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Saturday, September 21, 2019

How to Repair a Leaking Hydraulic Hose Without Special Tools or Expensive Equipment

Field Fit Hydraulic Hose fittings are a two (2) piece design that screw On To and In To a Hydraulic Hose using only basic hand tools and following a certain sequence, when fully assembled the connection is rated to work safely up to the full pressure rating of the hose.


Field Fit Reusable Hydraulic Hose Fittings are designed to repair leaking Hydraulic Hoses or to be used in new Hydraulic Hose assemblies, Field Fit Reusable Fittings only need basic hand tools for assembly no expensive equipment is required. 

To quickly repair or replace a leaking hydraulic hose you will require some basic mechanical knowledge, you should have access to simple hand tools and be capable and responsible enough to safely find and remove the damaged or leaking Hydraulic Hose. 




Below is a visual explanation of the Hose Assembly Process.
More details follow below this diagram. 



CAREFULLY look for and find the leak from the damaged hose. 
(Do Not use your hands if the machine is running, use a ruler or piece of cardboard, also wear neoprene gloves and safety glasses)


Once you have found the Leaking hose and removed it from the machine
 You will require the following five (5) things

1. A handful of D.I.Y Reusable Hose Fittings  

(The best way to identify the thread on a hydraulic hose fitting is to download a mobile phone app there are a few apps available from Parker, Ryco, and Taipan. 

Here is the link to  Ryco Thread ID Mate 

  


2. Hydraulic Hose cut to the correct length 
(see below on how to cut Hydraulic Hose)

3. Basic hand tools Spanners and Wrenches 
(Imperial Sizes spanners are preferred but metric ones will also do the job)   
4. An angle grinder with thin cut off wheel to cut the hose (or a Drop Saw that Cuts Steel)
(Disclaimer, Hydraulic Hose is Reinforced with many fine high tensile steel wires, Be Warned! carefully handle the Cut Hose Ends and any damaged hose as the fine steel wires will easily penetrate your skin causing you Pain and Loss of Blood! 
In an emergency you can cut the hose using a hacksaw with a fine tooth blade, (32 teeth per inch or more might just do it), but the cut will not be clean or tidy and may cause some assembly difficulties, also the blade or blades used will be useless afterwards) 



5. A Vise (with soft jaws if you have them) mounted to a solid bench or other heavy object. 
A vise is preferable but is not essential, but it will allow you to make your Hydraulic Hose assembly much faster and easier.  


Before you start we suggest you watch this informative 12 minute video to get an idea what is required to complete a Do It Yourself D.I.Y Hydraulic Hose Repair and or Assembly using Reusable Field Fit Hydraulic Hose Fittings.

Click here to watch our 12 minute You Tube D.I.Y hose assembly Video. 
or click the arrow on the You Tube picture below  


If this type of hydraulic hose repair  interests and challenges you and is within your technical and physical capabilities, Please visit our secure website for more information.

Mobile Hose Fixers & Hydraulics

Alternatively please visit our secure online store to select and purchase your required parts or follow the links below .




To Purchase 1/4" 2 Wire 5800 PSI rated hydraulic hose from our secure online store click here












To purchase 3/8" 2 Wire 4800 PSI rated hydraulic hose from our secure online store click here















To purchase 1/2" 2 wire 4000 PSI rated hydraulic hose from our secure online store click here














To purchase JIC Field Fit Hydraulic Fittings from our secure online store click here 














For a complete store overview and everything hydraulic, including, Hose, Fittings, Adaptors, Valves, Motors, Pumps, Filters, Pressure Gauges, Cylinders and Rams please visit our secure online store.

For an even more detailed explanation and instructions on the entire hose removal process, including the important hose selection, hose fittings and assembly please Click here

If you get stuck, need urgent assistance or just want to talk to a human about your particular project or problem please use the link below to contact us by phone or us or send a message.  

 For Mobile or Workshop Service, Advise and Technical Support click here to Contact us

Prepared, Written & Photographed.
by Minos Mantzavinos
Managing Director
Mobile Hose Fixers and Hydraulics
30 Palings Court,
Nerang, Gold Coast, 4211, Australia.
+61 (07 5563 1982
sales@mhfgc.com.au

Sunday, July 28, 2019

Earn Good Money Providing Mobile Hydraulic Hose Repair Services, PART ONE of an EIGHT Part Comprehensive online Course that will show you the skills required to Remove, Identify, Manufacture and Install High Pressure Hydraulic Hoses.

Introduction


This Hydraulic Hose Training manual has been put together by an Australian Company based on the Gold Coast. 
Mobile Hose Fixers & Hydraulics has been in business for over 20 years so they have learned quite a lot of skills and techniques about Hydraulic Hoses, Fittings and High Pressure Systems and Equipment.

