technical manual 2011
TRANSCRIPT
TECHNICAL MANUAL
ISSUED BY
INDEX
INTRODUCTION• Introduction• Warning on safety
BASICS OF HYDRAULICS• Hydraulic systems and fluids• Basics of hoses and assemblies• Hoses description• High pressure hydraulics: main applications
HOSE SELECTION• Introduction• Rubber hose structure• Hydraulic hose international standards• Hose selection criteria• Storage and shelf life conditions• Manuli recommendations• Service life considerations• Hose assembly routing
COUPLING SELECTION• Introduction• How to identify fluid connections• End-thread measurement• Couplings selection criteria• MF2000 Manuli part numbering system• MF3000 Manuli part numbering system• MF4000 Manuli part numbering system• Termination ends and torque values• SAE Standard connections• Metric couplings• BSP (British Standard Pipe)• Japanese Style fittings - JIS B 8363• NF French Standard connections• OEM Special connections• Torque values details• O-Ring recommendations• Adaptors• Port dimensions
MINING• Introduction• Mining product range• MDG41 Compliance• MF2000 Manuli partnumbering system • MF3000 Manuli partnumbering system • MF4000 Manuli partnumbering system • Mining adaptors part numbering system• Mining staples part numbering system• Mining ball valves part numbering system
QUICK COUPLINGS• Introduction• QSafe applications• Structure of a quick-coupling• QSafe product range • QSafe part numbering system
REFRIGERATION• Refrigeration applications• Hoses and fittings• Refrigerants and lubricants • Specifications
HOSE ASSEMBLY• Hose assembly data• Cleaning, inspection, testing• Hose assembly installation tips• Hose protection • European legislation on safety and conclusion
MAINTENANCE• Maintenance• Periodic inspections• Hose assembly troubleshooting guide
APPENDIX• System of units and conversion • Glossary• Type approvals
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www.manuli-hydraulics.com
Introduction
INTRODUCTION
The purpose of this booklet is to provide technical informationto support customers, OEMs and users for a proper selection,installation and use of the Manuli products.
Manuli offers an integrated hydraulic product range of fluidconnectors, hose assemblies, hydraulic hoses, couplings,adaptors, accessories and crimping machines.
Catalogue describes the complete product range, while thepresent technical manual has the target to advise you how toproper install and maintain hydraulic products.
All Manuli hydraulic products will provide you with a long ser-vice life if they are properly selected, installed and maintained;the best way to achieve this, is a preliminary deep study ofthe application in order to select the proper componentsconsidering the mission profile and a preventive mainte-nance programme.
Your system/equipment applications study will drive you inthe correct choice of the right Manuli components to achievereliable solutions, ergonomics and suitable hose configura-tions, etc. This booklet suggests how to study the applications,evaluating their severity and technical aspects, in order toavoid potential mistakes since the preliminary design activitiesof the system/equipment.
Preventive maintenance is especially important, in fact thehigh pressures and temperatures which characterise hydraulicapplications make hose and fitting selection, installation andmaintenance critical. If done incorrectly, the risk of injuryand/or excessive and costly downtime increases. That’s whythere are several good reasons to implement a preventivemaintenance programme:• improving workers safety;• avoiding production downtime;• reducing repairs costs, etc.
A preventive maintenance programme will enhance also theproductivity because your equipment will be in good operat-ing condition at any times, minimising safety hazards.
Combining the proper Manuli high quality products with aregular preventive maintenance programme, will keep yourhoses and fittings trouble-free for a long time. An effective pre-ventive maintenance programme can be summarised in thefollowing key elements:• proper hose and fitting selection, evaluating the application
type;• proper assembly installation;• maintaining a safe work environment;
Information contained in this document isintended for guidance only and may besubject to change. Any change will benotified (at the discretion of ManuliRubber Industries) via selected communi-cation channels.
Remark4
FLUID CONNECTORSPRODUCT RANGE
ENGLISH/ESPAÑOL
• regularly scheduled inspections;• troubleshooting (identifying problems and solutions);• well-trained personnel.
Additional technical information on components and acces-sories, are supplied in order to support the assemblers andusers: O-Rings dimensions, torque for coupling installation,routing tips, appendix with measurement units conversion,etc.
The information and details provided in this manual are alsoavailable through dedicated training courses. In addition,Manuli application engineers are always available to assistassemblers and OEMs on product applications. In case ofneed, please contact your closest Manuli representative.
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Safety applications training
WARNING ON SAFETY
Never underestimate the power of ablown hydraulic assembly. Serious injury,death and destruction of property canresult from rupture or blow-off of ahydraulic hose assembly.
Hoses:• damaged or worn out• incorrectly assembled or installed• not properly selected for the intended use/applicationare serious hazards.
Be aware of the dangers connected with hydraulic pres-surised systems/componentsHydraulic fluid under pressure is dangerous and can causeserious injury. Here are listed few common problems that mayarise during the use of hydraulic hose assemblies and systemsunder pressure:
PinholeHydraulic fluid, when released as a fine stream through a pin-hole in the hose, can easily penetrate the skin. If this happens,seek medical assistance immediately. Fluid injections are con-sidered a serious injury requiring prompt medical attention.
LeakLeaking hydraulic fluid is hazardous. In addition to makingworkplace floors slippery and dangerous, leaks also contami-nate the environment. Before cleaning an oil spill, alwayscheck local regulations.
BurstWhether due to improper selection or damage, a rupturedhose can cause injury. If it bursts, people can be burned, cut,injected or injured because of equipment malfunction.
Coupling blow-offIf the assembly is not properly made or installed, the couplingcould come off with subsequent risk for severe personal injury.
Whipping hoseIf pressurised hose ends or end fittings come apart, the loosehose ends can flail or whip with great force and fittings can bethrown off at high speed.
Stored energyHydraulic systems sometimes use accumulators to store poten-tial energy or absorb shock. This energy can create pressurethat keeps the system’s components moving. Charged accu-mulators can be lethal. Always open the accumulator’s valve torelease pressure. Stay out of hazardous areas while testinghoses under pressure. Use proper safety protection.
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Due to the serious criticalities of hydraulic applications it is impor-tant to select and install assemblies with proper criteria:
• select proper hose assemblies for the application, consideringthe numerous factors and conditions affecting the function-ality and technical ability of the hose to meet the require-ments;
• hose assembly routing must not create an injury hazard ordamage to the hose;
• select hydraulic components so that the application's tem-perature, pressure (including the possible peaks) and bendradius do not exceed recommended component limits;
• never mix products from different manufacturers: evaluationof hose and couplings combination requires relevant qualifi-cation programs, including in particular impulse testing andcannot be determined by a simple burst or proof pressuretest. Manuli disclaims all liability for any hose assembly madein violation of Manuli recommendations, procedures andcurrent swaging data (the swaging chart is updated everyyear);
• hoses must not be stretched, kinked, crushed or twistedduring installation or use;
• hoses must not be bent to less than the minimum bendradius;
• do not use hydraulic hose to convey high pressure gasesunless specifically designed and qualified for these applica-tions;
Follow good maintenance practices• establish a program of inspection and eventual replacement
of hose assemblies, considering factors including:- severity of application- frequency of equipment use (mission profile)- past performance of hose assemblies on the same equip-ment (historical data)
• record maintenance data regarding inspections and testingor substitution of assemblies, etc.
• only properly trained personnel should inspect, test or serv-ice hose assemblies.
Avoid injury for operating personnel and users/others• fluid under pressure can cause serious injury. It can be
almost invisible escaping from a pinhole, and it can pierceinto the body;
• do not touch a pressurised hydraulic hose assembly withany part of your body;
• if fluid punctures the skin, even if no pain is felt, a seriousemergency exists and a medical assistance is necessaryimmediately. Missing assistance can result in loss of theinjured body part or death;
• stay out of hazardous areas when testing hose assembliesunder pressure. Use proper safety protection;
• operating personnel must receive training on the use ofhoses, couplings and assembly equipment, hose installationpractices following the current operating manuals andswaging data;
• use only new (unused) recommended hose and fittingswith the recommended swaging machines and correctcrimp information; ensure that your assembly equipment isproperly maintained and calibrated;
• operating personnel must wear safety glasses and properprotective clothes;
• if there are risks impacting safety requirements install properprotective shields and/or restraint systems (whipcheck) toprotect the personnel from potential failures of the pres-surised hydraulic components;
• be aware that some hydraulic fluids are highly flammable.
Refer to SAE J1273 par. 4 specification for further details on safety aspects.
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J1273Recommended Practicesfor Hydraulic HoseAssemblies
Basics of Hydraulics
HYDRAULIC SYSTEMS AND FLUIDS
Energy transmission systemsMotors supply mechanical energy.An electric motor gets its motion from an electric flow of ener-gy, transforming it in mechanical power: supplying anotherform of energy to be used otherwise. Also chemical energy istransformed: a good example are diesel or petrol engineswhose movement supply energy.
Unfortunately this first transformation is often unsatisfactory forthe actual needs of many applications.Not always the place where the action is required can beequipped with a motor and a proper operator.The solution to this problem can be found making energy flowfrom the prime mover to the application point.A common way to do this is by the use of hydraulic systems.
Any mass can have potential and kinetic energy; a fluid canalso "transport" it from one point to another.
For example, waterfalls take advantage of the potential ener-gy linked to the different heights at which the water is beforeand after the transmission.
Some turbines get their motion from the kinetic energy of theused fluid.
Other systems (the ones we will deal with in this manual) usean energy flow under form of pressure.
Hydraulic circuitsA hydraulic circuit is a system to supply energy, transported bymeans of a fluid under pressure.A prime mover drives generally a pump whose task is to senda fluid into a circuit: it converts the mechanical energy of themotor into fluid power.The fluid moves along a pipeline and reaches an actuator:generally a cylinder but often also a hydraulic motor (rotaryactuator).The described circuits can be represented by simple schemesrelated to a system with a linear actuator (cylinder), similarly inthe case of rotative actuators (hydraulic motors).
The pipelineThe pipeline conveys the fluid; it may be built either with rigidsteel pipes or with flexible hoses or also using a combinedsolution.
Many applications would hardly accept a rigid pipeline; oftenthe connected parts are in relative motion between them-selves and a flexible hose suits at best the needs.Moreover, using fluid transmission mainly in engines operating
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fig. 1 - Hydraulic circuit with cylinder
fig. 2 - Basic hydraulic circuit
fig. 3 - Hydraulic cylinders
Actuator
Load
Load
Cylinders discharge linespotential criticalitiesfor hose assemblies:negative load surges
Pump outletspotential criticali-ties for hoseassemblies:- pressure surges- vibration - temperature- severe
installations
Pump
Motor
Tank
at high speed, the systems have also a lot of vibrations; aflexible part in the system can better absorb them so to createa sort of insulation.
Flexible hoses will be widely described in this manual; basicallythe hose consists in a rubber tube winded up by a reinforcementand covered with a rubber or textile layer. The reinforcementconsists in steel wires or textile yarns spiralled or braidedaround the tube (generally 4÷6 wire spirals or 1÷2 wire or tex-tile braids).
The actuatorThe most frequent actuator met in hydraulic systems is a cylin-der. Cylinders may be single or double effect:
• Single effect cylinders consist in a tube in which a piston ispushed by the pressurised fluid. These applications generallyuse gravity to end their cycle and return to the start position.
• Double effect cylinders have a piston with a non constantdiameter: for the whole length the piston's diameter is smallerthan the internal diameter of the cylinder; generally in thecentre of the piston the diameter is nearly equal so to haveat disposal two surfaces to "convert" pressure in force.
The circuit will direct the fluid to one or the other of the inletsmoving the piston, in one or the other direction.
The cylinder bears two oil inlets at each end.
Single acting cylinders and Double acting cylinders are repre-sented in the schemes at side.
Other types of actuators, for example hydraulic motors, arecurrently used to transform hydraulic energy into mechanicalpower.
The fluidsThe most common fluid is certainly water; yet most of the cir-cuits we are describing use oils to convey energy.
Actually the first systems used water and only with increasingcomplexity of technology oils started to be used.The necessity to change came because water couldn’t assurethe required properties: first of all a lubricant action, but alsothe absence of corrosive action and sediments, no evapora-tion at higher temperature and therefore a higher boiling tem-perature. These properties can be found with mineral oils.An oil pump can work at about 2000 cycles/1'. This means itcan be directly connected to the motor. Using a water pumpbetween it and the motor requires a speed reducer as the
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fig. 5 - Single acting cylinders
fig. 6 - Single acting cylinders
fig. 7 - Double acting cylinders
fig. 8 - Double acting cylinders
fig. 4 - Hydraulic motors
maximum number of cycles of this pump is about 200 (themotor can't work directly at such a slow rate).The necessity of a reducer leads to greater sizes of the wholeequipment creating space problems.Furthermore while water causes oxidation and corrosion, oilprotects the material of the pump assuring a longer life of theengines.From a chemical point of view oils have generally higher boil-ing temperatures than water, so they can be used at higherintensity gaining productivity.The difference in price purchasing oil instead of water is certain-ly covered by the advantages here mentioned. The most common oil used in hydraulics is mineral based.Lately it is becoming necessary to use environment-friendlyfluids. These fluids are bio-degradable and commonly calledbio-oils. Their use is constantly increasing replacing mineral oils.
Basically bio-oils can be divided in four families depending onthe base material they are made of:1. Polyethylene glycol base2. Rape-seed oil base3. Synthetic-ester base4. Water based oil
1. Polyethylene glycol base - This family presents raw mate-rial available at a relative low price and a wide temperaturerange. Yet these oils are watersoluble so they can let waterinside and damage the motors they are used for. Furthermorethey are absolutely not mixable with mineral oils.
2. Rape-seed oil base - These oils have cheap raw materialsas well and have a good compatibility with paints.Unfortunately the operating temperature range is not verywide due to bad working conditions at low temperatures andlow stability at high temperatures. They are mixable withmineral oils but this mixability isn't very good.
3. Synthetic-ester base - Long life and a very wide tempera-ture range are the top performances of this family. Of coursetheir price is higher than the others. The compatibility with themechanics of hydraulic systems is also very good.
4. Water based oil - Water based oils are fire resistant, envi-ronmental friendly and acceptable. Their price is quite high,and present limited maximum service temperature.
Also water is still used in certain applications but mainly whereit is directly used as working fluid and its consumption is sub-stantial: water cleaning and water blasting are exampleswhere the pressurised fluid carries out its function and getslost. The main difference between these two applications isthe level of pressure at which the water is used.
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fig. 9 - Pump
While water cleaning applications utilise pressures from 100 to400 bar, water blasting reaches 1450 bar and, water cuttingeven to 2000 bar. It's clear that the first is for domestic applica-tions while the second for industrial ones.Important characteristics to define a fluid are its density and vis-cosity.The density (usually identified by ρ) is the quantity of mass pervolume and measured in kg/m3.Usually the reference is taken at 20°C and the value is about870-900 kg/m3 (water has ρ = 1000 kg/m3).The viscosity is a measure of the resistance of a fluid to creep.Both kinematic viscosity ν and dynamic viscosity η can beused; their relation is η = ρν.
Kinematic viscosity is measured in centiStoke (cSt): 1cSt=10-6 m2/s.Dynamic viscosity in centiPoise (cP): 1cP=10-3 N s/m2.
Hydraulic energyHydraulic energy is usually identified by the letter H and meas-ured in meters.It can as usual be divided into two parts: potential energy andkinetic energy; the potential energy itself can be considered asdue to position (identified by z) and to pressure. Kinetic ener-gy is due to the fluid’s velocity and goes with its square value.The corresponding equation is:
γ is the specific weight
The applications we are interested in, using hydraulic hoses,transfer energy under form of pressure; that is the second termof the equation above, remains the one to be considered.
Just to give an idea about the importance of the three termslet's suppose a 4m long hose of 12,7 mm of diameter, operat-ing at 100 bar, with a water flow of 50 l/1’:
z can be at maximum 4m (hose completely vertical)100 bar = 10000000 N/m2;γ = 1 kg/l = 9810 N/m3 --> p/γ = 1019 m
Q = 50 l/1’ = 0,000833 m3/s
Q = v . πd2/4 --> v = 4Q/πd2 v = 6,58 m/s
g = 9,81 m/s2 --> v2/2g = 2,21 m
It can be noticed how pressure energy takes part for 99,39 %to the total so it can be considered alone for any calculation.
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A flexible conduit to transfer fluids or gases from one point toanother is called hose assembly.
An assembly is basically built with the hose itself, and theextremity connections, solid couplings or fittings.
The hose is the flexible part of the assembly; its structuredepends on the application and on the environment.Basically the inner most part of the hose is the tube, windedup by a reinforcement and completed with a cover.
To connect the hose to the outer system and prevent leakage,dedicated fittings are used. They are put at each end of thehose and crimped to force a tight seal on the tube.Fittings can be either permanent or reusable depending onthe application.
The interface between hoses and fittings is a very importantpoint in the design of the system: their functionalities are ofutmost importance for a correct application.
TubeAs described above the inner part of a hose is the tube; itsfunction is to contain and convey the service fluid.Furthermore it also protects the outer elements of the hosefrom the possible aggression of the conveyed fluid.The material of the tube is chosen among a great number ofsynthetic rubbers. The chemical composition of the com-pounds should be selected to meet the requirements of theapplications.Basically there are some typical families of material assuringspecial properties; the following list shows the most used:
ReinforcementThe tube itself can surely not assure the resistance to the pres-sure of the conveyed fluid; in fact, as mentioned above, thedesign of the tube considers only its compatibility with the fluidto contain, while the very wide range of pressures present inhydraulic applications must be analysed otherwise.
