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Fitting sizes are identified generally as: 6, 8, 10, 12, 14 and 16. These numbers come from 6/16”, 8/16”, 10/16”, and 12/16” which generally identify the tube diameter at the point that it passes through the attached threaded nut. An illustration of this measurement and a chart of sizes is shown below:
Fitting Sizes
TYPE OF FITTING ....................................................................PAGEPAD MANIFOLD ...........................................................................431QUICK DISCONNECT ..........................................................403, 417REDUCED DIAMETER .................................................................404REPAIR FITTINGS (Weld-On) .....................................................421RETROFIT PORTS .......................................................................434SERVICE VALVES .......................................................................435SHRADER PORTS / ADAPTERS .................................................434SPLICERS (Beadlock) .................................................................422SPECIALTY Adapters / Manifolds ..............................................442SUCTION TEE, TEE BLOCKS .....................................................440TUBE and LINE Repair Kits ........................................................404WELD-ON, SOLDER-ON ......................................................421, 434
Note: Metric connections are not included in this sizing method.
Tube O.D.
FlAre FiTTiNgsThe sAe 45° flare fitting is found on older cars and trucks, many european made cars, recreational vehicles, construction and agricultural equipment using r12. The flare fitting seals with metal to metal contact and requires higher torque than o-ring style fittings. Not recommended for use with r134a.
O-riNg FiTTiNgsThe concept of the o-ring fitting achieves an effective seal in automotive air conditioning systyems through the use of an o-ring placed in a specially designed groove or cavity intended to apply a mild compression on the o-ring. The threads of the o-ring fittings serve only as a mechanical connection and require substantially less torque values than the comparable flare design. This design has proven more reliable than the flare fitting design, and is widely accepted as an international standard for mobile air conditioning systems. Care should be taken to use only HNbr, HsN, or Neoprene rubber compounds (as opposed to the old Nbr or nitrile materials) in repair applications which involve the new r134a refrigerant and compatible lubricants.
spriNg lOCk FiTTiNgsThis is a dual o-ring style OeM style connection used and patented by Ford Motor Company. The dual o-rings seal in a precision “barrel” and are held together mechanically by the use of a tube flare behind a garter spring. This design requires no tools to assemble, but does require special tools to disassemble. Also, special care must be taken by the repair technician to insure that the “flare-to-garter spring” connection is fully engaged.
gAskeT and seAliNg wAsHer FiTTiNgsThere are many types of variation on the gasket seal concept which have been used by OeM’s in the last 30 years. All rely on fairly heavy compression of the sealing material to metal surfaces for sealing. some examples are listed below:
• pad – These are generally “manifold” style connections often seal inlet and outlet fittings with the same gasket. They are generally secured through the use of a “hold-down” bolt.
• Teflon™ – This is a seal based on a Teflon™ ring being compressed into a groove and is known as a rotolock fitting. These fittings always use a 1”–14 thread torque to produce the compression.
• O-ring – There are many A/C systems worldwide which use this “o-ring-in-a-groove” or “over the tube” design.
Aeroquip gH134 eZ Clip Hose eZ Clip only 15-3242 pliers (size 6-12), 15-3247 (#16)ATCO 3700 Two braid dimension, nylon barrier beadlock ATCO 15-3200A or 15-3256 burgaclip 3090 reduced barrier burgaclip, beadlock reduced 15-3243bC; 15-3200A or 15-3256Dayco 3103, 3054 single braid, reduced O.D. braid beadlock reduced, burgaclip ATCO 15-3200A *2, or 15-3256Dayco 3305 Two braid, nylon barrier beadlock ATCO 15-3200A or 15-3256Dayco T2 Two braid, all rubber beadlock ATCO 15-3200A or 15-3256goodyear 4816, Two braid dimension, beadlock 15-3242 pliers (size 6-12)4824, 4826 nylon barrier ATCO 15-3200A or 15-3256goodyear 4850, 4860 single braid, reduced O.D. barrier beadlock reduced, burgaclip ATCO 15-3200A *2, or 15-3256Manuli Type e, Class 1 High temp. braided synthetic rubber Manuli “Quick Click” only 15-3242 pliersparker 7634, 7637 reduced O.D. beadlock reduced, burgaclip ATCO 15-3200A or 15-3256parker bHk barrier Hose std. size beadlock ATCO 15-3200A or 15-3256
Section V: Illustrated Fittings
FITTING RECOmmENDATIONShose Type hose Description Recommended Fittings Recommended Crimper
hOSE SIzES and TypES
RECOmmENDED CRImp for hOSE COUpLINGS (clip types not shown)
A/C Hose size is determined by the inside and outside diameter of the hose. Outside diameters of hoses vary significantly and MusT NOT be used solely to determine hose size. All “beadlock-style” fittings shown in this catalog (i.e. parts with “b” or “bs” suffixes) are designed to be coupled to barrier two braid dimension hose ONlY1. Hose sizes also are known by the “6, 8, 10, 12, 14, and 16” number designations. The chart below shows hose i.D.’s and their corresponding size number.
