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Eaton Aeroquip 5400 series low air inclusion refrigerant couplings
Product Code: 5400

Eaton’s 5400 Series low air inclusion product line is designed for air conditioning, refrigerant, gaseous and fluid transfer applications. Formerly branded as Aeroquip 5400, this Series is a low air inclusion product line for air conditioning, refrigerant, gaseous and fluid transfer applications.

Features include:

- Brazed or threaded end connection
- Threaded together design allows connection and disconnection against pressure
- Lock washer and jam nut standard for optional bulkhead mounting
- Applications include: air conditioning, refrigerant etc.

- Eaton Aeroquip 5400 series low air inclusion refrigerant couplings

5400 Series Low Air Inclusion Refrigerant
Eaton 5400 Series Low Air Inclusion Refrigerant Female No Adapter Quick Disconnect Coupling with Guardian Seal Plating

Item # 5400-S5-8, 5400 Series/ Low Air Inclusion Refrigerant | Eaton Aeroquip 5400 series low air inclusion refrigerant couplings

Eaton’s 5400 Series low air inclusion product line is designed for air conditioning, refrigerant, gaseous and fluid transfer applications.
Product Features . Brazed or threaded end connections for versatility of installation on tubing or hose . Tubular valve construction for low fluid loss and air inclusion . Thread together design allows connection and disconnection against pressure . Lock washer and jam nut standard for optional bulkhead mounting . Standard seal material: Neoprene . Guardian Seal. plating for excellent corrosion resistance
Physical Characteristics Coupling Max. Operating Pressure Size Connected Min. Burst Pressure Connected Max. Operating Pressure Disconnected Male Half Female Half Vacuum Connected Only Rated Flow Air Fluid Inclusion Loss

(in) (bar) (psi) (bar) (psi) (bar) (psi) (bar) (psi) (in./Hg) (lpm) (gpm) cc. max. cc.max.
1/4 207 3,000 621 9,000 172 2,500 52 750 28 8 2 .10 .05
1/2 121 1,750 359 5,200 121 1,750 52 750 28 53 14 .10 .10
. 48 700 145 2,100 48 700 45 650 28 132 35 .30 .10
1 48 700 145 2,100 48 700 21 300 28 284 75 .50 .20

Applications & Markets Flow Data
Flow rate (l/min)
. Mobile Air Conditioning
1 10 100 1000
and Refrigerant 29,0
14.5

Pressure drop (PSI)
7,25
4,35
2,90
1.45
Flow rate (gpm)
Air flow rate at 100 PSI (6,89 bar) Inlet Pressure
5400 Series
Low Air Inclusion Refrigerant

Figure 1

Figure 5 Figure 6
Dimensions – No Adapter
Part Number Coupling Body Dimensions Neoprene Type Size Type Fig. A B Hex

Hex

Hex

mm (in) mm (in) mm (in) mm (in) mm (in)
5400-S2-4 Male 1/4 No Adapter 1 27.4 (1.08) 21.1 (.83) 19 (.75) - - - -
5400-S5-4 Female 1/4 No Adapter 2 28.7 (1.13) 21.1 (.83) 16.0 (.63) 19 (.75) - -
5400-S2-8 Male 1/2 No Adapter 1 34.8 (1.37) 32.0 (1.26) 29.0 (1.14) - - - -
5400-S5-8 Female 1/2 No Adapter 2 40.6 (1.60) 33.0 (1.30) 26.0 (1.02) 30.0 (1.18) - -
5400-S2-12 Male . No Adapter 1 44.2 (1.74) 46.4 (1.83) 41.0 (1.61) - - - -
5400-S5-12 Female . No Adapter 2 55.1 (2.17) 45.0 (1.77) 35.0 (1.38) 41.0 (1.61) - -
5400-S2-16 Male 1 No Adapter 1 46.5 (1.83) 53.0 (2.10) 48.0 (1.89) - - - -

5400-S5-16 Female 1 No Adapter 2 61.1 (2.41) 56.0 (2.20) 45.0 (1.77) 50.0 (1.97) - -
Dimensions – SAE 37° (JIC) (Dimensional reference only)
Part Number Coupling Body Port Dimensions Buna-N Type Size Size Thread Type Fig. A B Hex Hex
Hex