BASICS OF HOSES AND ASSEMBLIES
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HOSES DESCRIPTION
NBR (Nitrile ButadyeneRubber)
CR (Chloroprene)
Polyammide
PTFE
EPDM (Ethylene PropyleneDiene rubbers)
High resistance to mineral andbiodegradable oils and fuels
Mineral oils resistant
Resistant to wide range of fluids
High temperature, oil, fuel andchemicals resistant
Used for phosphate ester based fluids
Tube materials
This element was properly called reinforcement as its duty is togive pressure performance to the hose.The type of reinforcement classifies hoses in two basic families:
• Braided hoses• Spiral hoses
The pressure resistance of the hose must be higher than theworking pressure. The safety factor is defined as the ratiobetween the burst pressure and the max working pressure; forthe hydraulic applications the safety factor is set to 4:1 byInternational Standards, some special static applications aswater cleaning for example (ISO 7751) have 2,5:1 safety factor.For low pressure applications (up to 100 bar for example), tex-tile reinforcements may be used. So nylon, rayon or polyesterfabrics are woven, braided or wrapped around the tube.When the pressure gets higher stronger materials are neededand steel wire spirals or braids are used.Wire braided hoses bear generally one or two layers of rein-forcement (in some cases even three) while spiral ones havecommonly four or six spirals (layers).The application of braids and spirals can also be mixeddepending on the most appropriate design.Between each layer of braids or spirals an interlayer or breakerstrip is put to create a bonding effect and to prevent frictionalwear between the wires.
CoverEnvironment, machines and operators themselves can damagethe reinforcement. The cover, outermost element of the hose,is used to protect it.There are several types of cover, each designed depending onspecific requirements: economy, safety, abrasion resistance,chemical resistance, etc.; even aesthetics are features linked tothe choice of the cover (e.g. colour).
Rubber cover can have wrapped finish: instead of the smoothfinish a wet nylon tape is used around the hose during the vul-canisation; at last the nylon tape is removed and leaves thehose bearing its imprint.
Free steam vulcanisation is also used: the hose is directly vul-canised without any wrapping or shaping method.The vapour steam at high temperature is directly in contactwith the outer rubber cover of the hose.This allows to save some steps of the entire manufacturingcycle saving time and materials.Particular attention must be paid to maintain the tolerancesand to avoid local defects on the cover.Cover finish is smooth.
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fig. 1 - Single braided hose
fig. 2 - Double braided hose
fig. 4 - Spiral hose (6 spirals)
Rubber cover
Steel braid
Rubber tube
Rubber tube
Rubber tube
Innerbreaker
Adhesive rubber layer
Adhesive rubber layer
Rubber cover2nd braid
1st braid
Rubber cover
Body spiral carcass
Rubber cover
Innerbreaker
Rubber tube
Adhesive rubber layer
Body spiral carcass
fig. 3 - Spiral hose (4 spirals)
Also fabric braided cover are yet used: the cover is braidedfabric, often impregnated with rubber adhesive. This is thebest solution when minimum weight and heat dissipation arerequired. This solution is usually used on low or medium pres-sure hoses due to its relative weakness (e.g. R5 hose type).
Coverless type is usually only used for stainIess steel braidedhoses, mostly PTFE hoses.
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HIGH PRESSURE HYDRAULICS: MAIN APPLICATIONS
Construction and public works• road pavers• construction equipment• earth moving equipmentWell known applications use Manuli Rubber Industries universalproduct range. Tractor® hoses are widely used; for heavyapplications Rockmaster® covers is better suited for high abra-sion resistance. On big machines the Manuli RubberIndustries Extreme product range is recommended in orderto offer performances exceeding the standard requirements.
Underground and open pit mining• long wall support• open pit mining equipment• drilling machineFor these applications Manuli Rubber Industries recommendsRockmaster® and Shieldmaster® product ranges offering thehighest abrasion resistance, flame retardant properties of thecover (MSHA approval, etc.), ozone resistance, cover shield.
Energy• off-shore oil platformsThe very severe atmospheric conditions require hoses withcover compounds offering particular characteristics, such asresistance to ozone and sea water. Manuli Rubber Industriesrecommends the use of the Extreme Product range in parti-cular NoZone hose are suitable for extended life exposed toharsh weather conditions and ozone attack.
Logistics• port equipment• material handlingApplications working in continuous long term aging condi-tions, where hose flexibility and high abrasion resistance arerequired. Sometimes the twin hose version is requested.
Industrial machines• production machinery• injection moulding• steel works• marine fleetsApplications with continuous long term aging conditions,where pressure rates and related peaks, together with theheavy mission profiles require heavy duty hoses with specificswell over the actual working pressures. The Manuli Extremehose range is suggested.
Industrial and maintenance services• aerial platforms• street cleaning machines• airport equipment
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Applications with continuous long term aging conditions, wherepressure rates and related peaks require, ozone, weather andabrasion resistance.The Manuli Extreme hose range is suggested.
Agriculture• tractors• combined harvester• implementsLight duty applications for which the Manuli Universal productrange is fit for use.
Water blasting• cutting• waste removal• descalingWater blasting applications are growing in the industrial andconstruction sectors. A key factor for water blasting equipmentis safety and key performances required are compactness,lightness, flexibility and high abrasion resistance.The Manuli GoldenblastTM range is dedicated to these appli-cations
Water cleaning• industrial cleaning• paint removalWater cleaning systems are used not only in the hobby appli-cations but also in industrial sectors such as: agriculture, foodproduction, etc. Resistance to high temperature water andhigh pressure are required, together with abrasion resistance(for those hoses dragged along the ground).Manuli Rubber Industries water cleaning offer is included inthe Universal hose range.
Refrigeration applications• mobile refrigeration• bus air conditioning• off-highway vehicles a/cMobile refrigeration, bus air conditioning and off-highwayvehicles air conditioning use special hose assemblies offeredby Manuli Rubber Industries Refrigeration Connectors.
Hose Selection
Braid
INTRODUCTION
This section is presented as a guide through the basics ofhydraulic hose, fittings and assemblies to give the reader abetter understanding of proper hose selection, care and use,as important component in modern hydraulic equipment.
RUBBER HOSE STRUCTURE
Traces of history and reasons of developmentThe first really flexible rubber hose, was developed during the1870's. This was a rubber-coated canvass fire hose that wasdeveloped to replace leather hoses in use since the early1600's. The first pressure rated hydraulic hose was on the mar-ket in the mid 1920's, but development still had a long way togo. The German Government did a lot to push developmentof a reliable hydraulic hose because of a need to be able toretract airplane landing gear to increase the plane's speed.
This was the beginning and from then it has grown at a spec-tacular rate.
The primary reasons for this growth are:• hydraulic systems can do more work and occupy less space
than mechanical systems that use gears, pulleys, belts orchains;
• movement can be obtained between the various compo-nents when using flexible hose;
• hose will act as a system shock absorber while rigid steeltubing will not;
• hose will allow positioning of components almost anywhere;no required alignment as with conventional mechanicaldrives.
Hose structureHoses that are used to convey liquid and or gas under pres-sure are constructed in layers, and each layer is designed to fita particular need in the overall performance requirement.Most hoses have at least tthree layers, which include the tubeor inner liner, one or more layers of reinforcement and thecover. There are some hose types where the cover is also thereinforcement.
TubeThe tube or inner liner is generally made of some type of syn-thetic rubber or thermoplastic like nylon or polyester. The mainfunction of the tube is to convey the liquid, gas or a combi-nation of the two. For this reason it must be chemically resist-ant to the Fluid conveyed. Always consult the Manuli’schemical resistance information for proper selec-tion.
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fig. 1 - One braid hose
cover
fig. 2 - Two braids hose
fig. 3 - Wire spiral hose
fig. 4 - Suction hose with helix wire
SAE 100R4 Helix Wire
reinforcement innertube
ReinforcementThe reinforcement layer or layers, provide the strength to resistsystem pressure. They can be made from textile materials orwire. Some of the most common textile materials used arepolyester, polyamide and aramide. Wire materials can be car-bon steel, stainless steel of different strength and thicknesses. There are three common methods of applying the hose rein-forcement. The most common is braiding, where the wire ortextile materials are interwoven, to realise hoses from the lowto high pressure range. For very high and ultra high pressureapplications the reinforcement is generally applied in spiralconfiguration on the hose. Depending on the pressure range,multiple layers of reinforcement can be used. Another type ofreinforcement is a combination of textile braiding and a helixwire inserted between the layers of braid. The helix wire pre-vents collapse under vacuum and is used in suction hose. (SeeFigures 1, 2, 3 & 4)
CoverThe cover, as the name implies is the outermost layer of thehose. It's main function is to protect the tube and reinforce-ment from external damage. Cover materials are selectedbased on their ability to resist abrasion, sunlight, chemicals andextreme temperatures with consequent ageing effects.Another function of the cover is to provide a place for themanufacturer to identify the product. This branding or layline,as it is called, will often contain the manufacturer's name, partnumber, pressure range or application, size, date of manufac-ture, industry specification, etc. A common industry specifica-tion on hydraulic hose would be an ISO or SAE rating.
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HYDRAULIC HOSE INTERNATIONAL STANDARDS
In order to have a better understanding of the selection crite-ria for engineering, design and structure of hoses, it is usefulto introduce the main International Standards for wire braidedand wire spiral hoses.Generally speaking, Europe and the markets traditionallylinked to Europe have the tendency to refer to EN standards,while American markets and the market traditionally linked toAmerica have the tendency to refer to SAE standards.Both standards specify the minimum requirements and char-acteristics for all the different categories of hoses; among oth-ers, these are the ones relevant to the scope of this manual:
The norms specify mainly:• the physical dimensions (internal, external diameters, cover
thickness etc.)• hydrostatic requirements as the maximum working/burst
pressure• the minimum bend radius• the testing and qualification requirements.
In an effort to consolidate all norms, ISO standards are designedto merge both SAE and EN. Gradually ISO specifications aregoing to take place in the whole market:
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*
*100R1A, 100R1AT, 100R2A, 100R2AT
Manuli Rubber Industries has a wide range of products thatcovers all specifications of the international standards.
EN and SAE standards do not cover all the requirements in themarket. Therefore Manuli Rubber Industries also manufactureshoses that have characteristics well beyond the internationalspecifications.
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ISO Standard
Wire Braid
Textile
Wire Spiral
Current ENStandard
TraditionalInternational
Standard
ManuliHose Line
ISO 1436 - 1 STISO 1436 - 1 SNISO 1436 - 2 STISO 1436 - 2 SNISO 1436 - R1AISO 1436 - R1ATISO 1436 - R2AISO 1436 - R2ATISO 11237 - 1 SCISO 11237 - 2 SCISO 11237 - R16ISO 11237 - R17 -- -- -- --ISO 4079 - 1TEISO 4079 - 2TEISO 4079 - 3TEISO 4079 - R6ISO 4079 - R3ISO 3949 - R7ISO 3862 - 4SPISO 3862 - 4SHISO 3862 - R12ISO 3862 - R13ISO 3862 - R15
EN 853 - 1 STEN 853 - 1 SNEN 853 - 2 STEN 853 - 2 SN -- -- -- -- -- -- -- --EN 857 - 1 SCEN 857 - 2 SC -- -- -- -- -- -- -- --EN 854 - 1 TEEN 854 - 2 TEEN 854 - 3 TEEN 854 - R6EN 854 - R3EN 855 - R7EN 856 - 4SPEN 856 - 4SHEN 856 - R12EN 856 - R13 -- --
DIN 20022 - 1 STDIN 20022 - 1 SNDIN 20022 - 2 STDIN 20022 - 2 SNSAE J517 - 100R1ASAE J517 - 100R1ATSAE J517 - 100R2ASAE J517 - 100R2AT -- -- -- --SAE J517 - 100R16SAE J517 - 100R17SAE J517 - 100R5SAE J517 - 100R4DIN 20021 - 1TEDIN 20021 - 2TEDIN 20021 - 3TESAE J517 - 100R6SAE J517 - 100R3SAE J517 - 100R7DIN 20023 - 4SPDIN 20023 - 4SHSAE J517 - 100R12SAE J517 - 100R13SAE J517 - 100R15
Tractor / 1TRockmaster / 2STTractor / 2T
Harvester / 1T
Harvester / 2TTractor / 1KTractor / 2KLyte-FlexHarvester / 17CoverSpyrtex / KMultitexAstro / 2Astro / 3MultitexAdler / 2HydroplastGoldenspir / 4SPGoldenspir / 4SHGoldenspir / 12Goldenspir / 13Rockmaster / 15
Manuli Product Range
Proper hose selection is critical in order to realise a safehydraulic system. The first step in having a safe hydraulic sys-tem is selecting components that meet the needs.Compromises in hose selection may create situations of dan-ger, as well as affect the performance and durability of the sys-tem. The choice may work for the short run, but may not bea good long-term decision.
The most important target in this activity is the safety.
Many interacting factors influence the hose service life and theability of each fluid-power system to operate satisfactorily. Thecombined effects of these factors on service life are oftenunpredictable.Each system has to be carefully analysed in order to proceedwith a proper hose and related components selection, to cor-rectly design routings, to meet the system performance andreliability (hose service life requirements), and to minimise therisks of personnel injury and/or property damage. The“SEVEN EASY STEPS” is a useful method that must be carriedout for a preliminary analysis of the critical factors.
An effective way to remember the hose selection criteria is toremember the word STAMPED, acronym of:S = SizeT = TemperatureA = ApplicationM = Material to be conveyedP = PressureE = Ends of couplingD = Delivery (flow rate and fluid velocity).
Hose Size (Dash numbers)The inside diameter of the hose must be adequateto keep pressure loss to a minimum and avoiddamage to the hose due to heat generation orexcessive turbulence. Dedicated nomographics forpressure loss and fluid velocity can be used todetermine the most proper hose size following the
over mentioned criteria. Alternatively the traditional calculationschemes are also available on the Manuli web site.
In case of substitution of a hose on field applications, read thehose size on the branding of the original hose; in case theoriginal hose branding is worn off, the original hose must becut and inside diameter measured for size.
RemarkBefore cutting an original hose assembly, measure the overallassembly length and fitting orientation. These measures will benecessary to build the replacement assembly.
24
HOSE SELECTION CRITERIA
The hose size numbering systemsDifferent hose size numbering systems are currently used byhose manufacturers to identify hose sizes:• the “dash” numbering system: the I.D. (Inside Diameter) of
the hose is expressed in 1/16-inch increments. The dash sizecoincides with the number of 1/16-inch increments of thehose I.D.
• “inch” and corresponding “mm”• also the DN (Nominal Diameter) ref. ISO 4397 in mm are
currently used as reference.
For example 3/8” ID=6/16 inch therefore the dash size is –06.The corresponding value in mm is 9,53mm, the NominalDiameter by ISO 4397 is 10.
Exceptions to the hose size numbering system are PTFE hosesand SAE 100R5 hoses (see the scheme here below).
25
Standard hydraulic hoses (ref. ISO 4397)
InchesDash No. mm Inches mm
R5 and PTFE hoses
------
4.8 6.4 7.9 10.3 12.7 15.9
--- 22.2 28.6 34.9 46.0
--- 60.3
--- --- --- ---
------
3/16 1/4 5/16 13/32 1/2 5/8 ---
7/8 1 - 1/8 1 - 3/8
1 - 13/16 ---
2 - 3/8 --- --- --- ---
3.2 5.0 6.3 8.0 10.0 12.516.019.0
- 25.0 31.5 38.0 51.0
- 63.0 76.0 89.0 102.0
-
1/8 3/16 1/4 5/16 3/8 1/2 5/8 3/4 7/8 1
1 - 1/4 1 - 1/2
22 - 1/42 - 1/2
3 3 - 1/2
44 - 1/2
-2-3-4-5 -6 -8 -10 -12 -14 -16 20 -24 -32 -36 -40 -48 -56 -64 -72
Hose I.D.
The hose size numbering system
Hose is sizedon I.D.
Hydraulic Tubingis sized on O.D.
SAE 100R5and PTFE Tubing
Their size is designated by the tubing O.D. dash size whichthey would replace. PTFE and SAE 100R5 hoses have thesame I.D. as that of the equivalent dash size hydraulic tubing(SAE 100R5 hose type was the first hydraulic hose developedto replace rigid tubing: that’s why it remains traditionally iden-tified with the same sizing as tubing).See the enclosed table of correspondence.
In order to select the hose ID, which suits the flow rate of oilbeing pumped through the hydraulic system, the nomographprovided in this Technical Manual can be used.This diagram will help you to calculate the optimum hosediameter starting from 2 known values:
a) max. recommended fluid velocityb) flow rate of your system
As the correct fluid velocity choice is important to avoid turbu-lence and excessive pressure loss (for suction lines the poten-tial pump cavitation must be considered). Manuli reports thefollowing maximum recommended values:
Max. fluid velocity limits m/sec.:• Pressure lines up to Max. 8-10 m/sec.• Return lines up to Max. 3-4 m/sec.• Suction lines up to Max. 1,5 m/sec.See also ISO 4413 specification
26
Nominal diameter calculation
l / m
500400350300250
200
150
100
706050
40
30
20
10
5
4
3
2
1
100
75
50
40
30
20
10
54
3
2
1
0,50,4
0,30,25
4 ”
3 ”
2 ”
1 1/2”1 1/4”
1 ”
3/4”5/8”
1/2”
3/8”5/16”
1/4”
3/16”
DN 102
DN 76
DN 51
DN 38DN 31,5
DN 25
DN 19DN 16
DN 12,5
DN 10DN 8
DN 6,3
DN 5
0,1
0,2
0,3
0,4
0,5
1
1,5
2
3
4
56
810
0,5
1
1,5
22,533,54
5678910
15
20
gal / m
m / s
ft / s
Velocity
Flow Rate
Diameter
Knowing the flow rate of your system draw a line from thispoint to the limit velocity and read the intersection with thediameter line, the first upper value can be chosen for yoursystem. For example 70 l/1’ for pressure lines leads to a choiceof DN 19 (3/4”) considering maximum fluid velocity 5 m/s;30 gal/1’ for return lines need DN 38 (1-1/2”)Unlike hoses, hydraulic tubing is sized by its O.D. (OutsideDiameter). The number of 1/16-inch increments in its O.D.represents its dash size.
TemperatureWhen selecting a hose, care must be taken toensure that the system fluid and ambient tempera-tures, both static and transient, do not exceed thelimitations of the hose.Operating temperatures specified refer to themaximum temperature of the fluid being
conveyed. High heat conditions may have an adverse effecton hose due to degradation of the rubber which will limithose usefulness and reduce fitting retention.In some cases the fluid being conveyed will slow down thisdegradation whereas other fluids may accelerate it. Therefore,the maximum temperature of each hose does not apply to allfluids.
