AH-03: Bend Tubing Page 1 of 23 SAFETY FIRST o Follow all Caterpillar facility safety standards when performing this task. EQUIPMENT o tube benders, various sizes o levels o tube cutter, various sizes o squares o chamfer tools o tape measures o Parker #212FB Rotary flaring tool o various fittings RESOURCES o none Bend Tubing Note: This task will cover three types of bending profiles. Part A: Simple 90-degree ee Profile
Page 2 of 23 1. Measure e the length of the tubing. Note: Always measure e from om centerline to centerline. o Select the appropriate measuring device shown below. o Using a tape measure and a square, make the first measurement. o Measure from the beveled end of the fitting to the centerline of the tube and record the results.
Page 3 of 23 o Measure from the beveled end of the other fitting to the centerline of the tube, and record the results. 2. Mark the tube for bending. o Mark the tube with the first measurement. Continue the mark completely around the tube.
Page 4 of 23 o Select the appropriate tube bender shown below. o Insert the tube into the tube bender. o Align the mark on the tube with the L on the tube bender. The L indicates that the measurement was taken from the left. If the measurement was taken from the right, align the mark on the tube with the R on the tube bender. o Ensure that the zeros on both parts of the tube bender are aligned.
Page 5 of 23 o Pull the top part of the tube bender down until the zero on the top portion is aligned with 90 on the bottom. 3. Cut the tubing to length. o Position the bent tube at the fittings. o Ensure that the left end of the tube is at the start of the beveled edge.
Page 6 of 23 o Position the opposite end of the tube at the start of the beveled edge, and mark the tube. 4. Cut the tube. o Select the appropriate tube cutter shown below. o Position the tube in the cutter and cut the tube.
Page 7 of 23 5. Prepar epare e the cut ends of the tubing. o Select the appropriate chamfering tool shown below. o Place the tube in a vise. o Chamfer both inside and outside diameters. o Blow out the tube with compressed air.
6. Flare e the ends of the tube. Page 8 of 23 o Select the appropriate fitting shown below. Triple Lok 37, Intru Lok, and Ferulok Parker Fittings o Select the triple lok 37 degree shown below. Triple Lok 37
Page 9 of 23 o Slide the nut on the tube and then the ferrule. o Use the Parker #212FB Rotary Flaring tool or equivalent. Parker #212FB Rotary Flaring Tool o Insert the end with the nut and ferrule into the flaring tool.
Page 10 of 23 o Push the tube in until it is against the stop. o Slide the bolt and wing nut into the locking position, and tighten the wing nut finger-tight. o Lubricate the flaring cone with light oil.
Page 11 of 23 o Screw in the flaring cone until the end of the tube is flared. Note: Do not over or under flare the tube.
7. Install the tube. Page 12 of 23 Note: The tube should line up to the fittings, and the nuts on the tube should screw ew on easily.. Do not force ce the nuts on the fittings. o Check for any burrs and deburr if necessary. o Blow out the tube with compressed air. Part B: Tube with Two 45-degree ee Angles and a 90-degree ee Angle X = Y x 1.414
Page 13 of 23 1. Mark the machine or surface using a square e and level. o Using the square, make a vertical mark above the fitting. o Make a mark not less than 2 1/4-inches above the fitting. This mark will indicate the 90-degree angle. If this mark is less than 2 1/4-inch, the tube end will not fit in the fairing tool. o Using a level, make a horizontal line to the right of the other fitting. 2. Draw out a plan for the tubing to identify the Y and X. o Measure from the 90-degree mark to the horizontal mark above the vertical line. This is the Y. o Multiply the Y number with 1.414, the results will be the X measurement. The constant of 1.414 is only for 45-degree bends.
3. Bend the tube. Page 14 of 23 o Make the X measurements marks on the tube and ensure that the mark continues around the tube. o Insert the tube into the tube bender. This bend will be the first 45- degree bend. o Align the mark on the tube with the 45-degree mark on the top part of the tube bender. Ensure that the zeros on both parts on the tube bender are aligned. o Pull the top part of the tube bender down until the top zero lines up with the 45 on the bottom part.
Page 15 of 23 o Position the tube in the tube bender so that the second mark on the tube aligns with the 45 on the top portion of the tube bender. o Align the tube with the groove on the bottom portion of the tube bender to ensure a straight bend. The first bend is now pointing up. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 45 on the bottom. 4. Measure e the length of the tube to indicate where e the 90-degree ee bend should be made. o Measure from the fitting where the horizontal line is drawn to the vertical line. o Transfer the measurement to the drawing. o Lay the tube on the drawing and mark the tube for the 90-degree bend. o Place the tube in the tube bender. o Align the 90-degree mark on the tube with both zeros on the tube bender. o Align the tube with the groove on the bottom portion of the tube bender. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 90 on the bottom. 5. Cut the tubing to length. o Position the bent tube at the fittings. o Ensure that the left end of the tube is at the start of the beveled edge.