*Couplings must be ordered by components as shown on page 147. mm (in) mm (in) mm (in) mm (in) mm (in)
5410-S17-4-4* Male 1/4 7/16 7/16-20 SAE 37° (JIC) 3 47.8 (1.88) 21.1 (.83) 19 (.75) - - 16.0 (.63)
5410-S14-4-4* Female 1/4 7/16 7/16-20 SAE 37° (JIC) 4 49.0 (1.93) 21.1 (.83) 16.0 (.63) 19 (.75) 15.7 (.62)
5410-4-4* Complete 1/4 7/16 7/16-20 SAE 37° (JIC) 5 89.9 (3.54) - - - - - - - -
5410-S17-6-4* Male 1/4 9/16 9/16-18 SAE 37° (JIC) 3 48.0 (1.89) 21.1 (.83) 19 (.75) - - 16.0 (.63)
5410-S14-6-4* Female 1/4 9/16 9/16-18 SAE 37° (JIC) 4 49.3 (1.94) 21.1 (.83) 16.0 (.63) 19 (.75) 15.7 (.62)
5410-6-4* Complete 1/4 9/16 9/16-18 SAE 37° (JIC) 5 90.4 (3.56) - - - - - - - -
5410-S17-6-8* Male 1/4 9/16 9/16-18 SAE 37° (JIC) 3 55.4 (2.18) 31.8 (1.25) 29 (1.14) - - 25.4 (1.00)
5410-S14-6-8* Female 1/2 9/16 9/16-18 SAE 37° (JIC) 4 61.7 (2.43) 33.3 (1.31) 26 (1.02) 30 (1.18) 25.4 (1.00)
5410-6-8* Complete 1/2 9/16 9/16-18 SAE 37° (JIC) 5 107.4 (4.23) - - - - - - - -
5410-S17-8-8* Male 1/2 . .-16 SAE 37° (JIC) 3 57.9 (2.28) 31.8 (1.25) 29 (1.14) - - 25.4 (1.00)
5410-S14-8-8* Female 1/2 . .-16 SAE 37° (JIC) 4 64.3 (2.53) 33.3 (1.31) 26 (1.02) 30 (1.18) 25.4 (1.00)
5410-8-8* Complete 1/2 . .-16 SAE 37° (JIC) 5 112.8 (4.44) - - - - - - - -
5410-S17-10-12* Male . 7/8 7/8-14 SAE 37° (JIC) 3 69.9 (2.75) 46.5 (1.83) 41 (1.62) - - 35.1 (1.38)
5410-S14-10-12* Female . 7/8 7/8-14 SAE 37° (JIC) 4 80.3 (3.16) 45.7 (1.80) 35 (1.38) 41 (1.62) 35.1 (1.38)
5410-10-12* Complete . 7/8 7/8-14 SAE 37° (JIC) 5 135.4 (5.33) - - - - - - - -
5410-S17-12-12* Male . 1 1/16 1 1/16-12 SAE 37° (JIC) 3 72.6 (2.86) 46.5 (1.83) 41 (1.62) - - 35.1 (1.38)
5410-S14-12-12* Female . 1 1/16 1 1/16-12 SAE 37° (JIC) 4 83.1 (3.27) 45.7 (1.80) 35 (1.38) 41 (1.62) 35.1 (1.38)
5410-12-12* Complete . 1 1/16 1 1/16-12 SAE 37° (JIC) 5 140.7 (5.54) - - - - - - - -
5410-S17-16-16* Male 1 1 5/16 1 5/16-12 SAE 37° (JIC) 3 75.9 (2.99) 53.3 (2.10) 48 (1.89) - - 44.5 (1.75)
5410-S14-16-16* Female 1 1 5/16 1 5/16-12 SAE 37° (JIC) 4 89.7 (3.53) 56.9 (2.24) 45 (1.77) 50 (1.97) 44.5 (1.75)
5410-16-16* Complete 1 1 5/16 1 5/16-12 SAE 37° (JIC) 5 149.6 (5.89) - - - - - - - -