Continuous use at maximum temperatures or nearthe maximum rated temperatures will materiallyreduce the service life of the hose (e.g. ref. DIN20066, SAE J1273, etc.) and should always be avoided.Continuous use at or near the maximum temperature ratingwill cause a deterioration of physical properties of the tube andcover, deterioration that will reduce the service life of the hose.
Also the external ambient temperature must be carefully con-sidered:• extreme cold environmental temperatures for the potential
hose cracks due to bend efforts;• extreme hot ambient temperatures, in presence of irradia-
tion inside engine compartments, etc.,may have a highageing effect on the rubbers.
Most standard hydraulic hoses are designed to operate in thetemperature range between -40°C (-40°F) and +100°C(+212°F), range generally considered as standard.But also other categories of hoses exist: some hoses manufac-tured with special rubber compounds are designed to operatebetween:• -40°C (-40°F) and 121°C (250°F): range considered high
temperature• -55°C (-67°F) and 150°C (+300°F): range considered
extended temperature, etc.
27
For example, for extended temperature range applications useManuli EQUATOR™ hose (see the Manuli temperature rangecategories).
When selecting a replacement assembly, the same considera-tions must be applied: fluid temperature and ambient temper-ature must be carefully considered. The hose selected must becapable of withstanding the minimum and maximum temper-ature seen by the system. Care must be taken when routingnear hot manifolds: in extreme cases, heat shield may be advis-able.Additional information and limits on Manuli Rubber Industrieshydraulic hoses temperature ranges referred to specific fluidsmust be checked on the catalogue or contacting ManuliRubber Industries specialists.
ApplicationWhen selecting a hose, it is basically importantdetermining where or how the hose or assembly isto be used. To fulfil the requirements of the appli-cation, additional questions may need to beanswered, such as:
• where will the hose be used?• equipment type and mission profile?• fluid and ambient temperature?• working and surge pressures?• minimum bends radius?• excessive flexing movement?• fluid compatibility?• environmental conditions?• external abrasive stress?
28
STStandard Temperature 125 peaks
-40
100 continuous
Three main categories of temperature range
HTHigh Temperature 135 peaks
-40
121 continuous
ETExtended Temperature 150 peaks
-55
135 continuous
29
• what about vibrations?• hose flexibility/structure?• coupling termination end type and thread type?• suction or return line application?• routing requirements?• safety and industry specifications to be met?• external mechanical loads and/or unusual forces that need
to be considered• antistatic and/or flame retardant cover requested?• critical nature of the application (e.g. mines, etc.)
Let’s consider for example the harsh conditions covers, oftencause of failure. In general covers of hoses are subject mainlyto abrasion and ozone attacks. Working life can be substan-tially reduced in conditions where the cover of the hose isdragged against hard rough surfaces. The work in mines forexample or in some industries where the hose is rolled onpulleys or rubbed against sharp angles is very demanding.In this conditions standard covers are not recommended.Rockmaster® is a heavy duty hose line specially engineered forapplications such as marine & off-shore, forestry and mining.Shieldmaster® is a hose line with characteristics of abrasionresistance even more extreme!Under ISO 6945 abrasion resistance test, Rockmaster® coveroutperformed the standard requirements by an order of mag-nitude specifications requirements and Shieldmaster® coverwas so resistant that the result has lost significance: the coveroffers a resistance at least 1000 times higher than required bystandards.
In any case it is important always to ensure that the hose is fitfor the intended purpose.
Ensure also that the selected hose and fittings are either com-patible or protected from the specific environment to whichthey are exposed: severe environmental conditions such assalt water, chemicals, air pollutant, ozone and sunlight,etc. can cause degradation and lead to premature failure.
0,6
0,5
0,4
0,3
0,2
0,1
0
0,50
0,25
0,050,01 <0,001
0,500,50
EN 853
grams lost
ConventionalRubber
PU
0,250,25
0,050,050,010,01 <0,001<<<111 <0,001
Abrasion Resistance ISO 6945 (2000 cycles, 2,5kg)
OFFERS AT LEAST 1000 TIMES
HIGHER RESISTANCE THAN STANDARD
In order to support application engineers to carry out theirapplication analysis, a useful scheme is here enclosed asa guideline. It is also useful for field test analysis.
Even though each application must be carefully analysed,these are some general guidelines for the Manuli productselection criteria and application families:
Hydraulic earth moving machinesThe standard product are generally fit for use. The extremeproducts meet and exceed the requirements. On bigmachines the extreme products must be preferred.
Hydraulic agriculture machinesLight duty applications: the standard products are fit for use.
Hydraulic mobile equipment (trains, trucks, etc.)They are very particular applications, where the pressure playsa secondary role while the ozone, vibrations at high frequency,high temperature, powder, mud, water and cleaning waterjetting with aggressive detergents require the use of theExtreme hose range with eventually external protections.
Hydraulic continuous long term aging (industrialmachines, etc.)Let’s take as reference the world of the presses (mouldingmachines, etc.), where the pressure rates and the related peaks,the heavy mission profiles (continuous 24 h per day), etc.require selection of hose overdesigned respect to the actualworking pressures, because of the long term aging conditions.
Hydraulic systems on marine and off shore applicationsThe atmospheric conditions very severe require hoses withcover compounds with particular characteristics, like the resist-ance to ozone and sea water. The extreme products are forsure the most indicated. Stainless steel fittings are generallyrequested for naval and marine applications.
Mining applications, underground and open-pit minesCritical applications. Recommendations: Extreme productshigh abrasion resistant, flame retardant property of the cover,skive fittings, avoid very small diameters, robust fittings, etc.
Forestry machinesCritical applications: high abrasion resistant cover, resistance tohigh pressure, fatigue and twist, low bend radius, 3/4” and 1”are the most common used sizes and 1/2” also. Wire spiralsolutions are suggested for the most severe conditions.
LiftLarge size braided hoses are fit for use.
30
31
Field analysis data
Customer
Machine
Hose
Fittings
Working pressure Static
Fix
Weather
Abrasion
Environmental
Ozone
Industrial cleaning
Dynamic
Flexing
Certification requested
Industry
Near thefittings?
Transportation
Agriculture
Earth moving
Working pressure max/min Pmax Pminbar bar
bar
bar
m/sec
per hour
mmmmtheoretical effective
l/min.
bar Pump press.
MINERAL BIO
mi -1
P
P
T
hrs/day
∞C
T ∞C
h
Pressure peaks
Impulse frequency
Fluid velocity
Oil
Medium oil temperature
Working time
Installation
Anverage nr. of flexing
Min. bend radius
External temperature
Environmental conditions
Date Name
Relief valve setup
Total workingtime
h
Vibrations(frequency Hz,amplitude +/- mm)
32
Material to be conveyedSome applications require special oils or chemicalsto be conveyed through the system. Hose selectionmust assure compatibility of the hose tube, cover,couplings and O-Rings with the fluid used.
Additional caution must be used in hose selectionfor gaseous applications such as refrigerants, compressed airor LPG, etc. When selecting a hose for gaseous applicationswhere permeation of fluid through the hose wall may occur,consider the possibility of hazardous effects, such as explo-sions, fires and toxicity. Refer also to applicable standards forspecific applications such as refrigerants. If fluids permeatethrough the hose tube, consider the use of perforated coversto prevent fluid cover blistering under the cover (pin-pricking).Also ensure the compatibility of the system fluid not only withthe hose tube, but also with the braid, cover, fittings and othercomponents since permeation may expose the entire hoseassembly to the system fluid.
Regarding the hydraulic fluids, mineral & biological oils,Manuli wire braided and wire spiral hoses have a wide innertube compatibility: spiral hoses are also identified by the BIOlogo on the hose lay-line. Anyway each single oil brand namehas to be carefully checked, seen the wide differentiation ofthe additive packages used by many hydraulic oils producersin their fluids. That’s why an intense activity of oil compatibilityis currently performed on the Manuli rubbers, as support tocustomers and OEMs.
The hose selection activity must ensure compatibility mappingof the hose tube, cover and fittings with the type of fluid to beconveyed. If the end fitting type requires an O-Ring for sealing,ensure that the O-Ring compound is also compatible with thesystem fluid.For tube compound evaluations, please refer to the ManuliRubber Industries Approved fluid compatibility chart followingthe evaluation criteria supplied here below reported. For spe-cific information, contact Manuli Rubber Industries.For the mineral and biological oil classification you can refer tothe following table, summarising the main characteristics ofeach family, advantages and disadvantages, and cost estima-tion compared to the traditional mineral based.
33For particular or unusual fluids check compatibility togetherwith MRI’s specialists.
PressureKnowing the system pressure, including pressurespikes, surges, etc. is of the greatest importance forthe hose selection process. The hose catalogueworking pressures must be equal to or greater thanthe system pressure, including peaks. Pressure spikes
greater than the published working pressure will shorten hoselife and must be taken into consideration (e.g. ref. SAE J1273).Pressure peaks must be measured with electronic devicescapable to record very short transients not measurable withtraditional analogical instruments.The rated pressure of primary and eventual secondary valve ofthe system gives an additional information of what can be themaximum pressure peak inside the system. The Max working
Hydraulic oils classification
Mineral oils
Oil Family
Low: -40 ∞CHigh: +150 ∞C
Oper.Temp.
• The traditional solution, widely industrially available, suitable for the majority of relevant applications• Low cost if compared to alternative solutions
Advantages
• Not ecologically acceptable 1
CostDisadvantages
Natural oilbasedRape-seed
HETG
Low: -30 ∞CHigh: +80 ∞C
• Suitable for the majority of relevant applications
• Limited by their poor oxidative thermal and hydrolitic stability• May bio-degrade in the system: the oil stability is very susceptible to water contamination• Possible strong odours in use and formation of gums
2 to 3
Water basedfluids
HF
HF-ALow: -5 ∞CHigh: +60 ∞C
HF-CLow: -40 ∞CHigh: +60 ∞C
• FIRE RESISTANCE hydraulic fluids• Similar applicability than polyglycols• For their high water content they can be considered ENVIRONMENTAL FRIENDLY & ACCEPTABLE
• Moderate hydraulic fluid properties
3 to 6
Polyglycols
(HEPG)PEGPAGPPG
Low: -50 ∞CHigh: +130 ∞C
• Limited to areas where water solubility is advantageous, for example, inland waterways, spillage of non soluble products results in a perceivable surface film• Areas where cleaning by simple water washing is employed may also benefit
• Due to the high water solubility their use is somewhat limited or prohibited (Switzerland) due to the risk to pollute the water-bearing stratum• Absorbed water can effect the performances
5 to 7
Syntheticesters
HEES
Low: -30 ∞CHigh: +90 ∞C
• Better stability than vegetable oils, wider range of successful applications• Diesters: used mainly in aviation, automotive, compressor applications• Hindered esters: application similar to diesters and also steel rolling or industrial hydraulic
• Stability can be affected by water contamination• The high cost tends to limit their use
6 to 10
The hydraulic hoses of the Manuli product range are not designed for immersion in the service fluid. This type of special applications should be avoided or care-fully studied with additional external protections for the hoses, selection of special hose types, e.g. with thermoplastic cover and validation on the specific appli-cation. The turbulence of the fluid, the high temperature and nature of the fluid as well as other elements may impact the properties or integrity of the hosecover material (the cover compound of the hose is designed may impact the properties or integrity of the hose cover material (the cover compound of the hoseis designed to resist to oil drops and extrernal agents, not immersion in the service fluid). For more detailed information conact Manuli Rubber Industries.
pressure inside the system in fact cannot be simply equal to thepump rated working pressure, but must consider also thefunctional activities of the equipment (negative loads, vibra-tions, etc.) and the consequent pressure peaks.Be aware that hydraulic fluid under pressure can be potential-ly dangerous!
• An explosive bursts or stream of escaping fluid can causedamage to equipment or serious injury to persons nearby
• Highly pressurised fluid escaping from a small pinhole canbe almost invisible and yet exert extreme force capable ofpenetrating the skin and other tissue, causing possiblesevere injury
• Pressurised fluids, if released uncontrolled, can exert anexplosive force
• Hot fluids or chemicals can cause severe burns• Some fluids are highly flammable, etc.
The maximum rated working pressure of anyassembly will be defined by the lowest workingpressure of the hose, the end fitting or any adaptor(consequently it is recommended to select the proper cou-plings and adaptors with working pressure higher or equal tothe hose one, never lower). Always take into considerationany pressure spikes or potential pressure surges in the system,but also the fatigue mission profile of the application, numberof pressure impulses per hour/day/year, in order to proper pro-vide eventual oversizing of the hose reinforcement comparedto the minimum theoretical requirement. In particular also theposition of the hose inside the system must be considered,seen the different functions: see the following scheme andmission profiles of the applications.
34
Hose WP selection
hose WP
system pressurehistory
system WP
time
spikes
P
"The hose working pressure should include the pressure surges(spikes) that, even if not indicated on many common pressure gages,
must be identified on electronic measuring instrumentswith a high frequency response"
35
Pressure (Power) linesHigh pressure, may be also over 400-500 barFluid velocity: Max. 8-12 m/sHeavy duty working conditions (high fatigue stress) can bepresent, Manuli wire spiral and two wire braids hoses aregenerally requested
Suction linesLow pressure (max 5-10 bar)Fluid velocity: Max. 1,5 m/s (to avoid pump cavitation)Resistance to vacuum is requested up to -0,83/-0,90barLarge I.D. requested to reduce pressure dropSpirtex/K and two wire braided hoses are designed for thisapplications and in particular for vacuum resistance
Drain linesLow pressure (Max 20-30 bar)Fluid velocity: Max 3-4 m/sSmall bend radius requestedLarge I.D. requested to reduce pressure drop
Return linesLow pressure (Max 30-50 bar)Fluid velocity: Max. 3-4 m/sSmall bend radius requestedVacuum resistanceLarge I.D. requested to reduce fluid velocity and pressure dropMultitex and Astro hoses line generally suitable
For a proper hose selection in terms ofpressure resistance, it is also useful toconsider the following working pressureclassification, with progressive fatiguestress and consequent necessary designcriteria: • low pressure up to 70 bar• medium pressure up to 210 bar• high pressure up to 210-350 bar• very high pressure up to 350-420
bar or higher
Note
Pilot linesMedium pressure (Max 100 bar)Fluid velocity: Max. 5 m/sCompact dimensions & flexibility are a “must”Small bend radius requestedLightness is appreciatedThe Manuli solution for pilot lines is Pilot hose
Ends of couplingSelect the proper end fitting from the Manuli cata-logue, being careful to the maximum workingpressure of the termination end (by the referenceinternational specifications), in consideration of thehose to which it is applied.
Additional considerations of mechanical robustness and seal-ing capabilities of the termination ends can be advisable forheavy duty applications and/or specific installations: refer tothe coupling selection criteria supplied in the relevant sectionof the manual; contact Manuli Rubber Industries for specificdetailed information.When replacing an assembly, identify end connections andsealing surfaces. Once thread ends have been identified, con-sult the appropriate section of the Manuli Rubber Industriescatalogue for specific part number selection.Do not mix and match hose and fittings from differentsuppliers: in fact relevant testing qualification programs arenecessary to validate the hose and fittings compatibility.Hydraulic hose from one supplier is seldom compatible withfittings from another; in any case the assembler is responsiblefor the guarantee of proper compatibility existing between thehose and fitting if the manufacturer prescriptions are notcorrectly followed.Ensure that the correct inserts and ferrules are chosen for thehose type.
Delivery (Flow rate and fluid velocity)When replacing an assembly, we can assume thesystem is properly sized to efficiently transport fluid,that’s why the same I.D. of the original hose can beused.Eventually it can be useful to determine if the
system is properly sized to efficiently convey the max. flow rate:in this case follow the recommendations below.
If the system is new or altered, determine the hose I.D. neededto convey the max. flow rate considering the maximumrecommended fluid velocities for each application type (pres-sure lines, return lines, suction lines) and a max. pressure lossinside the line, in order to avoid excessive friction, vibrations
36
37
and heat generation. The use of Nomographic Charts or cal-culation schemes (see Manuli web site tool and the enclosedtable) can be useful to determine the minimum size neededfor the application, ensuring that the required system flow rateis available avoiding excessive pressure drop from occurring.
Data needed to determine pressure drop are:• Fluid type (specific gravity) and viscosity• Fluid temperature (in order to calculate the correct viscosity
value)• Flow rate• Hose size and length• Number and type of fittings
The traditional formula from hydraulics is the following:
dimensionally:
λt = friction factor (generally close to 0,03 for rubber smoothtube hoses. It is an adimensional coefficient). λt depends onviscosity and therefore on the fluid temperature.l = length of hose (m)
= fluid density (volumetric mass : kg/m^3)v = fluid velocity (m/s)d = Inside Diameter (m)
In addition the following parameters are requested: ν = fluid viscosity (cSt): to determine the friction factor Q= flow rate (l/minute) to determine the fluid
δ
See the following table reporting pressure loss data for themost common applications.
38
viscosity (cSt) 20 - oil specific gravity 0,85
diameters (mm)
flow (l/m)
125
10 15 20 25 30 40 50
100 200 300 400 500 600 700 800 900
1000
4,8
0,216 0,433 1,082 3,457
6,3
0,073 0,146 0,364 0,729 1,931 3,195
8,0
0,056 0,140 0,280 0,421 1,027
9,5
0,028 0,070 0,141 0,211 0,454 0,671 0,923 1,528
12,7
0,044 0,066 0,088 0,169 0,233 0,385 0,568 1,912
See also the calculation tool on www.manuli-hydraulics.com
16,0
0,026 0,035 0,044 0,078 0,128 0,190 0,638 2,147
19,0
0,018 0,022 0,026 0,057 0,084 0,282 0,949 1,930
25,4
0,007 0,008 0,011 0,021 0,239 0,486 0,804 1,188 1,635
31,8
0,006 0,024 0,082 0,167 0,276 0,409 0,562 0,736 0,930 1,143
38,1
0,010 0,035 0,071 0,117 0,173 0,238 0,312 0,394 0,484 0,582
50,8
0,003 0,009 0,018 0,030 0,044 0,061 0,080 0,100 0,123 0,149
Pressure loss (bar) per meter of hose
Table of oil viscosity according to temperature
30002000
1000
500
300
200
100
50
30
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 200
20
15
10
8
6
5
4
3
Note: Oil viscosity decreases when the temperature increases
Temperature °C
Vis
cosi
ty m
m2/s
1
2
34
567
1) ISO VG 3202) ISO VG 1503) ISO VG 684) ISO VG 465) ISO VG 326) ISO VG 227) ISO VG 16
39
Hose, Connectors & Adaptors Handling, Storage & Traceability – Hose
It is well known that, with time, rubbers age and their physicalproperties change. Eventually, the same rubbers can lose theiroptimal characteristics for the applications to which they arededicated.Consequently the targets for the storage methods of rubberbased products are aimed to avoid or reduce at minimumlevel the aging of rubbers:• reduce the storage period to a minimum, considering rub-
bers are subjected to ageing with time;• guarantee the best storage conditions, carefully considering
all the main parameters influencing the ageing process.
