (16mm) from crimped end of fitting or under fitting head if applicable. Wear safety goggles during this process. Preparing the Original Fitting Ensure fitting head is ground flat and square. Fittings to be brazed need to be clean for maximum adhesion. 3

4 Countersinking the Original Fitting This is necessary to give the fitting more strength. Set up the fitting to be countersunk in the machine vice and square to the drill bit. Only use a (10mm) drill bit with a specially ground shallow drill point (0.135 ) (BQ1010). Example of STD and Shallow Point drill bits The drill point on a standard drill bit can protrude too deep into the fitting head and allow damage to occur. Drill hole to a maximum depth of.137 (3.5mm). Drill should be run at 300 to 500 rpm. Counter sinking the fitting head Fitting head counter sunk slightly more than 3mm The following process would be required when using the HF01 and HF26 life savers. It will be necessary for the shoulder of the new crimp shell to sit flush against the fitting head; otherwise, the silver braze can flow down into the fluid port of the fitting and block the passage. If this happens, you will need to drill out the blockage with a.085 (2.2mm) drill bit. Fitting the lifesaver to the old fitting Ensure the lifesaver shoulder is against the fitting 4

5 Brazing New Crimp Shell to Reused Fitting This can be done using oxy/acetylene or MAPP Gas. Set oxy pressure to 5 10 psi (50 Kpa). Set acetylene pressure to 5 10 psi (50 Kpa). These pressure adjustments are done with the appropriate hand piece valve open. It is recommended that either a No. 6 or No. 8 welding tip be used. Open acetylene hand piece valve slightly and ignite the acetylene. Adjust valve until acetylene flame just stops smoking. Use a low temperature flame. Slowly open oxy valve and adjust flame to a small blue tip. Only a soft flame is required. Apply heat to fitting joint allowing most of the heat to be directed at the bulkiest section. Wear safety goggles during this process. Once sufficient heat is applied, bring in the silver brazing stick to the joint and allow melting and fusing together. Keep wiping the silver braze stick around the joint, applying any further heat only as necessary. It is recommended to use the prefluxed silver braze rods #BQ33 (cadmium free). 5

6 Avoid too much heat. Silver brazing is a low temperature brazing method, and applying too much heat can cause blisters and holes in the weld. Do not allow the fitting to become glowing red hot, as the fitting will oxidize and the braze won t stick. A MAPP Gas torch is an alternative to oxygen / acetylene. Refer to the instruction manual supplied with the MAPP Gas torch for the correct operation. The brazing technique is the same as for oxygen / acetylene. Pre-fluxed silver brazing rods (BQ33) are the easiest to use for this operation. Wear safety goggles during this process. Cleaning and Inspecting Fitting after Brazing Clean fitting by blasting or buffing and inspect for any blockages and flaws in the weld. Re-braze if you suspect an area may have been missed or if any of the joints have holes. Clean and inspect threads and grind off any surplus braze if necessary. 6

7 Installing a Lifesaver to a Center Support The only purpose for this fitting is to support the brake hose. It is not crucial to countersink the lifesaver into the reused center support. However, countersinking the fitting will assist with centralizing the (HF05) lifesaver. Cut the old crimp shell from the center support. Ensure the surface is square and clean and then silver braze with a new shell (HF05). Cut off the original crimp shell Square the face of the orignial center support Original center support with new shell fitted Reusing a Tube Style Banjo When reusing a tube style banjo the quickest way is to use the HF27 lifesaver. Just follow the pictorial: Cut off the original shell Install new shell to tube 7 Braze new shell on banjo tube

8 Reusing the 7mm Shank Style Banjo When reusing a tube style banjo the quickest way is to use the HF120 lifesaver. Just follow the pictorial: Cut off the original shell Install new shell to tube Braze new shell on banjo tube Applying Protective Coating If a fitting has been brazed, it will be necessary to apply a protective coating to the fitting to prevent rusting and for product presentation. It is recommended that you use Rustoleum quick drying spray paint. 8

9 Installing Protective and Decorative Hose Guards Spring Hose Guard Slide protective cover (BQ11 or BQ202) over the hose before installing the last fitting. This spring guard can be cut to length if too long or stretched if slightly too short. Two spring guards can be used on extralong hoses. Slide spring guard out of the way when installing crimp setting tool before crimping. BQ11 BQ202 High Temperature Sleeve Some applications require a high temperature protective sleeve placed over the hose to protect the hose from high temperature components. In these situations install the BQ312 high temperature sleeve over the hose before crimping on the end fittings. Stiffening and Abrasion Protection BQ200 rubber hose support is a heavy walled hose used to stiffen joints where excessive bending is applicable. BQ201 protective rubber sleeve is used for extra abrasion protection when necessary. 9

10 Converting an Inverted Seat to a Drill Point Seat This will be required when you have female fittings with an inverted seat in stock but need a drill point seat instead. 1. Place fitting squarely in a machine vice. 2. Select a drill bit that fits neatly inside thread. 3. Ensure cutting angel is approximately 118 o 125 o (standard drill bit angle is 118 o ). 4. Run drill at a maximum of 300 rpm. 5. Make sure fitting is very secured so there is no chatter. 6. Align fitting to center of drill bit and insert the drill bit into the female fitting. 7. Gently take small cuts until the desired finish and depth is achieved. For smooth finish add lubrication. 10

11 Reusing a Bracket Fitting Most bracketed fittings have a common fitting that the bracket is attached to. You will be required to reuse the existing bracket if you don t have the bracket in stock. 1. Following is the method used to remove the bracket from the original fitting and to install the bracket to the new fitting. 1. Clamp original fitting in vice Grind off peened over excess. 3. Tap fitting through bracket. Straighten if necessary and clean. Original bracket is ready for installation. 4. Place bracket onto fitting AFTER CRIMPING and secure with retaining screws (BQ71). 3. Ensure fitting is aligned to the correct position before crimping

12 Using Universal Fittings Banjo Fittings (HFB22, HFB23) These two universal banjo fittings are designed to be used with the HFIF06 female fitting to avoid the brazing process. Simply cut to length and flare the tube using a BQ2578 tube nut. Then bend to shape and attached to the HFIF06 fitting. Tube Style Fittings (HF02, HF03) These semi-finished fittings are usually required for hydraulic clutch hoses where there is a proliferation of similar ends. This allows you to satisfy customer requests. 1. Determine the length of tube and trim to size. Ensure you allow room for the flaring tool die and tube nut length. 2. Ensure tube end is square and free from rough edges. Buffing the end of the tube with a wire buff will also give you the desired finish. 3. Install correct tube nut onto the tube and then flare the end of the tube. 4. Bend to shape, if required. 12

13 Bending a Banjo Fitting Ensure hole is clear and there are no burrs or metal filings before bending. The special tool kit that is available (BQ22A and BQ22B) is ideal for this task. Most banjo fittings with a tube shank can be bent to at least 45 o. BQ22A End A is for bending banjo s up. End B is for inserting into the end of the crimp shell to bend the banjo sideways. BQ22B Bending a Banjo Fitting UP BQ2001W Constriction Gauge Checking the fitting for burrs and blockages. Prepare to bend the banjo fitting. Banjo fitting bent to the required angle. 13

14 Bending a Banjo Fitting SIDEWAYS Prepare to bend the banjo fitting. Banjo fitting bent to the required angle. Use BQ2033 Angle Gauge to check banjo angles. Bent Banjo fitting ready for assembly. 14