Above items must be ordered at the component level - see page 148.
5400 Series
Low Air Inclusion Refrigerant
Dimensions – Braze Tubing Adapter (Dimensional reference only)
Part Number Coupling Body Tube O.D. Dimensions Neoprene Type Size Size Type Fig. A B Hex

Hex

Hex

*Couplings must be ordered by components as shown on page 147. mm (in) mm (in) mm (in) mm (in) mm (in)
5401-S17-4-4* Male 1/4 1/4 Braze Tubing Adapter 6 38.6 (1.52) 21.1 (.83) 19 (.75) - - 16.0 (.63)
5401-S14-4-4* Female 1/4 1/4 Braze Tubing Adapter 7 39.9 (1.57) 21.1 (.83) 16.0 (.63) 19 (.75) 16.0 (.63)
5401-S17-6-4* Male 1/4 3/8 Braze Tubing Adapter 6 38.6 (1.52) 21.1 (.83) 19 (.75) - - 16.0 (.63)
5401-S14-6-4* Female 1/4 3/8 Braze Tubing Adapter 7 39.9 (1.57) 21.1 (.83) 16.0 (.63) 19 (.75) 16.0 (.63)
5410-S17-6-8* Male 1/2 3/8 Braze Tubing Adapter 6 44.5 (1.75) 33.3 (1.31) 29 (1.14) - - 25.4 (1.00)
5401-S14-6-8* Female 1/2 3/8 Braze Tubing Adapter 7 50.8 (2.00) 33.3 (1.31) 26 (1.02) 30 (1.18) 25.4 (1.00)
5401-S17-8-8* Male 1/2 1/2 Braze Tubing Adapter 6 44.5 (1.75) 33.3 (1.31) 29 (1.14) - - 25.4 (1.00)
5401-S14-8-8* Female 1/2 1/2 Braze Tubing Adapter 7 50.8 (2.00) 33.3 (1.31) 26 (1.02) 30 (1.18) 25.4 (1.00)
5401-S17-10-12* Male . 5/8 Braze Tubing Adapter 6 62.7 (2.47) 45.7 (1.80) 41 (1.62) - - 35.1 (1.38)
5401-S14-10-12* Female . 5/8 Braze Tubing Adapter 7 73.2 (2.88) 45.7 (1.80) 35 (1.38) 41 (1.62) 35.1 (1.38)
5401-S17-12-12* Male . . Braze Tubing Adapter 6 62.7 (2.47) 45.7 (1.80) 41 (1.62) - - 35.1 (1.38)
5401-S14-12-12* Female . . Braze Tubing Adapter 7 73.2 (2.88) 45.7 (1.80) 35 (1.38) 41 (1.62) 35.1 (1.38)
5401-S17-16-16* Male 1 1 Braze Tubing Adapter 6 71.1 (2.80) 56.9 (2.24) 48 (1.89) - - 44.5 (1.75)
5401-S14-16-16* Female 1 1 Braze Tubing Adapter 7 84.8 (3.34) 56.9 (2.24) 45 (1.77) 50 (1.97) 44.5 (1.75)

Dust Caps and Dust Plugs Dust Cap Dust Plug
Dust Cap with Gasket Dust Plug with Gasket Body Size
5400-S6-8 5400-S8-8 1/2 5400-S6-12 5400-S8-12 . 5400-S6-16 5400-S8-16 1

Adapter SAE
37° (JIC) Adapter SAE 37° (JIC)
O-Ring Brass Steel Body Size Thread Tube O.D. Size
22546-12 202220-4-4B 202220-4-4S 1/4 7/16-20 1/4 22546-12 202220-6-4B 202220-6-4S 1/4 9/16-18 3/8 22546-17 -202220-6-8S 1/2 9/16-18 3/8 22546-17 202220-8-8B 202220-8-8S 1/2 .-16 1/2
22546-23 -22546-23 - 202220-10-12S 202220-12-12S . . 7/8-14 1 1/16-12 5/8 .
22546-28 - 202220-16-16S . 1 3/16-12 1
Adapter – Braze Adapter – Braze