Page 16 of 23 o Position the opposite end of the tube at the start of the beveled edge and mark the tube. o Cut the tube. 6. Prepar epare e the cut ends of the tubing. o Place the tube in a vise. o Chamfer both inside and outside diameters. o Blow the tube out with compressed air. 7. Flare e the ends of the tube. o Slide the nut on the tube and then the ferrule. o Insert this end into the flare tool. o Push the tube in until it is against the stop. o Slide the bolt and wing nut into the locking position, and tighten the wing nut finger-tight. o Screw in the flaring cone until the end of the tube is flared. Note: Do not over or under flare the tube. 8. Install the tube. Note: The tube should line up to the fittings, and the nuts on the tube should screw on easily.. Do not force the nuts on the fittings. o Check for any burrs and deburr if necessary. o Blow out the tube with compressed air.
Page 17 of 23 Part C: Tube with Complex Bends Note: This tube will have a 90-degree ee and four 45-degree ee bends. The tube will be bent so that a length of it will rest against the wall. 1. Make both Y measurements ements first. o Using a small piece of tubing, lay the tubing against the wall. o Measure from the centerline on the tube to the center of the fitting. o Record this measurement.
Page 18 of 23 o Move to the opposite fitting, make the measurement, and record the readings. o Make a drawing and transfer both measurements to the drawing. These are the Y measurements. 2. Determine the X measurements. ements. o Multiply each Y measurement with the constant, 1.414. o Record the results on the drawing. 3. Make a horizontal line at the top fitting. Make sure the line is centerline of the fitting. o Using a tape measure and square, measure the length of the tube. Measure from the horizontal line to the beveled edge of the bottom fitting, and record the results. 4. Mark the tube with the X measurements ements for the 45-degree ee bends. o Ensure that the marks continue around the tube. o Leave enough room for the 90-degree bend. 5. Make the 90-degree ee bend. o Ensure that there are at least 2 1/4-inches for the 90-degree bend and for the first 45-degree bend.
Page 19 of 23 6. Make the first 45-degree ee bend. o Make the first X measurements on the tube and ensure that the mark continues around the tube. o Insert the tube into the tube bender. This is the first 45-degree bend. o Align the mark on the tube with the 45 mark on the top part of the tube bender. Ensure that the zeros on both parts on the tube bender are aligned. o Pull the top part of the tube bender down so that the zero on the top part of the tube bender lines up with the 45 on the bottom part.
Page 20 of 23 7. Make the second 45-degree ee bend. o Position the tube in the tube bender so that the second mark on the tube aligns with the 45 on the top portion of the tube bender. o Align the tube with the groove on the bottom portion of the tube bender, to ensure a straight bend. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 45 on the bottom. 8. Make the third 45-degree ee bend. o Slide the tube in the tube bender so that the third mark on the tube aligns with the 45 on the top portion of the tube bender. o Align the tube with the groove on the bottom portion of the tube bender to ensure a straight bend. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 45 on the bottom. 9. Make the fourth 45-degree ee bend. o Position the tube in the tube bender so that the fourth mark on the tube aligns with the 45 on the top portion of the tube bender. o Align the tube with the groove on the bottom portion of the tube bender, to ensure a straight bend. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 45 on the bottom.
10. Make the 90-degree ee bend. Page 21 of 23 o Position the tube in the tube bender so that the 90-degree mark on the tube aligns with the zero on the top portion of the tube bender. o Align the tube with the groove on the bottom portion of the tube bender, to ensure a straight bend. o Pull down on the top portion of the tube bender until the zero on the top is aligned with the 90 on the bottom. 11. 1. Cut the tubing to length. o Position the bent tube at the fittings. o Ensure that the left end of the tube is at the start of the beveled edge. o Position the opposite end of the tube at the start of the beveled edge, and mark the tube. o Cut the tube. 12. Prepar epare e the cut ends of the tubing. o Place the tube in a vise. o Chamfer both inside and outside diameters. o Blow the tube out with compressed air. 13. Flare the ends of the tube. o Slide the nut on the tube and then the ferrule. o Insert this end in the flare tool. o Push the tube in until it is against the stop. o Slide the bolt and wing nut into the locking position and tighten the wing nut finger-tight. o Screw in the flaring cone until the end of the tube is flared. Note: Do not over or under flare the tube. 14. Install the tube.
Page 22 of 23 Note: The tube should line up to the fittings, and the nuts on the tube should screw ew on easily.. Do not force ce the nuts on the fittings. o Check for any burrs and deburr if necessary. o Blow out the tube with compressed air. Part D: Compression and Flareless Fitting Assemblies Flodar,, Imperial Eastman Hy Duty Flareless, and Weather eatherhead head Compression Note: Follow the same procedur ocedures es as with flared fittings but with some exceptions listed below. 1. Ensure that the amount of tubing which terminates inside the fittings is factored in on all length calculations. 2. On 90-degree ee bends the fitting end can be less than 2 1/4-inch as clearance for a flaring tool does not have to be factored in.
Page 23 of 23 3. Ensure e that the tube ends are e square e and deburred ed inside and outside diameters. 4. Ensure e that the tubing is seated at the bottom of the ID of the fitting assembly. 5. Ensure e that the compression ferrule ule slide easily over the tube. 6. Ensure e that the assembly nut is not over torqued. 7. Assemblies should be bench assembled in a vise with soft clamps whenever possible.