It is very important that a proper combination of hose, fitting and crimp style be used to insure a coupling of high integrity. sAe J2064 Coupling integrity standards require that extensive testing be done on crimped hose assemblies to insure “leak-free” couplings that will be environmentally friendly. Testing has shown that the old barb fitting design when coupled with wormgear clamps or even ferrules and “face crimped” will not pass these new coupling integrity performance requirements. The only fitting and crimp designs which have been found to meet these sAe requirements are the “beadlock-style” fitting with a “bubble-style” crimp. both are illustrated below, along with a chart showing important details of the ATCO beadlock fitting design:
To determine the hose size that a specific fitting is designed to fit, measure the outside diameter of the hose insert as shown above.
Note: 1 reduced dia. barrier hose (goodyear #4850, 4860/Dayco #3054, 3103) supplied in single braid only. see following section “reCOMMeNDeD CriMp FOr HOse COupliNg” for additional info.
standard size hose and reduced diameter hose have different diameters.
0.290 6 0.385 8 0.480 10 0.600 12 0.745 14
REDUcED HOSE SIZES
std.illust. A (i.D.) 0.780” 0.940” 1.040” 1.165”
reduced illust. b (i.D.) 0.590 0.7187 0 .7812 .950
Hose size #6 #8 #10 #12
A B
Note:*1 Adjustable crimpers: weatherhead coll-o-crimp, Dayco Np 30 Or Np 60, gates pC707.*2 Fittings and crimp dies for reduced O.D. nylon barrier hose such as goodyear 4850 & 4860 or Dayco 3103 & 3054 are available for use with the #15-3200A crimper.
DeNOTes HOse siZe1 = No. 6 (5/16”) (std or reduced)2 = No. 8 (13/32”) (std or reduced)3 = No. 10 (1/2”) (std or reduced)4 = No. 12 (5/8”) (std or reduced)5-9 = step sizeNote: Does not apply to fittings with third digit of 7, 8, or 9
Fittings Section V: Illustrated
SERVICE pORT INFORmATIONThere are a number of fittings that include an integral service port (for attaching manifold charging hoses), either for r12 or r134a (see illust. A). in addition, some fittings may include a switch port, used for the purpose of attaching a pressure switch to the system. The standard size switch ports used are 1/4” (actually 7/16” - 20 thread), 3/16” (actually3/8” - 24 thread), and metric M10 and M12 sizes normally associated with r134a systems.
ILLUSTRATION A
r12 serViCe pOrT/r134a swiTCH pOrT r134a lOw siDe 13MM pOrT 1 r134a HigH siDe 16MM pOrT 1
Note:1 r134a service ports may be supplied in either standard flow, or High Flow (eaton ssV) type. both are interchangable, except for the replacement shrader core inside the port. The High Flow shrader core requires a special remover/installer (p/N 16-3434), and is the preferred style (if available), providing faster charging/evacuation periods.
TRUCk AIR NUmbERING SySTEm FOR hOSE FITTINGS (pART NUmbER FORmAT)NOTE: UNLESS NOTED, ALL FITTINGS SUppLIED WITh NECESSARy O-RINGS, CLAmpS, ETC.
NOTe: To be used as a general guide, and applies ONlY to Hose Fittings and MAY NOT apply to adapters, compressor and compression fittings, splicers, dual o-ring or metric fittings, spring lock fittings, service valves, or tee connectors. The format is approximately 99% accurate.