22546-17 202208-8-8B - 1/2 7/8-20 1/2

2254617 202208-10-8B 202208-10-8S 1/2 7/8-20 5/8
22546-23 202208-10-12B 202208-10-12S . 1 1/4-18 5/8
22546-23 202208-12-12B - . 1 1/4-18 .
22546-23 202208-14-12B - . 1 1/4-18 7/8
22546-28 202208-14-16B - 1 1 19/32-20 7/8
22546-28 202208-16-16B - 1 1 19/32-20 1
22546-28 202208-18-16B - 1 1 19/32-20 1 1/8
22546-28 202208-20-16B - 1 1 19/32-20 1 3/16
22546-28 202208-22-16B - 1 1 19/32-20 1 1/4

Hose Fitting SAE 100R5. Dimensions Hose Fitting SAE 100R5 O-Ring Fitting Assembly Body Size Hose Size Thread D (O-Ring Required)
mm (in) 22546-12 487-4-4S 1/4 -4 1/2-20 23.4 (.92) 22546-12 487-4-6S 1/4 -6 1/2-20 24.4 (.96) 22546-17 487-8-6S 1/2 -6 7/8-20 24.4 (.96) 22546-17 487-8-8S 1/2 -8 7/8-20 26.9 (1.06)

22546-23 487-12-10S . -10 1 1/4-18 27.2 (1.07)

.Additional dash styles available.
5400 Series
Low Air Inclusion Refrigerant
For assemblies, order by components as shown by base number and dash (-) size below. Example, if a 5401-S14-10-12 is required, order as components, (1) 5400-S5-12, (1) 202208-10-12B Adapter and (1) 22546-23 O-Ring.
Assembly Part Number 5400-S2 Male Half Quantity 5400-S5 Female Half Quantity 202208-Brass Braze-On Adapter Quantity 202220-Steel 37. SAE Adapter Quantity 22546 O-Ring Quantity

5401-S14-10-12 -12 1 -10 -12B 1 -23 1
5401-S14-10-8 -8 1 -10 -8B -17 1
5401-S14-12-12 -12 1 -12 -12B 1 -23 1
5401-S14-16-16 -16 1 -16 -16B 1 -28 1
5401-S14-4-4 -4 1 -4 -4B 1 -12 1
5401-S14-6-4 -4 1 -6 -4B 1 -12 1
5401-S14-6-8 -8 1 -6 -8B 1 -17 1
5401-S14-8-8 -8 1 -8 -8B 1 -17 1
5401-S17-10-12 -12 1 -10 -12B 1 -23 1
5401-S17-10-8 -8 1 -10 -8B 1 -17 1
5401-S17-12-12 -12 1 -12 -12 1 -23 1
5401-S17-14-16 -16 1 -16 -16 1 -28 1
5401-S17-4-4 -4 1 -4 -4B 1 -17 1
5401-S17-6-4 -4 1 -6 -4B 1 -12 1
5401-S17-6-8 -8 1 -6 -8B 1 -17 1
5401-S17-8-8 -8 1 -8 -8B 1 -17 1
5410-12-12 -12 1 -12 1 -12 -12S 2 -23 2
5410-16-16 -16 1 -16 1 -16 -16S 2 -28 2
5410-4-4 -4 1 -4 1 -4 -4S 2 -12 2
5410-6-8 -8 1 -8 1 -6 -8S 2 -17 2
5410-8-8 -8 1 -8 1 -8 -8S 2 -17 2
5410-S14-10-12 -12 1 -10 -12S 1 -23 1
5410-S14-12-12 -12 1 -12 -12S 1 -23 1
5410-S14-16-16 -16 1 -16 -16S 1 -28 1
5410-S14-4-4 -4 1 -4 -4S 1 -12 1
5410-S14-6-4 -4 1 -6 -4S 1 -12 1
5410-S14-6-8 -8 1 -6 -8S 1 -17 1
5410-S14-8-8 -8 1 -8 -8S 1 -17 1
5410-S17-10-12 -12 1 -10 -12S 1 -23 1
5410-S17-12-12 -12 1 -12 -12S 1 -23 1
5410-S17-16-16 -16 1 -16 -16S 1 -28 1
5410-S17-4-4 -4 1 -4 -4S 1 -12 1
5410-S17-6-4 -4 1 -6 -4S 1 -12 1
5410-S17-6-8 -8 1 -6 -8S 1 -17 1
5410-S17-8-8 -8 1 -8 -8S 1 -17 1