Also, hose storage requires particular conditions for the bestresults in maintaining the products initial properties andcharacteristics.
The following table lists the main specifications regardingstorage conditions for hoses:
specification issue date
ISO 8331 Ed. September 1991 - New Release 2007BS 5244 Ed. 1986, reaffirmed 1996DIN 20066 Ed. October 2002SAE J1273 Ed. August 2004
Summary of their recommendations:
ISO 8331: Rubber and plastics hoses and hose assemblies –Guide to selection, storage, use and maintenanceMax. storage duration <4 years before assembly operation<2 years for hose assembliesIf further storage periods cannot be avoided, hoses should beinspected and/or tested before use (tests are not specified).This specification does not state any max. service life durationfor the hose assembly.The new release of 2007 doesn't report any storage lifeduration requirements and refers to ISO 2230.
ISO 2230: Rubber products - guidelines for storageNot specific for hoses but for rubber goods, classified in 3groups (A, B, C). Manuli products are classified as B, with this storage requirement: • 7 years as initial storage period• 3 years as possible extension after test
STORAGE AND SHELF LIFE CONDITIONS
4 yearsmaximum age
of hose material
production datehose material
production dateassembly
2 years maximumstorage duration
6 yearsmaximum utilisation
limit of hose line
fig. 1 - Hose storage and utilisation limitsaccording to DIN 20066, part 5.
40
DIN20066: Hydraulic fluid power; hose assemblies; assessmentof service performance (fig. 1)Max. storage duration <4 years before assembly operation<2 years for the assembliesStress conditions are quoted which are potentially able to reducethe hose assembly service life.A max. functionality period of 6 years is indicated including thestorage period as assembly. As a consequence each storageperiod consumes an equivalent part of the service life of the hose.
BS 5244: Application, storage and life expiry of hydraulic rub-ber hoses and hose assembliesMax. storage duration for hoses and assemblies<3 years: no tests required on the hose• 3 - 5 years: hydraulic proof pressure tests required• 5 - 8 years: hydraulic proof pressure tests, impulse test, burst
test, cold flexibility test, electrical test required>8 years: hose to be scrappedMax. storage duration for assemblies installed on stored equip-ment<3 years: no tests required on the assemblies• 3 - 5 years: hydraulic proof pressure and burst test required>5 years: assembly to be scrappedThe service life duration of a hose assembly is quoted as being“dependent on the equipment” (to which the hose has beenfitted), therefore stating that a general estimate is not possible.It advises that “records be kept for each type of equipmentwith a view to establishing a working life for each particularapplication”.
SAE J1273: Recommended Practices for Hydraulic HoseAssemblies Max. storage durationRubber hose:<10 years in bulk form <10 years for assemblies passing visual inspection and proof testThermoplastic or PTFE hoses: considered unlimitedThe specification reports general requirements on factors thatcan affect hose products in storage.The specification does not give indications on hose assemblyservice life duration, stating that it is unpredictable, consideringthe combined effects of all the factors involved. Each systemhas to be carefully analysed for the purpose.The specification gives general criteria for a maintenance pro-gram of hose assemblies, to be carried out by the users. Themaintenance program must suit the specific application andeach specific hose on that application.The specification asks to evaluate factors such as the natureand severity of the application, past history, etc., to establishthe frequency of visual inspections and functional tests.
41
In all the specifications, general storage conditions and installa-tion guidelines are supplied. Generally the following parame-ters are listed and relative qualitative suggestions are included.
Manuli recommendations for hose storage: Max. 6 years storage for hoses, including max. 2 yearsas assembly.
TemperatureGenerally 0 to 35°C (preferably 15°C)
HumidityVery humid or dry conditions should be avoided: the recom-mended conditions are around and/or not higher than 65%of relative humidity
LightHoses should be protected from sunlight or strong artificiallights: it is generally suggested to paint the warehouse win-dows with red or orange colours, and/or to maintain thehoses stored in closed boxes.
Oxygen and OzoneMercury vapour lamps or tubes, closeness to high-voltageelectrical equipment, etc., should be avoided because of theharmful effect of ozone on rubber based products.Hoses should be protected from the circulating air and packedin closed boxes.
Oils, solvents, greasesThe potential contact of stored hoses with aggressive sub-stances must be avoided.
Heat sourcesHose should be stored away from potential heat sources,electric and magnetic fieldsStorage areas should not be in the proximity of equipment thatmay generate electrical or magnetic fields, or may be able toinduce currents in metallic parts, which in turn, generate heat.
Storage methodsWhenever possible hoses should be stored in a relaxed state,without imposed stresses and strains.Coils should be as large as possible and at least to the mini-mum recommended hose bend radius.Hydraulic hose should be stored in such a way to avoid abra-sion of the external cover through accidental contact withstorage systems.
MANULI RECOMMENDATIONS
42
Handling methodsHydraulic hose should be handled in a way that avoids possi-ble impact damage or hose cover abrasion.
Additional Manuli Rubber Industries observations andconsiderations:Manuli Rubber Industries fully meets all the above mentionedrequirements regarding the storage conditions for hoses andassemblies. Warehouses are designed to guarantee the beststorage conditions without any decay of the rubbers proper-ties and product performances, ensuring that hoses are deliv-ered to customers in optimum condition.
Should there be a problem related to a batch of hose then itmay be necessary to trace it back to the manufactured batch.This can be achieved by recording the manufacture codewithin the quality system. The batch number of Manuli hose isthe production date branded on the back of the hose.
In addition:• Consideration should be given to stock rotation. Hose with
an older manufacture date should be sold first, (unless a spe-cific manufacture period is requested). Manuli hose boxeshave a coloured circle on the box indicating the year ofmanufacture.
• There appear to be no general international recommenda-tions for the storage of connectors and adaptors, however,it is important to take precautions to prevent damage ordeterioration.
• Connectors and adaptors are supplied in boxes with internalprotective plastic bag. It is preferable that they remain in thoseboxes until ready for use. This will prevent accidental damageand environmental attack. Connectors and Adaptors will dete-riorate if subject to external influences such as dampness,humidity and contamination. Contamination may becomelodged in the connectors & adaptors and cause eventualproblems when fitted to a hose assembly on an application.Damage to the hose assembly and/or the application mayresult!
• Connectors with O-Rings should be stored in their originalboxes and not exposed to day-light. They should also bestored away from electrical equipment to prevent ozone attack.
• Care has to be taken to avoid damage to threads, as a resultof storage, handling and after installing onto a hose.
• External male threads & flange faced inserts are particularlyvulnerable and extra care during handling needs to be taken.
43
• All inserts fitted to hose assemblies should be capped to pre-vent accidental damage and ingress of contamination.
• Should there be a problem related to a connector or adaptorthen it may be necessary to trace back to the actual manu-factured batch. This can be achieved by recording themanufacture code within the quality system. The box num-ber gives this trace-ability.
• Connectors and Adaptors also have a coloured circle on thebox indicating the year of manufacture, therefore, the old-est boxes would be bought to the front of the shelves withnewer ones being stored behind.
Hydraulic hose and hose assemblies have a limited (finite) serv-ice life depending on the service conditions to which they aresubjected. A very severe application will result in a reduced lifeduration, a less demanding application will result in a longerservice life for the same hose.
Submitting hose and hose assemblies to conditions moresevere than the recommended limits significantly reduces serv-ice life; but also the exposure to combined functional parame-ters closed to the recommended limits, for example constantlyat the maximum recommended operating temperature, use atmaximum rated working pressure and minimum bend radius,etc. will reduce service life.
Eventual failures due to the missing use of proper selection cri-teria for the components, installation and maintenance, mayresult in injury to personnel and/or damage to equipment.Hose assemblies must be preliminarily selected according tothe detailed guidelines supplied in this manual. In additionwhen in service, they should be regularly inspected for dam-ages according to the equipment preventive maintenanceprogram. Assemblies showing signs of wear or damageshould be replaced immediately; criteria to evaluate the hoseassemblies and their eventual replacement are (see also SAEJ1273) signs of significant deterioration, for example:
• leaks at hose, fitting or in hose;• damaged, cut or abraded cover;• exposed hose reinforcement;• kinked, crushed, flattened or twisted hose;• hard, stiff, heat cracked or charred hose;• blistered, soft, degraded, or loose cover;• cracked, damaged or badly corroded fittings;• fitting slippage on hose, etc.
SERVICE LIFE CONSIDERATIONS
44
Maximum service life results can be achieved if the hoseassembly is subjected to correct functional conditions, com-plying with recommendations outlined in this manual and thecatalogue.The actual service life of a given hose assembly in a givenapplication is dependent on many variable factors, includingthose below, the main ones affecting service life duration:
Hose selection and routingCarefully analyse each system and application: design routings(installation configurations) and select hose and related com-ponents to meet the system-performance and hose-service-liferequirements, and to minimise the risks of personal injuryand/or property damage.Torsions, reduced bend radii, external tensile loads and/orcrushing stress applied on the hoses should be avoided.Excessive vibrations and/or severe flexing installations shouldbe properly studied in order to find suitable solutions.
Operating temperaturesOperating temperatures specified refer to the maximum tem-perature of the fluid being conveyed. High heat conditionsmay have an adverse effect on hoses due to degradation ofthe rubber which will limit hose usefulness and reduce fittingretention. In particular the applications for which permanenthigh temperature level is present, may be in continuousservice 24 hours per day, must be carefully treated: continuoususe at maximum temperatures together with maximum pres-sures should always be avoided. In fact they may cause a dete-rioration of physical properties of the tube and cover, thusreducing the service life of the hose.Also consider that different fluids conveyed can cause involvea different degradation of rubbers: that’s why the maximumtemperature of each hose does not apply to all fluids but mustbe checked also in correlation to the fluid being conveyed.
Pressure surgesGenerally, all the hydraulic systems develop pressure surges(rapid transient rise of pressure) which may exceed also therelief valves set up. Exposing the hose to surge pressuresabove the maximum operating pressure will reduce the hoselife and must be carefully considered. It is also necessary toknow that most of the surges can be recorded only with elec-tronic sensors due to their short duration, not being indicatedby many common pressure gauges: the hose selected musthave rated pressure higher than the maximum pressure peakor surge of the system.
Ambient temperatures and environmental conditionsVery high or low ambient (outside the hose) temperatures, willaffect cover material and the hose structure, coupling area,
45
etc. thus reducing the service life of the assembly, involved bythe rubbers aging phenomenon, also affecting the fittingretention capability.Also the extremely severe environmental conditions such assunlight exposure, powder, abrasive contacts with stones, onthe ground, external bodies, etc. (e.g. under carriage applica-tions on mobile equipment, marine/ships applications) mustbe considered with a proper selection of the hose, for exam-ple special cover compounds, special fittings, or dedicatedprotections of the assemblies.The severe environmental conditions, if present, must be prop-erly considered in the selection of special compounds or thestudy of proper protections and safety systems for the assem-blies in order to avoid the life reduction due to fast aggressiveactions of the external agents on the hose/rubbers.
Chemical resistanceConsider the chemical resistance of the tube compound withthe working fluid, following the chemical compatibility chartrecommendations.But also the cover compound has to be considered in thisanalysis: covers are generally resistant to oil drops rather thanfor complete immersion in the fluid, are resistant to cleaningsolvents diluted in the water, dust of grease, powder, drop offuels, etc.Also fittings and O-Rings must be considered in the chemicalresistance analysis.Improper selection of the products will lead to a potential pre-mature failure of the assemblies.
Hose fittingsManuli manufactures hose fittings to meet applicable interna-tional standards. It is possible to select a fitting with a connect-ing end that has a performance rating lower that the hose rat-ing. In selecting hose fittings, please consider the performancerating of the connecting end, avoiding potential leaks at thetermination end.
MaintenanceHose assemblies in operation should be inspected frequentlyfor leakage, kinking, abrasion, corrosion or any other signs ofwear or damage. Worn or damaged hose assemblies shouldbe replaced immediately.
46
The influence of design on the expected life of hoseassembly.
Pressure surges and pressure spikes have tremendous effects onworking life of pressure hoses. For a quantitative approach onthe damage caused by pressure fluctuations it is possible to referto SAE J1927. Note that this spec. and its interpretation is onlyvalid for applications with variable amplitude pressure where themajority of the peaks are between 100 and 200% of the ratedpressure. Within this range the damage is considered to be anincrease of the fatigue stress and therefore a reduction of the lifeof the hose, higher peaks will create permanent damage of thestructure and eventually will burst the hose.Considering the structural specifications defined in the norms itis possible to construct a P-N “cumulative damage curve” basedon the tests (burst tests and impulse cycle tests).
As an example consider SAE 100R2 hoses: burst pressure isdefined as 400% of pressure rated and impulse point is definedas 200,000 cycles at 133% of pressure rated.Considering a cumulative damage curve following the equation,Pa = Pb (N)S, where:Pa = Zero to max amplitude of pressure cycleN = Cycles of failure at pressure amplitude Pa
Pb = Burst pressure (one cycle life)S = Slope of curve on a log-log plot
The curve can be represented as a straight line on a log-log curve.
The effect of the amplitude of spikes can be inferred from thegraph: consider that if 200,000 spikes of 133% of pressure ratedwill not fail the assembly, while only 2,000 impulses of 200% of thepressure rated can seriously impact the service life of the assembly.On a system architecture design, the use of this graph is para-mount: in applications where the maximum pressure and theprobability of occurrence of the spikes and surges are known, itallows to select the proper hose. As long as the application definedas a P-N combination is below the curve the hose is appropriate.
1000
400
% RATEDPRESSURE
IMPULSE CYCLES
1001 10 100 1,000 10,000 100,000 1,000,000
133% IMPULSE
BURST
REF P-N CURVE
47
HOSE ASSEMBLY ROUTING
Here below some useful examples of correct routings in orderto design reliable solutions and increase the hose life duration.Please refer also to the examples supplied by the SAE J1273specification and ISO/TR 17165-2.
Under pressure, a hose may change in length. Always providesome slack in the hose to allow for this shortening or elonga-tion. It’s not recommended to have excessive slack (fig. 1).
If a hose is installed with a twist, operating pressures tend to forceit towards the straight position. The internal stress due to the twistcan cause reinforcement separation and the hose could burst atthe point of maximum strain or near the fitting (fig. 2).
On bended configurations, provide sufficient hose so that itdoes not have a bend radius less than its recommendedminimum bend radius, in addition the hose is not pulled.Too tight a bend may kink the hose and restrict or stop thefluid flow. In many cases the proper use of adapters and hosefittings (elbows 45°, 90°, etc) can eliminate tight bends orkinks (fig. 3).
Avoid contact with objects that can cause abrasion or damage.On moving applications, pay particular attention when specify-ing hose length to avoid tensile stress or abrasion (fig. 4).
In applications where there is considerable vibration or flexing,allow additional hose length. The metal hose fittings, are notflexible, and proper installation protects metal parts fromundue stress, and avoids kinks in the hose (fig. 5).
When hose lines pass near an heat source, they should beinsulated by a heat resistant sleeve or shield, firesleeve or ametal protection. In addition, the use of proper clamps keephoses in the right position and reduce risks of abrasions. Forinstallations where abrasion to hose cover cannot be preventedwith the use of clamps or brackets, a steel or plastic protectivespring or an abrasion resistant sleeve should be installed overthe hose (fig. 6).
Prevent hose bending in more than one plane: fix the assem-bly into separate segments, by clamping hose at change ofplane (fig. 7).
Refer to SAE J1273 par. 5 for further details on hose selection and routing.J1273Recommended Practicesfor Hydraulic HoseAssemblies
48
r min
abrasion
r < r min
abrasion
r < r min
min. dist.
r min
d
r min 1,5 d
Hose assembly routing
NOwrong use
YEScorrect use
NOwrong use
YEScorrect use
For detailed information concerningthe recommended practices for HydraulicHose assemblies, please refer to SAEJ1273.This document should be used as a guideto be considered when selecting, routing,fabricating, installing, replacing, maintainingand storing hose for hydraulic systems.
High temperature parts
fig. 1
fig. 2
fig. 3
fig. 4
fig. 5
fig. 6
fig. 7
Coupling Selection
INTRODUCTION
A hose fitting or coupling provides a latching system for thehose to various hydraulic components. Hose fittings mustalways be selected on the base of the application and thehose manufacturers specifications.Hydraulic hose fittings can be divided into two main cate-gories based on their method of attachment to the hose. Theycan be either reusable or permanently attached. Underthese two categories there are several variations.
Permanently attachedThe most widely used type of hydraulic fitting, is based on amethod of attachment to the hose called permanent. It isassembled on the hose in a manner which distorts the fittingby compressing its outer shell (ferrule) onto the hose and can-not be reused. There are two methods to install the perma-nent type of fitting: one is called the crimp method and theother is the swage.The crimp method uses movable die fingers to generate aradial force on the ferrule of the coupling to compress to acontrolled size onto the hose: this operation traps the hosebody between the fitting insert and the ferrule.Swaging uses a fixed diameter set of dies and the hose andfitting are pushed through the centre to compress the ferruleonto the hose.The crimping method is the most used.The result is always a permanent coupling attached to thehose, that cannot be reused.
Hydraulics fittings are generally permanent fittings and requirecrimping equipment to be assembled to a hose. They are avail-able in either preassembled (“one-piece”) or two-piece con-figurations.