You can use this course as both a guide and a reference to assist you to carry out your work safely, efficiently and most importantly profitably.

COURSE INDEX


Introduction      -        This Info / Training Manual and all it contains.  


Safety              -                Correct Attire

-                Safety Footwear

-                Safety Glasses

-                Head Protection

-         Dehydration

-                Hearing Protection

-         Vehicle Maintenance

-         Types of Vehicles to Use 



Site Safety       -        Positioning your vehicle
-                On-site Safety Regulations
-                Machine Safety
-                Hydraulic Pressure Tanks
                        -         Fault Diagnosis with Hands
-               Cracking a Hose
-        Welded Joints
-               Suction Hose (Wire Exposed)
-                Using Correct Tools
-                Job Completion
-        Business Safety
-        Workplace Harassment 
-        Discipline, your conduct and that of your team. 

Hoses                -        Types of Hoses
                           -        Dash Sizes
                           -        Hose Applications
                           -        Hose Identification
                           -        Hose Reinforcement

END OF PART ONE. 
For Outline of the Rest of Course (Parts Two to Eight) Please go to end of PART ONE.
DISCLAIMER
IMPROPER SELECTION, INSTALLATION, IMPLEMENTATION AND/OR OPERATION BY ANYONE OTHER THAN PERSONS WITH APPROPRIATE TECHNICAL AND MECHANICAL TRAINING CAN RESULT IN DAMAGE TO EQUIPMENT OR PROPERTY, SERIOUS PERSONAL INJURY OR DEATH.
PROPER PRECAUTIONS AND SAFETY PROCEDURES SHOULD BE IMPLEMENTED PRIOR TO  REMOVAL, REPAIR, INSTALLATION AND OPERATION OF EQUIPMENT.


Introduction

This Hydraulic Hose Training manual has been put together by an Australian Company based on the Gold Coast. Mobile Hose Fixers & Hydraulics has been operating for over 20 years so we know a few things about Hoses, Fittings and High Pressure Hydraulics.

You can use this course as both a guide and a reference to assist you to carry out your work safely, efficiently and most importantly profitably.

As a Hydraulic Hose Technician, you must make a systematic review of each situation and then select and install hoses and fittings and other spare or replacement parts necessary to fulfil the requirements of the application.

It is absolutely important that you observe and obey all safety requirements before, during and after work has been carried out.  You are required under the Australian Workplace Health and Safety Act to notify the owner or operator of any unsafe conditions or possible premature failure of hoses or associated fittings.

Care must be taken to avoid oil spills. Appropriate caps and plugs must be fitted and drip trays used where possible, in order to minimize spills. When spills occur, it is necessary to use rags or an approved oil absorbing material to ensure that the oil is contained and removed.

Note:  It is an offence against Australian Environmental legislation to allow oil to be introduced into the storm water drainage system. Under no circumstances may spilled oil be flushed or dumped into gutters or storm water drains.

This course is one of the major sections in the “Mobile Hose Fixers and Hydraulics Operators Folder" which is a guideline to assist you in marketing yourself as a Mobile Hose Fixer, It outlines “on the job” procedures, and gives practical advice on hose making.  You may, however, come across unusual situations requiring innovative solutions.  Using your initiative to resolve these situations will be required, and will help you to become a better Mobile Hose Fixer.  You must always adhere to all safety procedures, and ensure that checks are carried out under working conditions. 

Remember: Advice is only a phone call away.  If you are unsure, contact Mobile Hose Fixers& Hydraulics. in Gold Coast Australia. 

Your Workplace Safety Policy

Safety – General

Correct Attire
Try to always wear the Mobile Hose Fixers uniform. 
Black Cotton Cargo Pants (these pants give you room to move and lots of pockets), Black Cotton Short Sleeved Shirt, Black Cotton or Bamboo Socks and Black Steel Capped Safety Boots. As well as looking professional, the uniform of good quality and can stand a great deal of rough punishment.  Make sure you have enough uniform sets We recommend 5 sets changed Daily to suit your needs.  A Reflective or high-visibility vest or clothing is now mandatory on most work sites.

Safety Footwear
Safety footwear with Steel Toe Caps is a must and should be worn at all times when carrying out repairs either on-site, or in the workshop.  Safety footwear comes in a range of styles and a variety of materials.  Remember, the majority of spillage is oil, so the material of the footwear should be oil as well as slip resistant.


Safety Spectacles
Contrary to what most people think in regard to safety spectacles, is that you should only wear them when grinding, drilling, buffing etc, you should in fact wear them when dealing with anything high pressure whether it is static or fluctuation pressures.