FF - Female Flare MF - Male Flare FOr - Female O-ring MiO - Male insert O-ring FiO - Female insert O-ring
MOr - Male O-ring Fsl - Female spring lock Ms - Male spring lock FTO - Female Tube-O MTO - Male Tube-O
b = beadlock (std. Dia.)bC = burgaclip bD = beadlock (short Drop)br = beadlock (reduced Dia.)bs = beadlock (steel) (std. Dia.)-10 = 10 per box(bulk) e = eZ Clip s = steel Q = Manuli / Frigoclic
Third Digit
DeNOTes sTANDArD Or speCiAl TYpe0 = Aeroquip Type Male fitting 1 = Aeroquip Type Female fitting2 = special Threads(gMC/iHC 11/16” - 16)3 = r134a Male/Female O-ring w/port4 = r134a Male insert O-ring w/port5 = Male insert O-ring fitting6 = standard (non-step) fitting7 = step up/step down fitting8 = standard fitting w/port9 = step fitting w/port
FlAre TO O-riNg ADApTersConverts Male Flare to Male insert O-ring 6 ..............................08-8006 8 ..............................08-8008 10 .............................08-8010
FeMAle O-riNg X MAle iNserT O-riNgr134a serViCe pOrT ADApTers
r134a
ideal for adding r134a service ports to #8 and #10 Male insert O-ring Fittings
1) 16 mm port2) 13 mm port3) for 90° use 08-34894) for 90° use 08-3490
2-1/2” length
sHrADer pOrT ADApTer / reCeiVer Drier 1/8” pipe x 1/4” r12 .................................................................................08-80563/8”-24uNF2A X 1/4” std. r12 port ........................................................08-8057Converts female switch port to male port on filter driers.
rOTOlOCk TO Tube-O ADApTer ......................................08-3070Converts rotolock style York and Tecumseh comp. to Tube-O style. supplied 1 per box. (2 required)
FlAre ADApTers 90 °Flare to Female O-ring Adapter 8x8 ......................08-3962FO
DESCRIpTION FTG. SIzE pART NO. DESCRIpTION FTG. SIzE pART NO.
Fittings Section V: Illustrated
ADApTER FITTINGS (also see REtRoFIt PoRt ADAPtERs, page 434)
Tube-O TO rOTOlOCk ADApTers ........................................08-3076Converts Tube-O style York and Tecumseh comp. to rotolock style(2 per box)
MAle swiTCH pOrT ADApTer FiTTiNgMAle X MAle MeTriCM10-1.25 x 3/8-24 switch port ................................................................08-8058
M E T R I CMAle swiTCH pOrT ADApTer FiTTiNgMAle X MAle MeTriCM12-1.5 x 3/8-24 switch port ................................................................. 08-8059
M E T R I C
iNliNe CHArge FiTTiNgw/r12 port 6 ...........................08-8036A3/8” Male O-ring x 3/8” Female O-ring
r12
Drier ADApTer3/8” Male O-ring to 3/8” MiO ............................. 6 ....................................08-806011/16” Male O-ring to 3/8” MiO ......................... 6 ....................................08-8061
CHArge pOrT ADApTer3/8”-24 to 16mm (high side) ............................. 6 ....................................08-8064
r134a
r12
MAle iNserT O-riNg TO MAle 6 ..............................08-3009FlAre ADApTers 8 ..............................08-3069Converts O-ring to Flare 10 .............................08-3099(2 per box)
bULkhEAD FITTINGS Also see E-Z ClIP stylE, BulkhEAD FIttIngs, page 407.
bLOCk-OFF pLUGS see page 405.
MAle X MAle wiTH NuTsFor routing hose through firewall/cab/roof 6x6 ............................08-8066 8x8 ............................08-8068 10x10 ..........................08-8070 12x12 ..........................08-8072
FTG. STEELDESCRIpTION SIzE pART NO.
MAle iNserT O-riNg 6x6 ......................08-8076BS 8x8 ......................08-8078BS 10x10 ....................08-8080BS
45 Degree FeMAle Tube-O COMp.FiTTiNg with r134a serViCe pOrT 8 (16mm port) ...... 08-3442BS1”-14 Thread, steel 10 (13mm port) ...... 08-3443BS
TUbE and LINE REpAIR FITTING kITS
use for Metal line repairs on any A/C and Heater lines. (Can also be used on metal Transmission and power steering lines.)
LINE REPAIR KITS 5/16” O.D. line ...........................08-3100 3/8” O.D. line .............................08-3102 1/2" O.D. line.............................08-3104 5/8" O.D. line.............................08-3105 3/4" O.D. line.............................08-3106
step Down ..... 3/8” to 5/16” O.D. line ...............08-3101 step Down ..... 1/2” to 3/8” O.D. line .................08-3103
METRIC LINE REPAIR KITS 10mm O.D. line .........................08-3107 12mm O.D. line .........................08-3109 15mm O.D. line .........................08-3110 16mm O.D. line .........................08-3111
step Down ..... 12mm to 10mm O.D. line ..........08-3108
Compression fittings for Ford vehicles w/orifice tube in liquid line. Includes replaceable orifice tube. No. 8 x 8 Compression Fittings (1/2” O.D. Tubing) 3/4”-16 Nut; Blue Orifice Tube
Male Insert O-Ring No. 8 x 8 Compression Fittings(1/2” O.D. Tubing) 3/4”-16 Nut; Black & White Orifice Tube
Female nut with plug Male nut with plugfor Male insert O-ring Fittings for Female insert O-ring Fittings#6 ...............................08-3077 #6 .................................08-3081#8 ...............................08-3078 #8 .................................08-3082#10 .............................08-3079 #10 ...............................08-3083#12 .............................08-3080 #12 ...............................08-3084
TXV blOCk-OFF plug kiT ..........................................................08-3042used on block Type expansion Valves (TXV) to close off unused, un-needed ports. supplied with 1 pc. each: #6, #8, #10 plug
Step 2. Slip on Two ClipsInstall 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 assembley, both clips should 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 NippleLubricate 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 the nipple insertion.