50
fig. 1 - Fitting visual glossary
fig. 2 - Standard fitting (Crimped skive)
fig. 3 - Interlock
fig 4 - Screw together (Reusable)
• “One-piece” (fig. 5) couplings are made with the ferrulepermanently attached to the insert (stem).
• “Two-piece” (fig. 6) couplings consist of an insert (stem) anda separate ferrule.
When using two-piece couplings, it is important to match theferrule with its appropriate insert and hose.There are also two types of ferrules: skive and no-skive. Skiveferrules require the hose cover to be removed and crimpsdirectly onto the reinforcement wire, while no-skive ferrulescompress or grip the hose reinforcement through the hosecover.
For heavy duty applications, large size of wire spiral hoses,Manuli has engineered a special robust architecture of cou-pling, called “InterLock” (fig. 3). Internal and external skiveoperations are carried out in order to allow the insert and fer-rule to grip directly onto the steel reinforcement of the hose:this creates a sort of mechanical lock between the hose struc-ture and the coupling. This architecture guarantees a particu-larly reliable connection hose-fitting, important in special appli-cations impacted by relevant stress or safety aspects.
None of these components, hose, insert or ferrule, arereusable once they have been part of an assembly.
ReusableAs the name implies, this type of fitting can be reused. Whenthe hose needs to be replaced, the fittings can be removedand applied to a new hose.
51
fig. 5 - One piece configuration
fig. 6 - Two piece configuration
There are three very common variations of this type of fittingand they are:• Screw together• Clamp type• Push-on
The “screw together” type is usually two pieces, the ferrule andthe insert. The hose is screwed into the ferrule and the insertis screwed into the ferrule and the hose, resulting in the hosebeing trapped between the two steel components (see fig. 4).
The “clamp type” is made up of a nipple or insert which goesinto the hose and two clamp halves which are held securelyaround the hose and the insert using bolts and nuts. There isa locking area provided on the insert into which the clamphalves fit to prevent the insert from being pulled or blown outof the hose.
The “push-on type” is primarily used on very low pressure con-trol or industrial applications. The insert has very large barbs onthe portion that fits into the hose and it is used without clampsor ferrules. The hose used with this type of fitting is also specif-ically designed to provide a tighter grip on the fitting as pres-sure is applied (see fig. 7).
Coupling identificationA hydraulic coupling has two functional ends:• the termination end (or thread end) for port or adaptor
attachment and sealing properties;• the hose side end for hose attachment (fig. 1).
Termination end (thread ends and sealing surfaces) are identi-fied by the reference international specifications (ISO, SAE,etc.).In case of replacement, the termination end of a coupling canbe identified by comparing it with the coupling beingreplaced or by measuring the port or thread end to which itwill be fitted. The termination end may be in many different configurations,thread type, sealing surfaces configurations, with or withoutO-Rings, etc.Hose and thread ends are measured by industry standarddash sizes. The hose and dash size refers to the inside diame-ter in 1/16" (except for SAE 100 R5 and SAE 100 R14, whichare based on tubing O.D.).
The termination end depends on the hose type and size towhich it is attached (and the port to connect!). Couplingdesign is specified by the hose manufacturer to meet hose per-formance: Manuli presents the coupling type (insert and fer-rule) associated on the hose data sheet (catalogue).
52
fig. 7 - Push-on (Push-lock)
HOW TO IDENTIFY FLUID CONNECTORS
Measuring ToolsProper tool kits are generally available from hose or fittingsmanufacturers to identify the fluid connectors terminationends. They are provided of a seat angle gauge, thread pitchgauge and an I.D./O.D. caliper to make accurate measure-ments of commonly used connectors, generally in a uniqueuseful tool offering all the capabilities.
How to measure threadsThreads are designated by diameter (external on the male andinternal on the female), and by the number of threads perinch (Imperial system), or by the distance between eachthread in millimetres (metric system).
The Imperial system is identified in ‘teeth per inch’ (TPI).The metric system is identified by prefixing the thread diameterwith an “M” followed by the pitch of the thread.
Examples:3/8”-19 means thread diameter 3/8” and 19 teeth per inchM22x1,5 means thread diameter 22mm with a thread pitch of1,5mm
Use a thread pitch gauge to determine the number of threadsper inch or the distance between threads in metric connec-tions. Place the gauge on the threads until the fit is accurate.Match the measurement with the proper charts. Measure alsothe thread diameter with an I.D./O.D. caliper. Match themeasurements to the charts (fig. 1-2).
How to measure sealing surface anglesFemale connections are usually measured by inserting thegauge into the connection and placing it on the sealing sur-face. If the centerlines of the connection and gauge are paral-lel, the correct angle has been determined.Male flare type connectors are usually measured by placingthe gauge on the sealing surface. If the centerlines of the con-nection and gauge are parallel, the correct angle has beendetermined.
1) With the caliper measure the thread diameter at the largestpoint of the OD in case it is a male thread, the ID if it is afemale thread (fig. 4-5).
2) Using the pitch gauge determine the number of threadsper inch (imperial thread) or the distance between pitches(metric). Comparison of gauge and couplings threads againsta lighted background will ensure an accurate reading (fig. 3).
3) Match the measurement taken above against those in theappropriate tables that appear to be similar to the couplingunder consideration.
53
fig. 1
fig. 2
fig. 3
fig. 4
Read “Out” dimension
fig. 5
Read “In” dimension
fig. 6 - Right seat angles
fig. 7 - Wrong seat angles
centre Linesare parallel:
RIGHT
centre Linesat an angleWRONG
54
4) Measure the seat angle: when the centre line of the seatgauge extends parallel with the projected longitudinal axis ofthe coupling, then the angles of the gauge and seat match(fig. 6, 7).
5) Compare the measurement taken to the coupling standardtables.
END-THREAD MEASUREMENT
55
To identify thread size termination end, measure the exteriormale thread diameter O.D: or the internal female thread diam-eter I.D., then looking to the column mm, you will get the cor-respondent thread size.
End-Thread Measurement
Male O.D.
---
3/8"-24 UNF1/8"-28 GAS
M10x11/8"-27 NPTF
-7/16"-20 UNF
--
M12x1,5-
1/2"-20 UNF1/4"-19 GAS1/4"-18 NPTF
M14x1,59/16"-18 UNF
----
5/8"-18 UNFM16x1,5
-3/8"-19 GAS3/8"-18 NPTF11/16"-16 UN
M18x1,5--
3/4"-16 UNF
mm Female I.D.
8,58,79,29,49,610,010,410,511,011,411,612,012,212,513,013,914,014,214,514,615,115,515,716,016,516,617,317,418,018,518,819,0
3/8"-24 UNF1/8"-28 GAS
1/8"-27 NPSM--
7/16"-20 UNF-
M12x1,5-
1/2"-20 UNF1/4"-19 GAS
-1/4"-18 NPSM
M14x1,59/16"-18 UNF
---
M16x1,55/8"-18 UNF3/8"-19 GAS
3/8"-18 NPSM-
11/16"-16 UNM18x1,5
--
3/4"-16 UNF-
M20x1,51/2"-14 GAS
13/16"-16 UN
Male O.D.
-M20x1,5
-13/16"-16 UN1/2"-14 GAS
-1/2"-14 NPTF
M22x1,57/8"-14 UNF
-5/8"-14 GAS
-M24x1,5
----
1"-14 UNSM26x1,5
3/4"-14 GAS1.1/16"-12 UN3/4"-14 NPTF
M27x2--
M30x21.3/16"-12 UN
----
M33x2
mm Female I.D.
19,220,020,320,520,821,121,622,022,222,522,823,824,024,524,624,925,025,326,026,326,726,927,027,928,030,030,130,730,931,031,233,0
1/2"-14 NPSM-
7/8"-14 UNFM22x1,5
-5/8"-14 GAS
---
M24x1,5-
1"-14 UNS-
M26x1,53/4"-14 GAS-NPSM1.1/16"-12 UN
M27x2------
1.3/16"-12 UNM30x2
--
1"-11,5 NPSM1"-11 GASM33x2
1.5/16"-12 UN-
Male O.D.
1"-11 GAS1.5/16"-12 UN1"-11,5 NPTF
-M36x2
----
1.5/8"-12 UN1.1/4"-11 GAS
M42x21.1/4"-11,5 NPTF
-M45x2
----
1.7/8"-12 UN1.1/2"-11 GAS
M48x21.1/2"-11,5 NPTF
--
2"-12 UNM52x2
-2"-11 GAS
2"-11,5 NPTF-
2.1/2"-12 UN
mm Female I.D.
33,233,333,834,036,039,139,439,540,041,141,742,042,443,045,045,245,545,746,047,547,748,048,548,850,050,752,057,059,460,661,263,3
---
M36x2-
1.5/8"-12 UN1.1/4"-11,5 NPSM1.1/4"-11 GAS
M42x2----
M45x2-
1.1/2"-11 GAS1.1/2"-11,5 NPSM
1.7/8"-12 UNM48x2
----
2"-12 UNM52x2
--
2"-11 GAS--
2.1/2"-12 UN-
COUPLINGS SELECTION CRITERIA
Several factors, such as thread end compatibility, pressureand mechanical resistance, corrosion resistance, vibration,temperature, use of adaptors, fluid compatibility, etc. must beconsidered when selecting a coupling for an application orsystem/equipment.
Thread end and sealing surface compatibilityThread ends must be compatible in order to prevent leaking orfailure. Three elements must be considered in particular:thread interface, seat angles and eventual O-Rings. It is criticalthat both the male and female fittings are compatible toensure an effective seal. Incorrect sealing will cause leaks,which can represent a safety and environmental hazard.
TemperatureMetal surfaces can expand and contract under extreme tem-perature fluctuations. Selecting couplings with O-Rings, will givea better sealing even with metal components deformations.It may be necessary to use O-Ring materials that are suitablefor high temperatures and chemically compatible with theworking fluid at the requested temperature. If the application isat high temperature, it is advisable to avoid brass or aluminiumfittings.
Fluid compatibilityIt is common practice to select hoses taking particular care ofthe compatibility with the working fluid, it is far less commonto do so for couplings.. Also couplings, however, can also beaffected by fluids, in particular aggressive fluids. Always checkthe fluid compatibility chart for coupling and O-Ring materialsand contact Manuli for specific details or doubts.
Corrosion resistanceMost hydraulic fittings are manufactured from carbon steeland have zinc plating external treatment for corrosion resist-ance. Even if the high performance of the Manuli couplingstreatment pass 400 hours before red corrosion in the standardsalt spray tests (ASTM B117), other materials such as stainlesssteel can be necessary for special applications (marine equip-ment, mining, etc.).
Working pressureWorking pressure should be a relevant consideration whenselecting a fitting. Some fittings do not seal well at high pres-sures and can cause leaks. O-Ring type fittings as well as solidport connectors work well at high pressures. It is important tomake sure that not only the maximum rated working pressureis higher than the working pressure of the system but also thatthe architecture (thread type, sealing surfaces, thicknesses,shape of the connection, etc.) of the termination end is suit-able for the intended use.
56
Vibrations Hose flexing conditions and/or vibrations at the end connec-tion, can potentially weaken or reduce the connection capa-bility. It is important to select couplings accordingly: flangesor other couplings with O-Ring for sealing perform betterunder vibration, avoid use of couplings that seal on thethreads.
Couplings thread style and pressure performanceThe couplings termination ends are realised according to thereference international specifications, that define the threadtype, sealing surfaces angles and type, architecture of the ter-mination end, etc.Manuli couplings product range presents a wide variety of themost common termination end types, offering also someglobal OEM (Original Equipment Manufacturer) special con-nections and upon request even personalised solutions. Among the others we can mention:
BSP (British Standard Pipe) standard connections:• Male BSPP (Parallel) and BSPT (Tapered)• BSP 60°• BSP O-Ring 60°• BSP flat seat
DIN (Deutsches Institut für Normung) standard connec-tions:• DIN standpipe• DIN Metric 60°• DIN Multiseal• DIN Metric 24° (light and heavy series)
SAE (Society of Automotive Engineers) standard connec-tions:• JIC (Joint Industrial Council) connections• ORFS (O-Ring Face Seal) connections• SAE connections (90° cone)• NPTF (National Pipe Tapered Fuel) and NPSM (National Pipe
Straight Mechanical) connections• SAE flanges (3000 and 6000 psi)• STAPLE LOCK connections
NF (Norme Française) standard connections:• 24° metric connections• 24° gaz connections
JIS (Japanese Industrial Standard) standard connections
The following table is a summary (exceeding internationalspecifications) of hydraulic pressure performance by threadstyle and size for coupling termination ends.
57
The table is intended only as an approximate guide to fieldperformance of products, figures shown are maximum oper-ating pressures in bar, based upon a 4:1 safety factor relativeto the connection minimum burst pressure. Testing of Manulifittings range confirm the data; anyway the robustnessand high quality of the Manuli fittings generally exceedthe mentioned performance. Testing was conducted at therecommended assembly torque in hardened test blocks.The pressure rating of the hose assembly, complete of all thecomponents, including fittings and adapters, must be definedas the rate of the weakest component.Selecting a termination end for a given hose, means also aproper choice of the type, architecture and pressure rate com-patible with the hose one.
58
Coupling termination end type
Max. Working pressure (bar)
Termination end type
BSP Male
O-Ring BSP Female
BSP Female
Multiseal DIN Female
Metric 60° DIN Female
Metric Male 24° L Series
Metric Female 24° L Series
Metric Male 24° Heavy Series
Metric Female 24° Heavy Series
Millimetric Metric Male
Millimetric Metric Female
Metric Gaz Male
Metric Gaz Female
JIS Metric Female
JIS Gas Female
JIC 37° SAE Male
JIC 37° SAE Female
JIC 45° SAE Male
JIC 45° SAE Female
NPTF Male
NPSM Female
ORFS Female
CODE 61 SAE Flanges
CODE 62 SAE Flanges
XTRAFLANGES
WASH CLEANER FEMALE (M24913)
Ref. Specification
BS5200 - ISO WD8434-6
BS5200 - ISO WD8434-6
BS5200 - ISO WD8434-6
DIN 20066/Febr.'82
DIN 20066/Febr.'82
DIN 20066/Oct. '02
DIN 20066/Oct. '02
DIN 20066/Oct. '02
DIN 20066/Oct. '02
NORM. FRANC. E48-064
NORM. FRANC. E48-064
NORM. FRANC. E48-064
NORM. FRANC. E48-064
JIS B8363
JIS B8363
SAE J514
SAE J514
SAE J514
SAE J514
SAE J514
SAE J514
SAE J1453
SAE J518
SAE J518
SAE J518
-
3/16"
-03
5
350
-
-
250
-
415
415
630
630
630
630
630
630
350
350
350
350
350
350
350
350
420
-
-
-
-
1/4"
-04
6
500
500
500
250
-
400
400
630
630
630
630
630
630
350
350
350
350
350
350
350
350
460
-
-
-
420
5/16"
-05
8
460
-
460
250
-
350
350
630
630
630
630
630
630
350
350
350
350
350
350
280
280
460
-
-
-
420
3/8"
-06
10
460
460
460
250
-
330
330
630
630
630
630
630
630
350
350
350
350
350
350
280
280
460
-
-
-
420
1/2"
-08
12
430
430
430
250
-
275
275
630
630
630
630
630
630
350
350
350
350
310
310
245
245
420
350
420
-
-
5/8"
-10
16
350
350
350
160
-
250
250
450
450
420
420
420
420
280
280
350
350
240
240
210
210
420
-
-
-
-
3/4"
-12
19
350
350
350
-
63
215
215
420
420
420
420
420
420
280
280
350
350
240
240
210
210
420
350
420
-
-
1"
-16
25
280
280
280
-
63
165
165
385
385
420
420
420
420
280
280
280
280
210
210
175
175
350
350
420
560
-
1-1/4"
-20
31
250
250
160
-
63
125
125
350
350
250
250
250
250
175
175
210
210
170
170
145
145
275
280
420
560
-
1-1/2"
-24
38
210
210
125
-
63
100
100
280
280
250
250
250
250
105
105
160
160
140
140
145
145
210
210
420
560
-
2"
-32
51
210
210
80
-
40
-
-
-
-
250
250
250
250
105
105
125
125
105
105
145
145
-
210
420
450
-
Hose size / Dash
DN
Additional considerations on termination ends selection Some useful considerations as support to the termination endsselection, for a proper use in the requested application.
The fittings working pressures suggested by the internationalspecifications are the most important guideline to select theright termination end: working pressure of the hose assemblymust be the lowest level between hose and fitting ones. Fittingworking pressure should be selected higher or equal to thehose one.
But also other considerations are relevant.
For heavy duty applications, in presence of vibrations, highfatigue mission profiles and/or large size hoses, flanges areoften preferable compared to other termination ends. Whenthis is not possible, other robust termination ends can beselected, such as DIN Metric heavy series and ORFS.
The recommendation in favour of safety is to avoid selection oflow-pressure termination ends for hose assemblies dedicatedto the most severe mission profiles. Even thought the marketrequires the maximum availability of many different termina-tion end types (for example medium pressure termination endfor InterLock fittings dedicated to heavy duty wire spiral hoses)these should not be interpreted as optimum solutions.
In addition, O-Ring type termination ends are always to be pre-ferred for new projects, as also declared by the internationalspecifications ISO, SAE, etc. for their better performance com-pared to the traditional metal to metal sealing types. StandardO-Ring supplied are generally NBR based, suitable up to max.temperature of 125°C as from the international specifications;for eventual special applications different types of O-Ringscould be necessary, with a more appropriate compound, con-sidering chemical compatibility with service fluid and tempera-ture resistance.
For any doubt and specific advice, contact Manuli RubberIndustries specialists.