Safety Hats
Safety Hats or hard hats are to be worn where instructed, usually at a construction site or where a sign displays the use of safety hats.  Safety Hats will also protect your head and scalp from UV rays from the sun as well as from low obstacles that you need top duck under. The site Safety Officer may question you if you are not wearing a hat, and can actively order you off the site.

Dehydration
Just about every new guy we have employed has suffered from the effects of dehydration because they ignored our instructions on taking ample drinking water with them to a job. 

You will for the most part be working outside on an open exposed site under the sun, in the wind and usually in close proximity to hot equipment, engines and pumps. As this job can at times be physically quite demanding, the lack of available drinking water can lead to strange side effects such as lack of concentration, dizziness and nausea, if these effects are ignored can result in mistakes, and or even deadly accidents. 

Make sure you take with you to each job at least 3 liters of cool clean drinking water. If you perspire a lot you make also want to consider taking an electrolyte supplement to replace essential salts and minerals perspired out.

Ear Protection
The wearing of hearing protection may be a mandatory safety requirement in some workplaces, or at specific locations within a workplace.  In most instances appropriate signage will alert you to this requirement.   

However, even when hearing protection is not required, consideration should be given to wearing hearing protection in workplaces that do generate excessive noise. 
This would be more common in factory situations where injection molding or stamping machine were in operation.  

On construction sites, it would be wise to wear some sort of hearing protection if you were working close to drilling machines or rock breakers for some length of time.

Welding Goggles
Welding Goggles should be used at all times when electric or gas welding.  Similar to safety spectacles, they are to be used to protect your eyes.  Irreversible damage can be caused to eyes due to the brightness of the light that is radiated when welding

Vehicle Maintenance
The mobile hose operator, must maintain a regular service program for the vehicle regardless of its age. This ensures that the vehicle remains reliable (paramount to business success), and safe to operate.

In addition to regular mechanical servicing, the van operator must also check the condition of tyres, wiper blades, bulbs, fluid levels, reverse beepers etc. in accordance with the manufacturer’s recommendations.

Specific information should be available in the vehicle’s owner’s manual. Please see vehicle weekly Inspection Sheet in appendix. 

Types of Vehicles to Use 
We have tried and used, Utes, Vans and Light Trucks between 3.0 to to 4.5 tones Gross Vehicle Mass.

Based on our experience the most reliable, user friendly and available space has come from Using Light Trucks with swing up doors on all sides. They usually are built stronger can carry more weight and are more cost effective.

We choose to use Isuzu Trucks mainly because in Australia they have market share and therefore parts are readily available at a reasonable prices, but more importantly because we have found that with regular maintenance, parts are rarely required other than the mandatory consumables such as oil and air filters, tires, brake pads or shoes and the occasional starter motor. 


Light Truck 4.5 Ton GVM with Steel Box and Swing Up Doors
working on Marine Piling Barge Refit. 

Safety On-Site

Having the correct safety equipment is essential as mentioned in the previous section.  Further to this; and depending on the situation or the job which is being carried out by you, it may be necessary to check a few items before proceeding with the actual job. For your personal safety, complete a site assessment prior to beginning any tasks. Please see our compact site checklist. 

Position of the Vehicle
Always try to position the vehicle as close as practical to the work-site, without interfering with other people or their workplaces.  If in doubt, ASK! 
Always try and position your vehicle so that when the doors open they provide shade and protection from direct sunlight.
In windy, dry and dusty conditions (hot or Cold) try and use the vehicle to protect you and the job you are working on from these negative elements.

Safety Regulations
When entering or working on-site, observe all safety regulations, both inside of buildings and outside on construction sites.  This would include all speed limits and road signs etc.  If in doubt or an unfamiliar site, it would pay to call in at the office or seek directions from the appropriate persons.

Safety at the Machine
In all instances avoid working on a machine whilst it is in operation, or the motor is running.  It may be necessary for the operator to work his controls to correctly diagnose a fault or leak.  Once satisfied, the operator should turn everything OFF and vacate the machine or vehicle whilst you are working.  Many injuries and fatalities have occurred because of a misunderstanding.  Never start a machine before you are 100% sure of how to turn it off.  Anything could happen.  An arm could drop and injure somebody or worse.  Also once you start the machine, it doesn’t take long to pump all the oil out of a blown hose.  Then you’ve got all sorts of dramas.

Pressure Tanks
Some machines that you will work on, predominantly earth moving machines, may have a pressurized hydraulic tank.  If so, your initial procedure before undoing hose fittings will be to release the tank pressure.  Usually the operator is aware of the procedure.  However if in doubt, find out before proceeding.  As well as being embarrassing, it can be a dangerous situation undoing a pressurized fitting.