Step 4. Insert the Nipple into the HoseInsert 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 CageSnap 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 ClipsSlide the clips over the cage arms and into the channels on each arm.
Step 7. Close the Clips-6, -8, -10, -12 use #15-3242 pliers; (-16 use #15-3247) 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.
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.
Nose of the pliers should be firmly seated under the assembly bump and lock latch. Note: -16 only, tap the top latch until fully seated.
E-z CLIp Assembly Instructions
Step 1. Cut the HoseCut the hose to proper length with an appropriate tool. The hand-held hose cutter has been specially 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.
E-z Clip Lifesaver kitsEach KIT contains the correct components for replacement of a single hose assembly. The Aluminum Lifesaver Braze Fitting Kits are designed to rework failed OEM aluminum air conditioning tubing and hose assemblies in sizes 10mm to 18mm (metric tubing only, -6 to –12). This repair system allows the installer to reuse unique OEM terminal connections, while replacing the failed OEM hose and nipple with the E-Z Clip attachment system.
• Burgaclips’ state-of-the-art hose fittings are a breakthrough in the a/c industry.• A simple procedure to attach fittings to the hose.• This hose and fitting combo provides a permeation rate which is 74% less than the presently available hose assemblies in the marketplace.
bURGACLIp FITTINGS1. 3.2.
go....
how To Install Instructions
1. Cut hose to proper length. Use reduced diameter hose only.2. Place two proper size clips into the clip holder. For ease of assembly, both clips should have the same
orientation.3. Slip in the clipholder with the clips. Place the clipholder with the two clips on the hose. In such a manner that
the side with the smallest hole touches the end of the hose.4. Lubricate the fitting with a generous amount of the a/c systems lubricator oil (this lowers the force of insertion)5. Insert the Burgaclip fitting into the hose. Ensure that the fitting is fully inserted by checking the gap between the
end of the hose and the shoulder of the fitting.6. Close the clips with the Burgaflex clip pliers (#15-3243BC). The pliers open themselves when the correct
amount of force has been reached. Start with the clip closest to the end of the hose. DONE !
HOSE FITTING FTG. HOSE FTG. STEP PART NO. PART NO. PART NO. PART NO.cONFIGURATION SIZE SIZE THREAD FTG. AlUM. STEEl AlUM. 10Pk STEEl 10Pk.
spliCer Tips-iNNer lip DesigN 6 6 NONe 08-8120Cut off original hose at crimp, and 8 8 NONe 08-8111 08-8121weld tip onto old fitting. 10 10 NONe 08-8112 08-8122 12 12 NONe 08-8123
spliCer Tips-OuTer lip DesigN 6 6 NONe 08-8124 08-8100Cut off original hose at crimp, and 8 8 NONe 08-8125 08-8101weld tip onto old fitting. 10 10 NONe 08-8126 08-8102 12 12 NONe 08-8127 08-8103
REpAIR FITTINGS / SOLDER / WELD-ON
bArbeD eND
bArbeD eND
eVApOrATOr repAir FiTTiNgs 8 8 3/4”-16 08-8118 brAss MAle O-riNg sTrAigHT 10 10 7/8”-14 08-8119can be brazed/welded onto the ends of copper tubes, found on Red Dot evaporators.