59
MANULI PART NUMBERING SYSTEM
M = MF2000 fittingO = Banjo, Bolt, Flanges, etc.L = Push-Lock
First digit
The numbers stated in this position (from 0 to 8), refer respec-tively to the following descriptions:0 = Swaged Ferrule 1 = Multifit Type Male2 = Multifit Type Female3 = Interlock Type Male 4 = Interlock Type Female5 = Xtralock Type Male6 = Xtralock Type Female8 = Flange Clamps or Bolt
Second and third digit
MULTIFIT INTERLOCK DESCRIPTION XTRALOCK
00 Blank insert03 BSP Banjo05 55 BSP Parallel Thread (60° cone)06 BSP Parallel Thread (Flat face) 07 57 BSP Male Tapered Thread - JIS BSP Female08 58 BSP Parallel Thread O-Ring (60° cone)09 Metric Banjo10 Metric Thread (60° cone superlight) 11 Male Metric Thread (24° cone light type) 12 62 Male Metric Thread (24° cone heavy type)13 Metric Thread (Multiseal cone)15 Female Metric Thread (24° cone O-Ring light type 16 66 Female Metric Thread (24° cone O-Ring heavy type) 17 Metric Thread (French Millimetric)18 Metric Thread (French gaz)20 DIN Metric Standpipe L.T.21 DIN Metric Standpipe H.T.25 75 JIC Thread (37° cone)27 JIC Thread double exag. (37° cone) 24 74 ORFS type26 SAE Thread (45° cone)28 78 NPTF/NPSM Thread30 SAE O-Ring Thread33 83 Code 61 SAE flange 3000 psi36 86 Code 62 SAE flange 6000 psi38 JIS (Toyota) Thread39 89 Supercat flange40 JIS (Komatsu) Thread41 NPTF Swivel Male43 SAE O-Ring Thread Swivel Male44 ORFS Long Drop Elbow47 JIC Thread (37° cone) Elbow Long Drop48 Staple Lock Connection49 Wash Cleaning Female
85 Xtraflange
60
1 2 3 4 5
1 2 3 4 5
When the first digit is 8, it denotes Bolt type or SAE flangeclamps, namely:SAE Flange 3000 psi = 33SAE Flange 6000 psi = 36 BSP Bolt = 02 Metric Bolt = 08 Xtraflange = 85
Fourth digit
1 = Straight2 = 22,5° Swept3 = 30° Swept 4 = 45° Swept 6 = 60° Swept 7 = 67,5° Swept 8 = Compact type 9 = 90° Swept
Fifth digit
3 = Slip-on Nut2 = Thrust-wire Nut1 = Crimped-back Nut - Multifit flange0 = Male/Ferrule - Interlock/Xtralock flange
61
1 2 3 4 5
MANULI PART NUMBERING SYSTEM
OPB = One Piece BraidedOPNS = One Piece No SkiveOPS = One Piece Spiral
First digit
The numbers stated in this position (from 0 to 8), referrespectively to the following descriptions:1 = Male2 = Female8 = Flange Clamps or Bolt
Second digit
DESCRIPTION05 BSP Parallel Thread (60° cone)06 BSP Parallel Thread (Flat face)07 BSP Male Tapered Thread - OPS BSP Female 08 BSP Parallel Thread O-Ring (60° cone)10 Metric Thread (60° cone superlight)11 Male Metric Thread (24° cone light type)12 Male Metric Thread (24° cone heavy type) 13 Metric Thread (Multiseal cone) 15 Female Metric Thread (24° cone O-Ring light type 16 Female Metric Thread (24° cone O-Ring heavy type)20 DIN Metric Standpipe L.T.21 DIN Metric Standpipe H.T.25 JIC Thread (37° cone)27 JIC Thread double exag. (37°) - OPS JIC Thread Range24 ORFS type26 SAE Thread (90° cone)28 NPTF/NPSM Thread30 SAE O-Ring Thread33 Code 61 SAE flange 3000 psi36 Code 62 SAE flange 6000 psi38 JIS (Toyota) Thread40 JIS (Komatsu) Thread41 NPTF Swivel Male - Komatsu flange44 Long drop ORFS Female43 SAE O-Ring Boss Swivel Male46 Super Staple Lock Male 47 JIC Thread (74° cone) Elbow Long Drop 48 Staple Lock Connection49 Wash Cleaning Female
62
1 2 3 4 5
1 2 3 4 5
When the first digit is 8, it denotes SAE flange, clamps namely:SAE Flange 3000 psi = 33SAE Flange 6000 psi = 36
Fourth digit
1 = Straight 2 = 22.5° Flange angle3 = 30° Flange angle4 = 45° Swept6 = 60° Flange angle7 = 67.5° Flange angle8 = Compact type9 = 90° Swept0 = 101° Flange angle
Fifth digit
3 = Slip-on Nut2 = Thrust-wire Nut1 = Crimped-back Nut/Flange0 = Male
63
1 2 3 4 5
MANULI PART NUMBERING SYSTEM
First digit
The numbers stated in this position (from 4 to 9) refer respectively to the ends number 4 = one end5 = two ends7 = three ends 9 = four ends
Second digit
The numbers stated in this position (from 0 to 9) refer respectively to the gender and geometry of the ends
64
1 3 42 5 6
1 3 42 5 6
A = Adaptors
2
3
1
21
second digit 1st end gender 2nd end gender geometry
0 male male straight1 female female straight2 male female straight3 male male 45° elbow4 female female 45° elbow5 male female 45° elbow6 male male 90° elbow7 female female 90° elbow8 male female 90° elbow
One end
Two ends
second digit 1st end gender 2nd end gender 3rd end gender
0 male male male1 male male female2 male female male3 female female female 4 female female male5 female male female6 male 1 male 2 male 17 female 1 female 2 female 18 male 1 male 1 male 29 female 1 female 1 female 2
Three ends
second digit end gender
0 male plug1 female plug 2 sleeve3 nut
Third and fourth digit
The numbers stated in these positions indicate the end tailreferred to the second digit
Fifth and sixth digit
The numbers stated in these positions indicate end tail referredto the third digit 02 BSP Male Tapered Thread long/
BSP Female Tapered Thread 03 BSP Male Parallel Thread O’R (Flat Face) - ISO 1179-304 BSP Female fixed05 BSP Parallel Thread (60° cone)07 BSP Male Tapered Thread09 BSP Parallel Thread O’R (Flat Face) adjustable - ISO 1179-319 Metric ISO 6149 O’R (Flat Face)22 JIC Thread (37° cone) long23 JIC Thread (37° cone) bulkhead24 ORFS type25 JIC Thread (37° cone)27 ORFS type bulkhead28 NPTF Male - NPSM swivel female29 ORFS type long30 SAE O’R boss type31 SAE O’R boss type adjustable34 NPTF female fixed
65
1 3 42 5 6
1 3 42 5 6
2
4
1
3
second digit 1st end gender 2nd end gender 3rd end gender 4th end gender
0 male male male male1 male 1 male 1 male 1 male 22 male 1 male 2 male 1 male 23 male male male female4 male female male female5 male female female female6 female female female female7 female 1 female 1 female 1 female 28 female 1 female 2 female 1 female 29 male male female female
Four ends
TERMINATION ENDS AND TORQUE VALUES
Here below a summary presentation of the main fittings fami-lies and torque values for correct installation.
JIC (37° Flare - SAE J514 / J516 ISO 8434-2)JIC fittings seal on a flare with a central angle of 74° (37° if weconsider the seal surface inclination compared to the fittingaxis) and are available with thrust wire or slip on nut depend-ing on the geometry (slip on nut can’t fit on parallel sizes).
RecommendedTorqueValues(Nm)
FemaleThreadI.D.*
MaleThreadO.D.*
NominalThread
Size
InchSize
350
220
180
150
120
105
80
50
35
22
Maxmininchmminchmm
15
250
180
150
120
100
80
60
35
20
18
12
2.41
1.79
1.54
1.22
1.09
.98
.80
.67
.51
.45
.39
61.2
45.5
39.1
31.0
27.7
24.9
20.3
17.0
12.9
11.4
9.9
2.50
1.88
1.63
1.31
1.18
1.06
.88
.75
.56
.50
.44
63.5
47.4
41.4
33.3
30.0
26.9
22.3
19.0
14.2
12.7
11.2
21/2 - 12
17/8 - 12
15/8 - 12
15/16 - 12
13/16 - 12
11/16 - 12
7/8 - 14
3/4 - 16
9/16 - 18
1/2 - 20
7/16 - 20
2
11/2
11/4
1
7/8
3/4
5/8
1/2
3/8
5/16
1/4
-32
-24
-20
-16
-14
-12
-10
-8
-6
-5
-4
DashSize
X 25 XX JIC Thread 74° cone
66
SAE STANDARD CONNECTIONS
67
ORFS (SAE J1435 / J516 - ISO 8434-3 / 12151-1)SAE J1453 specifies this type of sealing, more robust comparedto the JIC design; ORFS guarantees sealing through an O-Ringtrapped onto a flat surface. This type of fitting is designed forvery high pressure (even 6000 psi) with no leakage problem at all.
The solid male O-Ring face seal will mate only swivel female fit-ting. The O-Ring is on the male (for dimensions see the dedi-cated section).
SAE J512 90° CONEThe American SAE J512 specifies a central cone angle of 90°(45° if we consider the seal surface inclination compared tothe fitting axis) rather than the 74° angle of the JIC type. Careneeds to be taken with selection because some of the threadsizes and pitches are the same as the JIC sizes, however, thedifferent cone seats are not compatible.These fittings are dedicated to low pressure applications.
FemaleThreadI.D.*
MaleThreadO.D.*
NominalThread
Size
InchSize
inchmminchmm
.99
.80
.68
.56
.45
.39
.34
.27
25.1
20.3
17.0
14.2
11.4
9.9
8.6
6.9
1.06
.88
.75
.62
.50
.44
.38
.31
26.9
22.3
19.0
15.7
12.7
11.2
9.6
7.9
11/16 - 14
7/8 - 14
3/4 - 16
5/8 - 18
1/2 - 20
7/16 - 20
3/8 - 24
5/16 - 24
3/4
5/8
1/2
3/8
5/16
1/4
3/16
1/8
-12
-10
-8
-6
-5
-4
-3
-2
DashSize
X 26 XX SAE J512 90° cone
60
50
30
16
15
12
10
8
RecommendedTorquevalues
N/m
RecommendedTorqueValues(Nm)
FemaleThread
I.D. (inch)
MaleThread
O.D. (inch)
NominalThread
Size
InchSize
DecimalFractionDecimalFraction
215
180
130
92
65
45
26
15
1.92
1.61
1.36
1.11
.93
.75
.63
.51
115/16
15/8
13/8
11/8
15/16
3/4
5/8
17/32
2.00
1.69
1.44
1.19
1.00
.82
.69
.56
2
111/16
17/16
13/16
1
13/16
11/16
9/16
2 - 12
111/16 - 12
17/16 - 12
13/16 - 12
1 - 14
13/16 - 16
11/16 - 16
9/16 - 18
11/2
11/4
1
3/4
5/8
1/2
3/8
1/4
-24
-20
-16
-12
-10
-8
-6
-4
DashSize
X 24 XX ORFS Type
68
NPTF/NPSM - SAE J516The NPTF male has 30° inverted seat and tapered threads. Theseal take place by deformation of the thread (NPTF on NPSMfixed female) or on 30° cone for NPSM swivel female.NPTF is not interchangeable with BSPT connectors becausethe thread angle is 60°. The torque obtained can vary considerably depending onthread condition. Proper sealing can occur at values muchover than the maximum values listed.When the junction is with a female straight thread, reducesthe maximum values by 50%.If sealant is present reduces the torque by 25-30%.
FemaleThread
I.D.(inch)
MaleThread
O.D. (inch)
NominalThread
Size
InchSize
DecimalFractionDecimalFraction
25/16
113/16
119/32
11/4
1
25/32
5/8
1/2
3/8
2.30
1.82
1.58
1.24
.98
.77
.63
.49
.38
2.38
1.90
1.66
1.32
1.05
.84
.68
.54
.41
23/8
129/32
121/32
15/16
11/16
27/32
11/16
17/32
13/32
2 - 111/2
11/2 - 111/2
11/4 - 111/2
1 - 111/2
3/4 - 14
1/2 - 14
3/8 - 18
1/4 - 18
1/8 - 27
2
11/2
11/4
1
3/4
1/2
3/8
1/4
1/8
-32
-24
-20
-16
-12
-8
-6
-4
-2
DashSize
120
100
90
70
55
40
30
20
MaximumTorquevalues
N/m
150
X 28 XX NPTF/NPSM Thread
69
SAE MALE O-RING BOSS (SAE J516/J514)The O-RING BOSS male will mate with a SAE J1926 portfemale. The threads are the same of JIC but sealing is assuredby an O-Ring on the male and a seal part on the female (port).
FemaleThread
MaleThread
NominalThread
Size
InchSize
inchmminchmm
11.2
12.6
14.1
18.9
22.1
26.9
33.1
41.1
47.4
0.44
0.49
0.56
0.74
0.87
1.06
1.31
1.62
1.87
9.9
11.5
12.9
17.5
20.5
24.9
31.3
39.2
45.6
0.39
0.45
0.51
0.69
0.81
0.98
1.23
1.54
1.79
20
25
35
70
100
150
250
300
350
3/4 - 16
9/16 - 18
1/2 - 20
7/16 - 20
1/2
3/8
5/16
1/4
-08
-06
-05
-04
DashSize
X 30 XX SAE O'R Threads
17/8 - 12
15/8 - 12
15/16 - 12
11/16 - 12
7/8 - 14
11/2
11/4
1
3/4
5/8
-24
-20
-16
-12
-10
RecommendedTorquevalues
N/m
70
SAE FLANGESThis connection is commonly used in fluid power-system.Flanges are specified from various standard (SAE J518, DIN20066, ISO 6162, JIS B8363) but all are interchangeableexcept for bolt sizes.There are two pressure rating called Code 61 or 3000 psiseries and Code 62 or 6000 psi series. The design concept isthe same but the hole spacing, flanged head and thicknessare larger for 6000 series (higher pressure).Sealing is achieved by means of an O-Ring inserted into theface of the flange and compressed against a flat surface by useof bolted clamps (captive flange or split flange halves withthreaded holes to match the port).The port is an unthreaded hole with four bolt holes in a rec-tangular pattern around the port.
BoltSpacing C
FlangeOD
NominalThread SizeInch
Size
inchmminchmminchmm
31.7
41.3
47.6
54.0
63.5
79.4
1.19
1.50
1.75
2.00
2.38
2.81
40.5
50.8
57.1
66.7
79.4
96.8
1.59
2.00
2.25
2.63
3.13
3.81
-08
-12
-16
-20
-24
-32
M8x1.25x30
M10x1.5x35
M12x1.75x45
M12x1.75x45
M16x2x55
M20x2.5x70
5/16-18x11/4
3/8-16x11/2
7/16-14x13/4
1/2-13x13/4
5/8-11x21/4
3/4-10x23/4
1/2
3/4
1
11/4
11/2
2
DashSize
Code 62 - 6000psi series
BoltSpacing A
inchmm
18.1
23.8
27.8
31.8
36.5
44.5
0.71
0.94
1.09
1.25
1.44
1.75
MaxWP
BoltTorque
N/mpsi
6000
6000
6000
6000
6000
6000
20-25
34-45
56-68
85-102
158-181
271-294
D
C
A
BoltSpacing C
FlangeOD
NominalThread SizeInch
Size
inchmminchmminchmm
30.2
38.1
44.4
50.8
60.3
71.4
84.1
101.6
1.19
1.50
1.75
2.00
2.38
2.81
3.31
4.00
38.1
47.6
52.4
58.7
69.8
77.8
88.9
106.4
1.50
1.88
2.06
2.31
2.75
3.06
3.50
4.19
-08
-12
-16
-20
-24
-32
-40
-48
M8x1.25x25
M10x1.5x30
M10x1.5x30
M10x1.5x30
M12x1.75x35
M12x1.75x35
M12x1.75x40
M16x2x50
5/16-18x11/4
3/8-16x11/4
3/8-16x11/4
7/16-14x11/2
1/2-13x11/2
1/2-13x11/2
1/2-13x13/4
5/8-11x13/4
1/2
1/4
1
11/4
11/2
2
21/2
3
DashSize
Code 61 - 3000psi series
BoltSpacing A
inchmm
17.4
22.2
26.2
30.2
35.6
42.8
50.8
61.8
0.68
0.87
1.03
1.19
1.40
1.68
2
2.43
MaxWP
BoltTorque
N/mpsi
5000
5000
5000
4000
3000
3000
2500
2000
20-25
28-40
37-48
48-62
62-79
73-90
107-124
186-203
C
A D
71
METRIC COUPLINGS
Metric couplings usually means DIN couplings.Metric thread forms are identified through a number of speci-fications.
The primary specification is the German DIN 2353 - ISO8434–1, which relates to the tube diameter, thread type andcone angle (24°), used also by compression tube fittings.Fittings are available in two series, light and heavy series tosuite the two types of compression coupling types.
DIN 3861 - ISO 8434 -1 spec. specifies male threads in lightand heavy series commonly identified as CEL and CES. Themale has 24° cone seat, straight metric threads and matchesthe tube OD of the coupling used with it (metric standpipe or24° female or multiseal 24° and 60°).
DIN 3865 - ISO 8434-4 / 12151-2 spec. specifies a female cou-pling with cone angle of 24° and an O-Ring fitted on the coneseat of the female, commonly identified as DKOL and DKOS.This connection type gives improved sealing performance tothe coupled unions. There are light and heavy series, identifi-cation is made measuring both thread size and tube OD.
DIN 3863 spec. specifies a cone with a central angle of 60°and does not relate to compression coupling thread forms. Itcan only be mated to a corresponding 60° union.
DIN 3868 spec. is designed to mate with both 24° and 60°metric cone seats and for this reason is identified as “multiseal”female.
Multiseal product is present until Pipe 18 mm (M26x1,5).Over this, thread of 24° product (Myy x 2) are different from60° (Myy x 1,5) product, so the multiconnection is not guar-anteed.
STANDPIPE
X 21 XX Standpipe (Heavy Type)
72
24° CONE SEAT (DIN 3861 - ISO 8434-1) MALEO-RING 24° CONE (DIN 3865 - ISO 8434-4) FEMALE
X 11 XX Metric Thread (24° Cone Light Type) CEL
X 15 XX Metric Thread (24° Cone O'R Light Type) DKOL
Pipe/TubeO.D.
Heavy series
Pipe/TubeO.D.