Feeling for a Leak
When diagnosing and more specifically looking for a leak in a hose, it may become difficult in locating because of the different circumstances surrounding the position of the hose.  If so, resist using your hand to feel for a fault on the hose, it can cause you injury which in turn could result in having you laid off work and hence, no income.

Cracking a Hose
At the point of actually starting to undo the hose fitting or “cracking” the hose, it is imperative that you are confident that it is not going to cause a hazardous situation to you, or cause damage to the machine or surrounding fixtures etc. 

·         If in doubt check with a person who does know before proceeding. 
·         Fatalities have occurred due to the fact that this has been overlooked. 
·         In some cases it may be necessary to remove several hoses or hose fittings, and because these hoses are not at fault, they may still be holding pressure in which case you may have to chock or secure a certain part or parts of a machine before proceeding.
·         Please ensure that all hoses that have been disconnected are free from any blockages and or check valves.
·         Ensure that both ends are free from plugs and caps before cutting, re-ending or shortening.
·         Ensure all parts/linkages are secured properly/resting securely on the ground

Pinhole Leaks and Oil Injection Injuries
Probably the most common injury associated with hydraulic systems is the result of pinhole leaks in hoses. These leaks are difficult to locate. 

A person may notice a damp, oily, dirty place near a hydraulic line. Not seeing the leak, the person runs a hand or finger along the line to find it. 

When the pinhole is reached, the fluid easily can be injected into the skin as if from a hypodermic syringe. Immediately after the injection, the person experiences only a slight stinging sensation and may not think much about it. Several hours later, however, the wound begins to throb and severe pain begins.

By the time a doctor is seen, it is often too late, and the individual loses a finger or entire arm. Unfortunately, this kind of accident is not uncommon. To reduce the chances of this type of injury, run a piece of wood or cardboard along the hose (rather than fingers) to detect the leak (see Figure 1).

Figure 1 The Dangers of Oil Injection
and how to safely check for Leaks

Removing Welded Joints
When at any stage you apply heat to a fitting which still has the remains of a hose attached, do it with care and always have a hose tail or fitting secured when applying heat, as it will blow off with a force strong enough to cause injury if struck.

Suction Hose !
Although suction hose is only used at a low or negative pressure and doesn’t appear to create a safety threat, it is the makeup of the hose which can cause serious injury.  Suction hose, because of its application, can in some cases collapse which will cause a restriction.  To overcome this, two spring steel strands are moulded into the hose.  The unsafe condition arises when the hose is cut.  The wire strands are exposed and tend to protrude outwards.  In all cases the wire is to be made safe by cutting it behind the end of the hose end.

Correct Tools for the Job
As well as selecting the correct spanners for a certain size hose tail of swivel nut, or the correct size welding tip, or even the correct jaws for the crimping machine, along with the correct tools comes the associated safety equipment.
e.g.             Welding:                       Gloves, Goggles, Boots and Clothes
                                                Grinding:                          Gloves, Safety Spectacles, Boots, Clothes and Hearing Protection
                                                Dismantling:                     Clothes, Boots, Gloves and Safety Spectacles.

Completion of Job
Along with checking the job for leaks, and hose positioning, point out if necessary any unsafe condition to the operator.  If it’s out of your control to make safe, then as well as telling the operator, you should make a note of it on your docket.  Any extra materials, equipment or oil spillage should be removed or cleaned up; or the necessary arrangements made for the removal and clean up.  The bottom line is to cover yourself, especially where safety is involved.

Business Safety

Protect your business and that of the remainder of the team by completing the job so that the machine you’ve worked on is safe.  E.g., If you haven’t cleaned the dirt out of a hose or if you put dirty oil back in the tank, a number of failures could occur.  Make sure that your future work with that customer is safe.

 Workplace Harassment                               
As your company grows and you add team members your company should strive to maintain an environment of mutual respect, free of all forms of harassment. Inappropriate behaviour, such that gives offence; makes employees feel intimidated or humiliated at work; negatively impacts on employee morale or interferes with work performance, will be considered and treated as harassment. Furthermore any or all discrimination based on sexual orientation, ethnicity, racial, religion, disability or age will be considered harassment.
Scope
This workplace harassment policy applies to all employees or contractors, public visitors, clients and anyone else whom employees come into contact with during the discharge of their professional duties.

Policy elements
Harassment may include but is not limited to bullying, intimidation, insults, malicious gossip, victimisation etc. Employees should not be obliged to tolerate any form of misconduct that undermines the integrity of their relationship to the company or creates a hostile work environment.