spliCer Tips-OuTer lip DesigN 6 6 NONe 08-8124B 08-8100BCut off original hose at crimp, and 6 6r NONe 08-8100BR 1weld tip onto old fitting. 8 8 NONe 08-8125B 08-8101B 8 8r NONe 08-8125BR 08-8101BR 1 10 10 NONe 08-8126B 08-8102B 10 10r NONe 08-8126BR 1 08-8102BR 1 12 12 NONe 08-8127B 08-8103B 12 12r NONe 08-8127BR 1 08-8103BR 1
10 12 NONe step Down 08-8128B 10 12 NONe step Down 08-8128BR 1 10 12 NONe step Down 08-8105B 10 12r NONe step Down 08-8105BR 1 12 14r NONe step Down 08-8114BR 1
FIELD REPAIR FITTING90° DegreeCharging Port ....... 16MMSwitch Port ............M10#8 Beadlock (Reduced Dia.) Female08-6998BR ................. #8PACCAR
HARDLINE FITTINGCONDENSER Charging Port ....... 16MMM10 Port (2) Female MIO08-1022S .....#8 ......... #8PACCAR
HARDLINE FITTINGCONDENSERBeadlock Reduced Dia. Charging Port ....... 16MMM10 Port (2) Female Reduced08-1022SR ...#8 ......... #8 PACCAR
On Field Repair Fittings and Hardlines (as noted on pages 423-424)
The fittings and hardlines supplied are all designed as field-repair replacement items only. They do not have crimp-on shells attached. Instead, they have male insert o-ring ends. This allows the technician to couple a female o-ring fitting onto the end, which can then be crimped onto the hose. This also allows use of any type of hose (Goodyear standard or reduced, E-Z Clip, etc.) and any configuration of fitting (straight, 45°, 90°). See illustration.
Step 2. Slip on the Double Clamp Place the double clamp on the cut end of the SAE J2064 Type E refrigerant hose in such a way that the tooth of the bar comes in contact with the cut end of the hose.
Step 3. Oil the NippleLubricate the end of the coupling joint with a generous amount of lubricating oil. Use the same lubricate oil as used in air conditioning systems.
Step 4. Insert the Fitting Into the HoseFind the correct orientation and insert the fitting completely into the hose.
Step 5. Fit the Coupling in PlaceA. Position the round nose of the “CLIC” open-close pliers at the hook shaped end of the clamp. B. Position the thin nose of the “CLIC” open-close pliers at the end with the hooked teeth. C. Tighten the clamp until the click. To Disassemble - just reverse the position of the ends of the pliers on the clamp.
NOTE: The pliers should be positioned squarely on the clip connection points and should remain square during the closing of the clip.
for BLACK HOSE HOSE END for GREY HOSE PART # CLAMP PART #
Step 1. Cut the HoseCheck the dimensions of the components. Cut the end of the hose to proper length in a perpendicular direction using Refri*Master manual cutter. The hand-held hose cutter is especially designed for cutting non-wire reinforced hose, SAE J2064 Type E refrigerant hose. Be sure the cut is made square to the hose length.
for BLACK HOSE HOSE END for GREY HOSE PART # CLAMP PART #
BLACK HOSE HOSE HOSE PART# END LENGTH09-7036 #6 70 ft09-7038 #8 75 ft09-7040 #10 75 ft09-7042 #12 60 ft
15-3265 HOSE CUTTER
IMPORTANT: There are two (2) types of Manuli hose used with clip-on fittings black and grey. We do not supply the grey colored hose. The black hose will replace the grey hose, but only if used with the correct style clamp & cage assy. (the clamps are different O.D.)
For black hose use clamp & cage assembly numbers 09-1028Q through 09-1031Q (these have 2 small holes drilled in the bar)
For grey hose connections, use 09-1016Q through 09-1019Q (these do not have the holes in the bar)
For the above reasons, all Manuli fittings are supplied without the clamp & cage assy. You must order the correct ones required per type of hose used.
REpAIR OR REpLACE ANy OE hOSE WITh pAD CONNECTIONS!NO WELDING REQUIRED!
Now you can make up your own hose assemblies using our exclusive line of field repair fitting adapters for all makes of heavy duty trucks - Freightliner, Kenworth, Navistar, Peterbilt & Volvo.
See the examples below. Photos are of actual OE components on a late model Volvo VN truck. The same concept applies to all other makes of trucks. Allows the mechanic the option to make up hoses with ordinary beadlock or EZ-clip fittings, using choice of Goodyear/Parker/EX-clip hose in either standard or reduced diameter size.
1. Determine compressor head type (see Diagram A) (Tube-O, rotolock, #8 - #10 O-ring, or Flange).2. Determine type of refrigerant used in system (r12 or r134a).3. Determine choice of type of service valve (standard or back seat type and/or beadlock Hose end) (see Diagram b).
SERVICE VALVES – ORDERING INFORmATION
Compressor head Types - Diagram A
Vertical Tube “O” Type
Types Of Service Valves - Diagram b
(1) Back seat type valves contain a manually operated valve which controls the position of the service valve, either allowing full refrigerant flow, a mid-way test/flow, or totally blocked off refrigerant flow from the rest of the A/C system. The standard type service valve can be substituted but allows only constant full refrigerant flow.