Light series
FemaleThread
I.D.
Recommended torque values
MaleThreadO.D.
MetricThread
Size
(1.50)
(1.18)
(.98)
(.78)
(.63)
(.55)
(.47)
(.39)
(.32)
(.24)
38
30
(1.65)
(1.38)
(1.10)
(.87)
(.71)
(.59)
(.47)
(.39)
(.32)
(.24)
42
35
25
20
16
14
12
10
8
6
mm (inch)mm (inch) inchmminchmm
28
22
18
15
12
10
8
6
1.97
1.70
1.57
1.34
1.11
.96
.89
.81
.73
.65
.57
.49
.41
(nm)
12 - 14
20 - 25
30 - 35
35 - 42
42 - 50
50 - 58
58 - 65
75 - 85
100 - 110
110 - 125
180 - 200
200 - 220
250 - 28050
43
40
34
28
24.5
22.5
20.5
18.5
16.5
14.5
12.5
10.5
2.04
1.77
1.65
1.41
1.18
1.02
.94
.87
.78
.71
.63
.55
.47
52
45
42
36
30
26
24
22
20
18
16
14
12
M 52 x 2.0
M 45 x 2.0
M 42 x 2.0
M 36 x 2.0
M 30 x 2.0
M 26 x 1.5
M 24 x 1.5
M 22 x 1.5
M 20 x 1.5
M 18 x 1.5
M 16 x 1.5
M 14 x 1.5
M 12 x 1.5
X 16 XX Metric Thread (24° Cone O'R Heavy Type) DKOS
X 12 XX Metric Thread (24° Cone Heavy Type) CES
60° CONE SEAT (DIN 3863)XxxxxxMETRIC FEMALE “MULTISEAL” (DIN 3868)
73
X 13 XX Metric Thread (Multiseal)
Use withPipe/Tube
O.D.
FemaleThread
I.D.
MaleThreadO.D.
MetricThread
Size
1.65
1.38
1.10
.87
.71
.59
.47
.39
.32
inchmm inchmminchmm
.24
42
35
28
22
18
15
12
10
8
6
1.99
1.71
1.44
1.12
.96
.81
.65
.57
.49
.41
50.5
43.5
36.5
28.5
24.5
20.5
16.5
14.5
12.5
10.5
2.04
1.77
1.50
1.18
1.02
.87
.71
.63
.55
.47
52
45
38
30
26
22
18
16
14
12
M 52 x 1.5
M 45 x 1.5
M 38 x 1.5
M 30 x 1.5
M 26 x 1.5
M 22 x 1.5
M 18 x 1.5
M 16 x 1.5
M 14 x 1.5
M 12 x 1.5
X 10 XX Metric Thread (60° Cone Superlight)
BSP (BRITISH STANDARD PIPE)
(BS 5200 - ISO 8434-6 - ISO 228, PT & BSPT Tapered -ISO 7-PT)
The BSP threads also known as Whitworth threads (55°) maybe parallel (BSPP) or tapered (BSPT).
The BSPP thread is parallel and the male has a 30° flare seatwhich seals with a BSPP female on its 30° cone seat. Thethreads holds the connection mechanically.
The BSPT male thread is tapered and usually mates with a port.The seal takes place by thread deformation, that’s why asealant is recommended.Port connections are also made with BSPP male threads: in thiscase a soft metal sealing or an O-Ring (dowty washer orshaped seal) are used to realise the sealing.
The sealing can also be obtained with the 30° seat and O-Ringon female couplings (BSP O-Ring female).
74
X 07 XX Tapered Thread
SuggestedTorque(Nm)
FemaleThread
I.D.
MaleThreadO.D.
NominalThread
Size
InchSize
300
215
156
104
85
51
45
25
15
inchmminchmm
10
2.23
1.77
1.53
1.19
.95
.81
.73
.59
.45
.34
56.656
44.845
38.952
30.291
24.117
20.587
18.631
14.950
11.445
8.566
2.35
1.88
1.65
1.31
1.04
.90
.83
.66
.52
.38
59.614
47.803
41.910
33.249
26.441
22.911
20.955
16.662
13.157
9.728
2 - 11
11/2 - 11
11/4 - 11
1 - 11
3/4 - 14
5/8 - 14
1/2 - 14
3/8 - 19
1/4 - 19
1/8 - 28
2
11/2
11/4
1
3/4
5/8
1/2
3/8
1/4
1/8
-32
-24
-20
-16
-12
-10
-8
-6
-4
-2
DashSize
X 05 XX Parallel Thread (60° Cone)
75
A flat face sealing version exists (06 codes).
The BS 5200 specification relates to an O-Ring version (08codes).
X 06 XX Parallel Thread (Flat Face)
X 08 XX Parallel Thread O'R (60° Cone)
76
30° FLARE (BSP) PARALLEL THREAD (TOYOTA STYLE)The male and the female have straight threads and 30° seat.The 30° flare is on the female; the thread is conform to JISB0202 specification and is the same as BSPP. The cone is invert-ed if compared to BSP female.
30° CONE (BSP) PARALLEL THREAD (NISSAN STYLE)The male and the female have straight threads and 30° seat.The 30° flare is on the male.The product is interchangeable with BSP female (except forsome cone dimensions details). The male cone is on the female as BSP product.
30° CONE METRIC PARALLEL THREADS (KOMATSU STYLE)The Komatsu style is identical to Toyota style except for thethreads that is a metric fine thread compliant to JIS B0207specification (not interchangeable with Toyota product).
JAPANESE STYLE FITTINGS - JIS B 8363
30° FLARE (BSP) PARALLEL THREAD (TOYOTA STYLE)
30° CONE (BSP) PARALLEL THREAD (NISSAN STYLE)
30° CONE METRIC PARALLEL THREADS (KOMATSU STYLE)
They have 24° seat and metric threads.These terminations are similar to DIN types, but the threads arefine type in all the sizes and the sealing is metal to metal on the24° cone (No O-Ring).The male will mate with the 24° female or a tubing sleeve.GAZ type and MILLIMETRIC type differ from tube OD dimen-sions (see pipe dimensions).
77
NF FRENCH STANDARD CONNECTIONS
PipeThread
NF FRENCH STANDARD CONNECTIONS
MILLIMETRIC
27x1,5
27x1,5
30x1,5
33x1,5
36x1,5
39x1,5
18
20
22
25
28
30
PipeThread
GAZ
20x1,5
24x1,5
30x1,5
36x1,5
13,25
16,75
21,25
26,75
STAPLE LOCK CONNECTIONS (SAE J1467 - DIN 20043)
KOMATSU 5/8” FLANGE5/8” is not a SAE size flange: Komatsu specifies general dimen-sions for it.
SUPERCAT FLANGESCaterpillar flanges have the same flange OD as SAE code 62,but they have a thicker flange head (14,3mm). Split flangescode 62 cannot be used.
STAPLE LOCK CONNECTIONS (SAE J1467 – DIN 20043)These connections are used on mining equipment worldwide.The seal is made by an O-Ring and a Backup-Ring on a cylin-drical surface (installed on the male).The connections are held together by a staple.
78
OEM SPECIAL CONNECTIONS
KOMATSU 5/8” FLANGE
SUPERCAT FLANGES
79
The correct torques to connect the fitting termination ends onthe ports are generally provided by the specifications or sug-gested by the manufacturer.Anyway the topic is quite complex if we consider the differentconditions at which the fittings can be at the moment of instal-lation: they may be wet, or cover of dust of oil or in dry con-ditions, that’s why the torque applied can have a differentimpact on the connection.Generally it is to be intended a value of torque momentin dry conditions.
Manuli Rubber Industries recommends to use always a torquewrench and the torque values reported in the reference tables.However it is well known that there are common practices inthe market that allow tightening of threaded componentswithout the use of the proper tools. These practices and pro-cedures can be very dangerous: the threads are designed tohave a proper seal at the proper torque, undertorquing maycause leaks and overtorquing may shear or damage threadsand reduce the life of the assembly.Some of these procedures are well structured have a solidtechnical base and are supported by a good statistical analysisof the connection. These procedures are not broadly valid:generally they are specific to the material of the componentsand to the thread type.One of these tightening method is reported here as an exam-ple and is only valid for Manuli Rubber Industries JIC SwivelFemales inserts.
1. Tight the female byhand on the male adap-tor
2. Mark the hand tight-ening relative positionbetween the female nutand the adaptor(optional)
TORQUE VALUES DETAILS
3. Block the counterhexwith a wrench and
start to tight the swivelnut (from hand-tighten-ing position) avoidingrelative rotation of theinsert
4. Tighten the female bya wrench on swivel nutwith the number ofround or flats prescribedin the table
80
81
5. Check the position ofthe marks if compliantwith the flats pre-crimped
Recommendations & General Guidelines• Torque values shall be intended as in dry conditions• They are valid for plated carbon steel components• The torque wrench needs to be applied on the swivel nut
female• Block the counterhex if present or avoid the female rotation
(avoid twisting of the hose)
THREAD TYPE(dash size)
7/16-20 (04)
9/16-18 (06)
3/4-16 (08)
7/8-14 (10)
N° OF TURNS(N° of flat)
1/2 turns(n° 3 flats)
1/2 turns(n° 3 flats)
1/2 turns(n° 3 flats)
1/2 turns(n° 3 flats)
TORQUEPRESCRIPTION
(SAE Nm, wet conditions)
16 Nm MAX
28 Nm MAX
53 Nm MAX
80 Nm MAX
82
Table O-Ring indications
O-RING RECOMMENDATIONS
24° DKOS femalepublished on 8434-1
Hardness: 90 ShA - d x s (mm)
6 x 1,56 x 1,5
7,5 x 1,59 x 1,59 x 1,510 x 212 x 2
16,5 x 2,420,3 x 2,425,3 x 2,433,3 x 2,4
DKOS type
M 216X3 - 03 - 16M 216X3 - 04 - 16M 216X3 - 04 - 18M 216X3 - 05 - 20M 216X3 - 06 - 20M 216X3 - 06 - 22M 216X3 - 08 - 24M 216X3 - 10 - 30M 216X3 - 12 - 36M 216X3 - 16 - 42M 216X3 - 20 - 52
24° DKOL femalepublished on ISO 8434-1
Hardness: 90 ShA - d x s (mm)
4 x 1,56 x 1,5
7,5 x 1,57,5 x 1,59 x 1,512 x 215 x 220 x 226 x 2
32 x 2,538 x 2,5
DKOL type
M 215X3 - 03 - 12M 215X3 - 04 - 14M 215X3 - 04 - 16M 215X3 - 05 - 16M 215X3 - 06 - 18M 215X3 - 08 - 22M 215X3 - 10 - 26M 215X3 - 12 - 30M 215X3 - 16 - 36M 215X3 - 20 - 45M 215X3 - 24 - 52
BSP O-Ring femalepublished on BS5200
Hardness: 80 ShA - d x s (mm)
6,5 x 1,08,1 x 1,612,1 x 1,613,1 x 1,617,1 x 1,622,1 x 1,629,1 x 1,635,1 x 1,648,1 x 1,6
BSP type
M 208XX-XX-04M 208XX-XX-06M 208XX-XX-08M 208XX-XX-10M 208XX-XX-12M 208XX-XX-16M 208XX-XX-20M 208XX-XX-24M 208XX-XX-32
Code 61 and 62 flangespublished on SAE J518 and ISO 6162
Hardness: 90 ShA - d x s (mm)
18,64 x 3,5324,99 x 3,5332,92 x 3,5337,69 x 3,5347,22 x 3,5356,74 x 3,5369,44 x 3,5385,32 x 3,53
Flange
M 23XX1-XX-08M 23XX1-XX-12M 23XX1-XX-16M 23XX1-XX-20M 23XX1-XX-24M 23XX1-XX-32M 23XX1-XX-40M 23XX1-XX-48
O'Ring indications
d
s
83
SAE MALE O-Ring BOSS (SAE J514)O-Rings dimensions for the fittings M13010 and M14310 arepublished by the SAE J515 specification (O-Ring size specifica-tions for SAE J1926/2 and SAE J1926/3, ISO 11926-2 and ISO11926-3).
O-Ring compound is according to SAE J515 specification.For petroleum based and water based hydraulic fluids, withworking temperature range -35°C to 125°C:Hardness: 90 ShA, Compound: NBR based
ORFS MALE (SAE J1453 - ISO 8434-3)O-Rings dimensions for the fittings M12410 are published bythe SAE J515 and ISO 8434-3.
O-Ring compound is according to SAE J515 specification.For petroleum based and water based hydraulic fluids, withworking temperature range -35°C to 125°C:Hardness: 90 ShA, Compound: NBR based.
STAPLE LOCK O-Rings and Back-up Rings
Fitting ref. code
M 13010-04-04
M 13010-06-06
M 13010-06-08
M 13010-08-08
M 13010-08-10
M 13010-10-12
O-Ring dimensionsID x section diameter (mm)
8,92 x 1,83
11,89 x 1,98
16,36 x 2,21
16,36 x 2,21
19,18 x 2,46
23,47 x 2,95
SAE Male O-Ring Boss (SAE J514)
Fitting ref. code
M 14810-04-04M 14810-06-06M 14810-08-08M 14810-12-12M 14810-16-16M 14810-20-20M 14810-24-24M 14810-32-32
O-Ring (s x d) mm
6,0 x 2,010,0 x 2,013,0 x 2,519,0 x 2,525,0 x 2,533,0 x 2,540,0 x 3,050,0 x 3,0
Back-up Ring (s x d x OD) mm
0,8 x 6,8 x 10,00,8 x 10,8 x 14,00,8 x 14,0 x 18,00,8 x 20,0 x 24,00,8 x 27,0 x 31,00,8 x 34,0 x 38,01,5 x 42,0 x 47,01,5 x 51,0 x 56,0
STAPLE LOCK CONNECTIONS (SAE J1467 - DIN 20043)
Fitting ref. code
M 12410-04-04
M 12410-06-06
M 12410-06-08
M 12410-08-08
M 12410-08-10
M 12410-10-10
M 12410-12-12
M 12410-12-16
M 12410-16-16
M 12410-20-20
M 12410-24-24
O-Ring dimensionsID x section diameter (mm)
7,65 x 1,78
9,25 x 1,78
12,42 x 1,78
12,42 x 1,78
15,60 x 1,78
15,60 x 1,78
18,77 x 1,78
23,52 x 1,78
23,52 x 1,78
29,87 x 1,78
37,82 x 1,78
ORFS Male (SAE J1453)
84
ADAPTORS
Some couplings connect directly to a port, while others needadaptors. Connecting directly to the port eliminates the needfor an additional connection, but can make installation moredifficult. Adaptors can make installation easier, eliminating theneed for coupling orientation but introduce an additional con-nection or possible leak point.
Adaptors are used in the following situation:1. To avoid fitting orientation. If an elbow fitting is required on
both ends of a hose assembly, use it on one end only; usea straight fitting and an elbow adaptor on the other. Thismakes installation easier and eliminates the need for orien-tation of the fittings while assembling at the swagingmachine.
2. When jump-size fittings are not available, make the jumpwith an adaptor.
3. To ease port connection and hose installation.
4. To obtain a different thread configuration, when usingadaptors, the preferred method is to install the adaptor first,the hose assembly next.
The adaptor is an interface for connecting a number of portswithout direct compatibility. Adaptors can be classified intoPRODUCT GROUPS (JIC, ORFS, BSP, etc.) depending on theend configuration type as fittings.The Manuli MF4000™ (*) range is manufactured from a solidpiece of steel: straight ones from cold drawn bars and 45°,90°, Tee and Cross geometry forged and then machined. Thisprocess eliminates the potential leak of points that are typicalof brazed fittings.Standard O-Rings supplied with MF4000™ adaptors range aremade in NBR 90±5 ShA and they are suitable for petroleum-base and nonflammable water-base hydraulic fluids.MF4000™ products are zink plated so to provide corrosionprotection responding to SAE and ISO standards and to com-ply with ASTM-B177, ISO 9227 salt spray test method.
(*) The MF4000TM range is Manuli Rubber Industries completeoffer of adaptors.
Some male swivel type couplings haveinternal O-Rings: Fluid compatibility withthe O-Rings must also be considered.
Caution
85
UNF-UN Thread Port Dimensions (SAE J475 - J1926)
The thread ends of a SAE OR connection, have UN/UNF straightthreads. The O-ring is fitted on the male end and the female porthas an angular sealing surface.When the male is threaded the O-ring is sandwiched between themale shoulder and the female surface. Sealing comes from the O-ring being energised and compressed by the resistance and hold-ing power for service pressure.Adjustable adaptors can be assembled following the proceduredescribed at the end of section.
• If the face of the port is on a machined surface, dimensionsA and B do not need to be considered as long as the flat sur-face rugosity, requirements are respected (Ra max 3.2 μm)and damage of the OR is avoided during assembly.
• C is the maximum recommended spotface depth to allowsufficient wrench grip for proper tightening of the fitting orlocknut.
• Spot faced surface (dimension B) must be squared (0.2 mm)to thread in port.
• F diameter must be concentric (0.1 mm) to thread in port.• Surface on length G needs Ra 3.2 μm max in order to avoid
damage OR during installation.
7/16"-20
11.111.5 12 14 5 21 15
12.45 2.5 12° 9.5
8.92 x 1.83
21
T Nom.C Max.D Min.E Min.K Min.A Min.B Min.F ± 0.05G ± 0.2Y ± 1°H Ref.O' ring
Assemblytorque (Nm)
ThreadDimensions (mm)
UNF-UN Thread Port Dimensions (SAE J475 - J1926)
1/2"-20 9/16"-18 3/4"-16 7/8"-14 1"1/16-12 1"3/16-12 1"5/16-12 1"5/8-12 1"7/8-12
12.7 1.5 12 14 6 23 16
14.05 2.6 12° 9.5
10.52 x 1.83
26
14.291.5 13 16 7.5 25 18
15.70 2.7 12° 10.5
11.9 x 1.98
37
19.052.4 17 20
12.5 34 26 24 2.7 15° 12
16.36 x 2.21
74
22.232.4 17 20
12.5 34 26 24 2.7 15° 13.5
19.18 x 2.46
105
26.992.4 20 24 16 41 32
29.20 3.5 15° 15.5
23.47 x 2.95
180
30.162.4 20 24 18 45 35
32.40 3.5 15° 15.5
26.59 x 2.95
225
33.34 3 20 24 21 49 38
35.55 3.5 15° 15.5
29.74 x 2.95
285
41.27 3 20 24 27 58 48
43.55 3.5 15° 15.5
37.47 x 3.00
305
47.623 20 24 33 65 54
49.90 3.5 15° 15.5
43.47 x 3.00
390
PORT DIMENSIONS
DETAIL X
K
T
D
C
E
B
AX
TT
H
YF
Y
G
545°± °
86
BSPP Thread Port Dimensions
(Retaining RING seat type, ISO 1179-3)
ISO 1179 ports are designed for different sealing methods on thetop flat face of the port. For all non-adjustable adaptors the assem-bly procedure is the same as for SAE OR except for different sealingmethods.