What is the definition of harassment in the workplace?
While it is impractical list all occasions which would constitute harassment, we nonetheless provide some indicative examples:
·         Sexual harassment
·         Discriminatory harassment
·         Unwelcome sexual advances,
·         Requests for sexual favors or coerced sexual acts
·         Derogatory comments on a person’s ethnic heritage/religious beliefs
·         The display of objects which are degrading to members of a particular group
If an employee experiences or witnesses harassment by any other employee, customer or vendor, they are obliged to report the incident as soon as possible to their immediate supervisor or to the Human Resources department. All reports will be discreetly and confidentially investigate to determine whether harassment has occurred.
Grievance Procedure
All your supervisors and managers are responsible for ensuring that policies designed to prohibit harassment in the workplace are applied at all times and that all procedures and practices are free of discrimination.  All staff are obliged to follow legal guidelines and company principles.
In cases when rules are adjudged to have been violated, employees can address the offender directly. If the issue is not resolved the complainant can report it to the Human Resources department or their immediate supervisor. The report will be investigated in a timely fashion and all parties listened to. The employee that suffered the offense will be protected against any further form of harassment or victimization.
Disciplinary Consequences
Any such actions, when determined, will bring prompt disciplinary steps against the offending party, including counseling, warnings, suspensions or termination.
Hydraulics

Damaged gear from skip bin truck pump caused by over speed and heat. 

Hydraulics in general like valves, valve banks, cylinders, motors and pumps etc. are an area that you should consider expanding into and as such there will be times when you will be completely out of your level of expertise, experience and comfort zone. In these situations if you are unsure just say so, but also advise the client that you will call the main service centre and ask for backup or advice.

A hydraulic system may be simple and easy to follow, or on the other hand, with a number of assorted valves installed in a system, it can be very complicated as well as expensive to repair.  It may be that you feel obliged to help the customer by removing hydraulic parts which may be at fault.  However, you must know your limitations.

Try and build alliances with companies that deal in hydraulics or specialise in one brand of machine only.
As you gain experience, so does your ability to diagnose faults in a hydraulic system.  If you can confidently refer someone, as well as helping the customer, you are giving the hydraulics person an opportunity to carry out a repair.  This referral should be reciprocal and hopefully a “win – win” situation.

Hose And Fittings

5 Short Hose Assemblies with BSPP Female Swivel Ends 
What is a Hose?

A hose may be made up from many different materials and constructions depending on the specific application and environment.  It consists of a tube to carry liquid or gas, a reinforcement to enable the tube to use high pressure, and a cover to protect the reinforcement and the tube from the environment.

Basic Hose Construction
There are a number of different hose construction each with their own special or general recomended applications we use the common SAE100R** designations as they are widely used in the Australian Hydraulics Industry.

Please be aware that  the higher the SAE100R** number does not always represent the higher the pressure or specification of the hose.

Mobile Hose Fixers And Hydraulics use the following main types of SAE Designated Hose Construction.
100R1AT, 100R2AT, 100R4, 100R5, 100R7, 100R12, 100R13, 100R14, 100R15, 100R19    

Types of Hoses
Because of the different substances as well as the range of different pressures hoses endure, so too, the range of different hose constructions.  These hose constructions can vary from your common push on low pressure, single cotton braid type hose, to ultra high pressure multi-spiral type hoses. 

Stainless steel convoluted Teflon hose to six inch stainless steel delivery hose.  These different sizes and types of hoses are illustrated below.

The most common hose used in hydraulic oil transfer as a pressure hose, is steel wire reinforced synthetic rubber hose.  

Specialty hoses, such as chemical transfer hose, may have to be sourced for specific uses.  If so, refer to a hose compatibility chart or chemical resistance chart in your Catalog.  As you become more experienced, the more conversant you will become with regard to the best and most practical hose to use for a particular job.

Hose Sizes
All hoses, regardless of size, pressure rating or material, is measured and identified by its inside diameter (I.D.).  These measurements are in imperial measurement, and are generally in increments of 1/16 inch.  In the case of SAE Hydraulic hose, measurement (although measured in 1/16 inch increments) is referred to in a code size.  These code sizes are also known as “dash” sizes.

Hose Size and Dash Sizes
Hose sizes are expressed in terms of 1/16 inch increments.  That is, size 04 = 4/16” I.D. or ¼”; size 
Full Inside Diameter. – Normally used in high pressure rubber covered hose.