5400 Series
Low Air Inclusion Refrigerant
Assembly Instructions/Component Part Numbers

Typical Male Coupling Half (S2)
Assembly Instructions
Steps:
1. After tubing or hose has been connected to adapters

1 and
12 , install O-Rings
2 and
11 . on adapters. Be sure O-Rings are not twisted.
2. Oil O-Rings
2 liberally with system fluid to prevent them from scuffing and tearing when coupling body is threaded on adapter.

3. S2 Half—Lubricate poppet face with system fluid. Insert poppet valve assembly

3 into body
4 . Tighten body 4 on adapter 1 . After body and adapter make metal-to-metal contact, tighten by rotating body
4 1/8” with respect to adapter
1 or torque per table value.
S5 Half—Oil O-Ring 9 . liberally with system fluid. Insert valve and sleeve assembly 10 into body
8 . Tighten body

on adapter
12 . After body and adapter make met-al-to-metal contact, tighten by rotating body 8 1/8” with respect to adapter
12 or torque per table value.
4. Coupling Connection—Lubricate gasket seal
5 on 5400-S2 half with system fluid. Thread union nut

on 5400-S2 half. Tighten union nut to torque values shown in table. Be sure S2 and S5 bodies do not rotate during connection.
Component Part Numbers
Item Dash Size –4 Number O.D. Tube Size 1/4”–3/8”
Typical Female Coupling Half (S5)
Bulkhead Mounting—S2 Half
Install lock washer
6 on S2 half. Insert S2 half through bulkhead, and tighten jam nut
7 so that lock washer teeth are fully compressed.
NOTE: Lock washer 6 must be between hex of S2 half and bulkhead.
Maximum Bulkhead Thickness
Body Lock Washer Lock Washer Size Installed Not Used
. .206 .256
. .136 .203
. .232 .292
1 .101 .161
Torque Values
Recommended torque values in ft. lbs., are listed below.
Adapter to Body
Dash Braze Type Non-braze Type S2 Half Size or Aluminum Steel or Brass to S5 Half
–4 6–8 12–15 10–12
–8 15–20 35–45 35–37
–12 35–40 45–55 45–47
–16 50–60 55–65 65–67
.IMPORTANT: Generous lubrication is required for all gaskets and O-Rings. Use refrigeration oil only when used in refrigerant system.
–8 –12 –16 Line 1/4”–5/8” 5/8”–7/8” 7/8”–13/8” Ref.
Typical Male Half 1
1 Tubing Adapter 202208–*–4 202208–*–8 202208–*–12 202208–*–16 2
2 O-Ring 22546–12 22546–17 22546–23 22546–28 3
3 Poppet Valve Assembly 5400–S20–4 5400–S20–8 5400–S20–12 5400–S20–16 4
4 Body 5400–17–4S 5400–17–8S 5400–17–12S 5400–17–16S 5
5 Gasket Seal 22008–4 22008–8 22008–12 22008–16 6

6 Lock Washer 5400–54–4S 5400–54–8S 5400–54–12S 5400–54–16S 7
7 Jam Nut 5400–53–4S 5400–53–8S 5400–53–12S 5400–53–16S 8
Typical Female Half 9
8 Union Nut and Body Assembly 5400–S16–4 5400–S16–8 5400–S16–12 5400–S16–16 10
9 O-Ring FF91178–10 FF91178–112 FF91178–116 FF91178–214 11
10 Valve and Sleeve Assembly 5400–S19–4 5400–S19–8 5400–S19–12 5400–S19–16 12
11 O-Ring 22546–12 22546–17 22546–23 22546–28 13
12 Tubing Adapter 202208–*–4 202208–*–8 202208–*–12 202208–*–16 14

*Specify O.D. Tubing size of adapter required in 16th of an inch. Example: –4 coupling with 3/8” O.D. tubing is 6/16 or –6. Part number is then 202208–6–4.