Tube Size
Tube size is measured on The Outside Diameter (O.D.), and should be taken into account when replacing with hose. In some cases hose is manufactured to cater for the I.D. of the tube size.  Examples of these are:

·         Air conditioning hose
·         Steel Seamless tubing
·         Air brake hose
·         Teflon hose


Hose Reinforcement
Pressures may vary from low pressure or a vacuum, to extremely high pressure.  The pressure will determine the amount and type of reinforcing.  The reinforcing varies from a cotton or nylon braid for low pressure, to multi-spiral high tensile stainless steel reinforcing for ultra-high pressure applications.  Flexibility and size must be considered for a given pressure range.  The layers of reinforcing in some hoses are separated by a layer of rubber or other materials.

Note:  Most hoses have a 4:1 safety margin. E.g., 5000 psi working pressure : 20000 psi burst pressure.

BRAID AND SPIRAL REINFORCEMENTS

Single Fabric Braid

Single Wire Braid

Double Wire Braid

Multi Spiral

Hose Selection

When it is necessary to select a hose for a particular application, the following information will be required for the correct selection:

1.         Operating pressure
2.         Flow Rate
3.         Fluid or substance to be carried by the hose
4.         Temperature range of fluid or substances
5.         Ambient temperature of surrounding conditions

1.    Operating Pressure

The operating pressure determines the hoses reinforcement.  The working pressure or operating pressure should be equal to at least any peak pressure the hose may encounter.

2.    Flow Rate

The flow rate determines the inside diameter of the hose.  When replacing a hose, always try to select a hose equal to the one you are replacing.  Avoid replacing a hose which is smaller in diameter.  If at any stage you have not got the correct diameter hose for the replacement, go larger in diameter than smaller.

3.    Fluid to be Carried by the Hose

This will help determine the hose tube material.  Refer to the compatibility chart in the catalogue and select a suitable hose and fitting material, compatible with the fluid to be carried.

4.    Temperature Range of Fluid or Substance

This will help to determine the hose tube material.  Refer to the hose section of the catalogue and select a hose that will suit the fluid temperature range encountered.

5.    Ambient Temperature and Type of Atmosphere

This will help determine the material used in the hose outer cover, which is normally equal to that of the hose tube listed in the hose section of the catalogue

Caution:              The maximum flow rate of the hydraulic pump in a system may not be the maximum flow to be carried by the hose.  For example; a hydraulic lifting cylinder may be allowed to descent rapidly under the influence of its load, causing a much higher rate of flow in the hoses connected to the cylinder than that encountered during the lifting cycle when only the pump flow rate is seen.



Hose Identification
Identifying hoses for a specific purpose becomes easier as the more experienced you become as a Hose Fixer. Along with identifying the hose by its size (I.D. measurement) hoses can be identified by the cover colour and reinforcing. In many cases all information which is relevant for a repair is written on the hose cover, (i.e. type, working pressure, size etc.)

Hoses that are used for specific purposes (petroleum, gas etc.) have standard markings so that they can be identified easily, and there is less chance of a mistake being made. 

Low pressure, or push on hose, comes in a variety of types for a number of different purposes.  If you are in doubt as to whether the hose selected is suitable, ask or refer to a hose chart.

Attention to this detail is paramount where spillage could cause contamination to equipment or the environment.  Chemical transfer hose is sometimes identified by a helical strip on a black cover.  Another hose which can be identified by a coloured strip is suction hose.  This is larger in diameter, and holds its form by two (2) spring wires vulcanised into the rubber.  As mentioned previously, experience plays a big part in hose replacement.  If in doubt, use a hose that would adequately do the job.

Although the service van has a range of hoses, the most common hoses used are wire braided and multi-spiral hoses as shown in the diagrams and specifications below.


Hose Colours
Hoses may be found in a number of colours and may include a coloured lateral trace.  The most common colours include red, blue, grey and black.  In the past these colours were used to identify various attributes (including pressure and temperature ratings), however this is not usually the case with modern hoses.  The most common colour in current use is black.

Hose Inner Tube
The hose inner tube is made up from a number of different sizes and varied materials.  Depending on what substance and in what volume per minute (flow) is being transferred, will depend on the inner tube material and size, and in some cases the covering also.  A particular hose inner tube may be compatible to a number of different substances, and if in doubt as to the compatibility, reference should be made to the chemical resistance chart, Appendix 2.


Below is a list of the more common hose inner materials.

·         Neoprene (synthetic rubber)
·         Nitrile
·         Teflon
·         Nylon
·         Polyester

Below are examples of different types of hoses with different types of inner tubes.

100R1AT

Good Medium Pressure Hose 
PRESSURE Depending on size: Working pressures from 1200 to 3200 PSI (88 to 225 Bar) 
APPLICATION:  Medium pressure hydraulics. 
FlUIDS: Oil, Air, Water, Coolant, Diesel. 
FLUID TEMPERATURE RANGE:  -40 degrees C to +120 °C  
TUBE:  Synthetic rubber.
REINFORCEMENT:  1 layer of Braided high tensile Wire.
COVER:  Abrasion, UV, Ozone &weather Resistant Synthetic Rubber.


SAE 100 R2AT
Good High Pressure Hose 
PRESSURE Depending on size: Working pressures from 2400 to 5800 PSI (165 to 400 Bar) 
APPLICATION:  High pressure hydraulics. 
FLUIDS: Oil, Air, Water, Coolant, Diesel. 
FLUID TEMPERATURE RANGE:  -40 degrees C to +120 °C  
TUBE:  Synthetic rubber.
REINFORCEMENT:  2 layers of Braided high tensile Wire.
COVER:  Abrasion, UV, Ozone &weather Resistant Synthetic Rubber.



SAE 100 R4
Application: Low Pressure Oil suction & discharge hose for use in low pressure and vacuum applications with petroleum base hydraulic fluids.
PRESSURE Depending on size: Working pressures from  - full Vacuum to 60 - 300 PSI (-1 to 4 - 20 Bar) 
CONSTRUCTION - Inner Tube; Synthetic oil resistant rubber. 
FLUID TEMPERATURE RANGE:  -25  °C to +100 °C
REINFORCEMENT One high tensile polyester cord  and (1 or 2 helix wire).
COVER Synthetic oil and weather resistant rubber - Black


SAE 100 R5
Medium Pressure hose with above average temperature resistance. 
PRESSURE Depending on size: Working pressures from 300 to 3000 PSI (20 to 200 Bar) 
APPLICATION:  Medium Pressure Hydraulics extensively used in Heavy Duty Automotive and Marine Engines.
FLUIDS:  Hydraulics handling petroleum and water base fluids and air, 91 octane fuel, diesel and lubricating oils, fire resistant hydraulic fluids and other industrial fluids 
FLUID TEMPERATURE RANGE:  -49 °C to +150 °C  
TUBE:  AQP Elastomer.
REINFORCEMENT:  1 layer of Braided high tensile Wire.
COVER:  Polyester Braid in Black or Blue.

SAE 100 R12, SAE 100 R13, and SAE 100 R15
Ultra High Pressure Hoses
WORKING PRESSURE 
Irrespective of Hose Bore Size 
ALL SAE 100 R12  HOSES ARE RATED TO 4000 PSI (272 Bar)

ALL SAE 100 R13  HOSES ARE RATED TO 5000 PSI (340 Bar)
ALL SAE 100 R15  HOSES ARE RATED TO 6000 PSI (400 Bar)

APPLICATION:  High to Ultra High Pressure Hydraulics with Repeated High Pressure Impulses.
FLUIDS: Oil, Water, Liquid Bentonite (Drilling Mud) 
FLUID TEMPERATURE RANGE:  -40 °C to +121 °C.
TUBE:  Synthetic Oil Resistant Rubber.  
REINFORCEMENT:  Sizes -12, -16 = 4 layers of spirally wound high tensile wire,  
Sizes -20, -24 = 6 layers of spirally wound high tensile wire.
COVER:  Abrasion, UV, Ozone & Weather Resistant Synthetic Rubber.



SAE 100 R14
Medium Pressure High Temperature Hose 
PRESSURE Depending on size: Working pressures from 880 to 3200 PSI (60 to 220 Bar) 
APPLICATION:  Medium pressure Fluids Gasses and Chemicals. 
FLUIDS: Hot liquids, Gasses and Chemicals, Some Food Products, Oil, Compressed Air, Water, Steam, Coolant, Fuels. Brake Fluids. 
FLUID TEMPERATURE RANGE:  -54 degrees °C to +260 °C  
TUBE:  Polytetrafluroethylene  P.T.F.E. (Teflon) .
REINFORCEMENT:  1 layers of Braided Stainless Steel 304 High tensile Wire.
APPLICATION :High temperature and/or corrosive fluids.



SAE 100 R7
Medium Pressure Hose 
WORKING PRESSURES, Depending on size: Working pressures from 1000 to 3000 PSI (70 to 210 Bar) 
APPLICATION:  Medium pressure Fluids Gasses.
FLUIDS: Oil, Compressed Air, Water, Coolant, Fuels, Brake Fluids. 
FLUID TEMPERATURE RANGE:  -40 degrees °C to +100 °C (Water limited to 70°C) 

TUBE:  Unplasticised Polyester Tube .
REINFORCEMENT:  1 Layer of Braided Polyester Fibre.
COVER: Black Polyurethane Outer cover also available in Orange Non Conductive Outer Cover. 


SAE 100 R19
High Pressure Hose
WORKING PRESSURE Irrespective of Hose Bore Size 
ALL SAE 100 R19 HOSES ARE RATED TO 4100 PSI (278 Bar)

APPLICATION: High pressure hose with improved impulse cycles, great performance, smaller OD and Flexibility than SAE100 R12 . Suitable for passage of mineral and vegetable oils, water based solutions and inert gases.
FLUID TEMPERATURE RANGE: Continuous: -40˚C to +100˚C (intermittent to 120˚C)
TUBE:  Synthetic Oil Resistant Rubber.  
REINFORCEMENT:  2 layers of Braided high tensile Wire.
COVER:  Abrasion, UV, Ozone &weather Resistant Synthetic Rubber.


Water Blasting & Jetting Hose
APPLICATION High Pressure HOT water for professional pressure water cleaning applications.
Ideal for dairies, Food processing facilities and other general cleaning applications.


WORKING PRESSURES, Depending on size: Working pressures from 3600 to 5800 PSI (245 to 395 Bar) 
TEMPERATURE RANGE -10˚C to +155˚C.
CONSTRUCTION - Inner Tube; Synthetic rubber resistant to detergents.
REINFORCEMENT: One or two high tensile steel wire braids. 
COVER Abrasion, weather, ozone and detergent resistant synthetic rubber. In low marking Blue or Grey.


Contact information

 
For Hose Repairs, Heavy Equipment & Mobile Machinery Repairs & Service, 
Tel :   (07) 5571 6155
For Online Product Purchase Pick Ups.  
30 Palings Court, Nerang, Gold Coast, QLD, 4211.
Calling from outside Australia
          +617 5571 6155
After hours 24 / 7 Breakdown Support (Greater Gold Coast Area Only)
          0431 022 452
Online Hose Fixers Course Inquiries

For Online Course Details and Pricing 
Or Call our Sales Director
Minos Mantzavinos on +61 (0) 431 022 452 
END OF PART ONE
PARTS 2 to 8 Available from MPM Trading Pty LTD.
Details of remaining Course. 
PART TWO 
                           -        Hose Selection
                           -        Hose Assemblies
                           -        Measuring Hoses
                           -        Hose Skiving
                           -        Hose Positioning
Hose Tails / Couplings

-                Dash Sizes
-                Coupling Sizes
-                Coupling Identification (E, K, L, & N Couplings)
-                Coupling Selection
-                Permanent Couplings
-                Field Service Attachable
-                Push-on Couplings
-                Lifesaver Couplings


PART THREE 
Threads            -        Thread Sizes 
-                Types of Threads
-                B.S.P. Parallel
-                B.S.P. Tapered
-                J.I.C / S.A.E. / U.N.O.
-                N.P.T.
-                Metric

PART FOUR 
Crimp Machines
-                Finpower (Service Truck and Shop)
-                K501 Service Truck
-                Die Sizes and Selection
-                Gauge Settings



Making a Hose
                        -        Working Pressure
-                Hose Diameter
-                Selecting the Correct Hose
-                Hose Application
-                Hose Length
-                Hose Positioning
-                Type of Couplings
-                Skived Hoses
-                Crimp Settings
-                Using a Mandrel
-                Lay of the Hose (the natural bend) 
-         Making a Hose
-         Workshop (Practical Video , You tube)

PART FIVE

Business Procedures

-                Minos Mantazvinos
        
                        -         More Safety

-                Hose Tails / Couplings

-                Threads

-                Hoses (Types)

-                Making a Hose

-                Welding

PART SIX 
Sales Training another important skill to practice and learn as you your profits, success and growth depend on it. 

PART SEVEN

Marketing your products and services

You tube Film

Adaptors           -        Refer Suppier’s Catalogues

Workshop         -        Facilities (Workshop etc)

-                Cut & Weld

Hose Fixer to cut, Machine, File & Silver Solder a Specific Fitting
Welding           -         Lifesavers (its not what you think)
-                Male & Female Adaptors
-                Silver Solder
-                Brazing
-                Hose Cleaning

Communication 
                        -        General
-                Film

-                Actual

PART EIGHT 

Hydraulics        -        Do’s and Don’ts of Hydraulics

Lubricants        -        Monster M Hydro 68
-                Gulf Western ISO 68
-                Dextron III


Profile of a Good Hose Fixer
                           -        Expanded Points from the Training Manual

Conclusion

Revision

Examination    -        Theory
·         Written
·         White / Blackboard Drawings
         ·        Practical
·         Make a Hose
·         Make an Adaptor