Adjustable adaptors can be assembled following the proceduredescribed at the end of section.
• If the face of the port is on a machined surface, dimensions Aand B do not need to be considered as long as the flat surfacerugosity requirements are respected (Ra max. 3.2 μm) anddamage of O-Ring is avoided during assembly.
• C is the maximum recommended spotface depth to allowsufficient wrench grip for proper tightening of the fitting orlocknut.
• Spot faced surface (dimension B) must be squared (0.2 mm)to thread in port.
1/8"-28
9.73 1 8 13 17 9.8 6.5
7.97 x 1.88
20
T Nom.C Max.D Min.E Min.A Min.B +0.2/-0H Ref.O' ring
Assemblytorque (Nm)
ThreadDimensions (mm)
BSPP Thread Port Dimensions (Retaining RING seat type) (ISO 1179-3)
1/4"-19 3/8"-19 1/2"-14 3/4"-14 1"-11 1"1/4-11 1"1/2-11
13.16 1.5 12
18.5 21
13.2 9
10.80 x 2.62
35
16.66 2 12
18.5 24.5 16.7 9.5
13.95 x 2.62
70
20.962.5 14 22 30 21
11.5 17.86 x 2.62
100
26.442.5 16 24 37
27.1 13.5
23.47 x 2.62
190
33.25 2.5 18 27 46
33.3 15
29.70 x 3.53
300
41.91 2.5 20 29 54 42 16
37.70 x 3.53
330
47.802.5 22 31 61
47.9 16
44 x 3.53
400
H
T
H
T
K
T
ED
C
B
A
45°±5°
87
BSPP Thread Port Dimensions
Sealing achieved by matching female parallel thread (port) andmale tapered (fitting).
1/8"-28
5.5 9.72
4 6.5
V Min.UNS - WorkingThread
ThreadDimensions (mm)
BSPT - BSPP Thread Port Dimensions (ISO 7-Thread)
1/4"-19 3/8"-19 1/2"-14 3/4"-14 1"-11 1"1/4-11 1"1/2-11
8.5 13.15
6 9.7
8.5 16.66 6.4 10.1
10.5 20.95 8.2 13.2
13 26.44 9.5 14.5
14.5 33.24 10.4 16.8
17 41.91 12.7 19.1
17 47.8 12.7 19.1
V
U45°±5°
P
SN
88
Metric Thread Port Dimensions (Retaining RING seat type - ISO6149)
ISO 6149 male and port ends are similar in design to SAE male andport ends so the assembly procedures are similar as well.
Sealing with O-Ring and retaining washer.• If face of port is on machined surface, dimensions A and C need
not apply as long as the surface requirements (Ra min 3.2 ) areable to avoid damage to the OR during installation.
• C is maximum recommended spotface depth to permit sufficientwrench grip for proper tightening of the fitting or locknut.
• Spot faced surface (dimension B) must be squared (0.2 mm) tothread in port.
• F diameter must be concentric (0.1 mm) to thread in port.
10x1
10 1 8
13.5 16 10 8
8.1 x 1.620
T Nom.C Max.D Min.E Min.A Min.BH Ref.O' ringAssemblytorque (Nm)
ThreadDimensions (mm)
Metric Thread Port Dimensions (Retaining RING seat type) (ISO 6149)
12x1.5 14x1.5 16x1.5 18x1.5 20x1.5 22x1.5 26x1.5 27x2 33x2
12 1.5 12
18.5 20 12 9
9.3 x 2.2 35
14 1.5 12
18.5 21.5 14 9
11.3 x 2.2 45
16 1.5 12
18.5 24 16
10.5 13.3 x 2.2
55
18 2 12
18.5 27 18 12
15.3 x 2.2 70
20 2 14
20.5 30 20 12
17.3 x 2.2 80
22 2.5 14
20.5 32 22
12.5 19.3 x 2.2
100
26 2.5 16
22.5 36 26
12.5 23.6 x 2.9
170
27 2.5 16 24 37 27
14.5 23.6 x 2.9
170
33 2.5 18 26 45 33
14.5 29.6 x 2.9
310
42x2
42 2.5 20 28 55 42 15
38.6 x 2.9 330
48x2
48 2.5 22 30 62 48
17.5 44.6 x 2.9
410
H
T
H
T
C45°±5°
ED
B
A
K
T
89
NPTF Thread Port Dimensions
Sealing achieved by matching female tapered thread and maletapered thread (deformation at the crests).
1/8"-27
7.910.24.19.57.6
V Min.U ref.NPS - WorkingThread
ThreadDimensions (mm)
NPTF Thread Port Dimensions (SAE J476)
1/4"-18 3/8"-18 1/2"-14 3/4"-14 1"-11,5 1"1/4-11,5 1"1/2-11,5
11.413.55.812.511.6
11.7176.115.911.8
15.421.28.119.815.4
15.926.58.625.115.7
19.033.110.231.519.6
19.541.910.740.220.2
19.548
10.746.320.6
45° U
V
N
P
S
SAE, ISO and BSP Adjustable End Assembly
1. Inspect both ends (male and port) to make sure that thereare no damages, scratches foreign particles, burrs or nicks.
2. Install O-Ring on the male, if it is not pre-installed. Make surethat the O-Ring is not damaged in the process.
3. Lubricate the O-Ring with suitable lubricant: it could be thesame system oil or it must be compatible with the O-Ringelastomer and with the system fluid.
4. Back off the lock nut as far as possible and push as far aspossible the back-up washer as well (fig. 1).
5. Screw the fitting into the port until the back-up washer con-tacts the face of the port (fig. 2).
6. To align the tube end of the Adaptor with the hose assembly,unscrew by the required amount. Do not unscrew morethan one full turn (fig. 3).
7. Tighten the locknut to the appropriate torque value (fromthe appropriate tables) with a torque wrench while holdingthe fitting in the right position with a second wrench (fig. 4).
8. Inspect the connection to make sure that the back-up wash-er is in the correct position and is flat on the port thus ensur-ing that the O-Ring is properly seated (fig. 5).
90SAE J1926/3 schemes
fig. 1 - Locknut Backed Off
fig. 2 - Fitting installed hand tight
fig. 3 - Fitting backed-off for alignment
fig. 5 - Final assembly of adjustable stud end
Locknut
Back-upwasher
O-Ring
fig. 4 - Fitting locknut tightened to appropri-ate torque
Mining
INTRODUCTION
The Manuli Mining product range includes a comprehensiveprogram of hose inserts, staple-lock adaptors and ball valves.
These products are used in:• hydraulic equipment and long walls installations (for coal
and soft rock mining)• undreground and open pit mines (soft-rock and hard-rock
mines)• high pressure and heavy duty hydraulic lines, medium pres-
sure line, return lines.
Mining processes1. SOFT ROCK Mining
a. LONG WALL Miningb. ROOM and PILLAR Mining
a. LONG WALL MiningThis method operates through a series of hydraulical roofsupports used to prop up the ceiling of a mine (see fig.1).A shearing machine is used to cut the coal/rock under-ground.
b. ROOM and PILLAR MiningIs a method whereby pillars of coal/rock are used to supportthe roof of the mine. Compared to the Long wall process, thismethod is used on a lower volume production. Normally,continous mining machines are required.
2. HARD ROCK MiningKnown for applying drilling machines, explosives, and theroof bolters (to pin and make safe the roof of a mine - seefig.3) and the crushers (to break up lumps of minerals intomanageable pieces).
3. OPEN PIT MiningIt is characterized by drilling operations of rocks with explo-sives and removal of materials using large excavators, dumptrucks (see fig.5).
HosesThe hose features normally required, for an application in suchenvironment, are:• High abrasion resistance (from coal dust and machine
movement)• High ozone resistance • High ageing resistance (to temperatures)• Anti-staticity, to prevent electrical static created by moving
machine parts and frictions by coal dust• Flame retardant characteristic• Low toxicity of smokes in case of fire
92
fig. 2 - Room and Pillar Mining
Minerals Pillar
Black areas are blocks of mineralsColored areas are mined where minerals hase been removed
Entry Ways or “Rooms”
fig. 1 - Long wall mining
fig. 3 - Roof bolter
fig. 4 - Crusher
fig. 5 - Open pit Mining
MINING PRODUCT RANGE
The Manuli hoses specifically suggested for Mining applica-tions (as detailed under “Processes” refer to previous page) are:
• ROCKMASTER® family • SHIELDMASTER®MINE family• ETERNITY/2™ • DIAMONDSPIR™
ROCKMASTER® specifically (approval for SHIELDMASTER®MINEis on progress) has been approved by mining safety Institutesall over the world, such as:• MSHA (USA), • FRAS (Australia),• Polish Safety B (Poland), • MA (China), • DGMS (India).
The technical key-features of the two main hose families, areshown in the table here below:
ETERNITY/2™High-Performance wire braided hose.Compact structure, also provided with Rockmaster® miningcover compound, for applications with high fatigue profiles inrestricted spaces on modern mining equipment.
DIAMONDSPIR™High-Performance wire spiral hose, provided with Rockmaster®
mining cover compound for heavy duty applications.
Manuli Mining hoses meet and exceed the requirements of maininternational specifications for mining (high temperature resistance,abrasion resistance, low electrical resistance, low toxicity), by:• BC174 (UK Coal), ISO 6805, MDG41 (Australia).
93
Manuli mining hoses
fig. 6 - Shieldmaster®Mine
fig. 7 - Diamondspir™
ABRASION ResistanceWeight loss lower than 0,05 g with25 N weight and 2000 cycles(method ISO 6945)
OZONE Resistance
ELECTRICAL ANTISTATICY property
FATIGUE Resistance
More than 300 hours of dynamicozone test ISO 10960 method
Resistance lower than 1MOhm
Excellent: more than 1 Million impulsetest cycles for wire spiral structures.Heavy duty hoses tested with flexingimpulse tests
Weight loss negligible with 2000 cycles(method ISO 6945). Resistance up to 2 million abrasion cycles (1000times better than specifications requirements)
Higher performance is due to the exter-nal plastic material applied
Resistance lower than 1MOhm
Excellent: more than 1 Million impulse testcycles for wire spiral structures. Heavy duty hoses tested with flexingimpulse tests
FEATURES ROCKMASTER® SHIELDMASTER®MINE
HOSE FAMILIES
STAPLE-LOCK systemThe staple-lock is a fitting designed to be easily connected anddisconnected without need of spanners. Sealing is assured byo’ring and back-up ring.
The staple-pin locates in the grove on the male to secure theconnection.It’s also removed by levering with a screwdriver to disconnectconnection.
The staple-lock system is in compliance with SAE J1467 andDIN 20043.
FittingsHigh performance long wall mining fittings range consists ofthe following families:• STAPLE-LOCK• SUPER STAPLE-LOCK• FLUSH-FIT Manuli fittings for mining are specifically indicated for soft-rockmining.
All of them are defined in the:• two pieces (MF2000) range: (Multifit, Interlock, Xtralock)• one piece (MF3000) range: (OPB, OPNS, OPS).
All the fittings have these common characteristics:
• “Drab olive” zinc plating treatment:- it ensures corrosion resistance higher than 450 hours beforered corrosion (tested according to ASTM B117 (ISO 9227)method – higher than international specifications require-ments, e.g. SAE J516 with 72 hours before red corrosion.
• High mechanical robustness and fatigue resistance:- safety factor burst/working pressure is higher than 4:1.
• Highly robust staples have a smaller connection “footprint”and “high” fatigue resistance:- the staple design permits quick and easy connection inconstrained environments.
• Excellent hydraulic sealing, leak free solutions.
94
Manuli mining fittings
AdaptorsManuli adaptors for mining are specifically designed for thesoft-rock mining process.
STAPLE-LOCK adaptorsThe staple-lock design permits an easy connection in confinedspaces. These are important to both maintain and to supportunderground equipment (see fig. 1).
Available with male and female staple ends as well as thread-ed options.
These types of adaptors need to have a high corrosive protec-tion surface finish to meet the requirements of a difficult envi-ronment. For this reason, staple adaptor in stainless steel arealso available.
The standard staple-lock adaptors meet and exceed all interna-tional standards, including DIN 20043, SAE J1467 and NCB 638.
Super STAPLE-LOCK adaptorsThe Super Staple-lock has been developed to satisfy high flow,high pressure system demands, necessary to achieve fastermore cost effective mining production (see fig. 2). Use forlarge bore, high pressure, wire- spiral Rockmaster® andShieldmaster®, along with Diamondspir™ DN63 (2 ½”) at 350bar (5000 psi), Super Staple-lock.
SPECIAL adaptorsSpecial adaptors are available to accommodate suddenchanges in direction and piping configuration, multi-pipingtake off ports for pressure supply and return lines (see fig. 3).
FLUSH-FIT adaptorsIncreased performance concept of which locks the male andfemale inserts together with a staple-pin. In this case, the instal-lation of hydraulic hoses side by side or coiled, do not run therisk of damage during movement as a result of machineryoperation. This means that the staple-Lock pin is hidden insidethe body of the adaptor but can still be quickly removed dueto the creation of a gap to initiate staple extraction (see fig. 4).
Their main features are: • Increased strength and performance, compared to standard
staple• “Snag free profile” provided by flush-fit design• Smaller connection “footprint’”
95
fig. 1 - Staple-lock adaptor
fig. 2 - Super staple-lock adaptor
fig. 3 - Special mining adaptors
fig. 4 - Flush-fit adaptors
96
Mining BALL VALVESManuli ball valves are specifically designed for the soft-rockmining process.Designed to meet a variety of mining needs: from isolatingsections of pipelines, to flow control.
The design concept of valves is always the same, meantimethe material can change to suit the pressure, environment ormedium to be controlled.
The products are available in:• Staple-lock and Super Staple-lock versions (from DN6 (1/4”)
to DN63 (2 ½”))• swivel female available also (together with fixed ones)• 2-ways; 3-ways and 4-ways designs utilizing staple or thread-
ed connections• provided with different handle styles (the lockable handle to
be used with a padlock).
Particularly important in the mining field, has become theMDG41 (MECHANICAL DESIGN GUIDELINE), published by theNSW (New South Wales) Department of Primary Industry(from Australia) and recognized in other states as well. It refers to the fluid power systems at all mines which operateabove 5 Mpa (720 psi) or 60 degrees Celsius.The objective of the guide is to minimize risks and exposure tohazards by people wherever fluid power systems are in use (sim-ply, to reduce the amount of fluid injection and burn injuries).This guide should be used in conjunction with OH&SRegulation 2001.It affects mine operators and contractors.
The hose assembly, to be compliant with MDG41:
1. must be fit for purpose (meets the required working pres-sure)
2. must be FRAS, if being used in an underground coal minecomponents must not be mixed (the hose coupling andhose
3. must be made by the same manufacturer4. must be made to the manufacturers exact specifications5. it must be pressure tested (twice RMWP)6. a permanent label must be fitted showing:
- date of manufacture- who made it- serial or traceability number- assembly length (normally the overall length)- end fitting type (DN10 staple male for example)
7. the supplier should keep records of all hose assemblies
Manuli ball valves
MDG41 COMPLIANCE
97
8. pressure test certificate (on request)9. burst suppression sleeve where applicable10. sleeve securing options, such as glue lined heat shrink.
First digit The numbers, stated in this position, refer respectively to the following descriptions:
1 = Multifit Male Type 2 = Multifit Female Type 3 = Interlock Crimped 5 = Xtralock Male Type
Second and third digit description 46 Super Staple-lock Connection 48 Staple-lock Connection 59 Flush-fit Connection
Fourth digit 1 = Straight
Fifth digit 0 = Male/Flush-fit Female
Ferrules Male/Flush-fit
digit “0” M Ferrule MF2000
digit “1” 0 Always
digit “2”-“3” 01 Ferrule M00100 MF2000-ferrule R1 reusable 08 Ferrule M00800 MF2000 09 Ferrule M00900 MF2000 13 Ferrule Interlock 4-6 spirals 14 Ferrule Interlock 4 spirals 18 Ferrule Xtralock 6 spirali34 Ferrule 3400 MF2000
digit “4” 0 Ferrule release 00 1 Ferrule release 01 2 Ferrule release 02
digit “5” 0 Always
0 1 6 7-2 3 4 5
0 1 6 7-2 3 4 5
Size
0 1 6 7-2 3 4 5
0 1 6 7-2 3 4 5
40 1 6 7-2 3 5
0 1 6 7-2 3 4 5
MANULI PART NUMBERING SYSTEM
First digit The numbers stated in this position, refer respectively to the fol-lowing descriptions:
1 = Multifit Male Type 2 = Multifit Female Type
Second and third digit description 46 Super Staple-lock Male 48 Staple-lock Connection 59 Flush-fit Female
Fourth digit 1 = Straight
Fifth digit 0 = Male/Flush-fit Female
digit “0” A Adaptors
digit “1” The numbers stated in this position refer to the ends number.
4 One End 7 Three Ends5 Two Ends 9 Four Ends
98
0 1 2 5 6 7 8- - 9 103 4
0 1 2 5 6 7 8- - 9 103 4
MANULI PART NUMBERING SYSTEM
MINING ADAPTORS PART NUMBERING SYSTEM
First digit The numbers stated in this position, refer respectively to the fol-lowing descriptions:
1 = Multifit Male Type 2 = Multifit Female Type
Second and third digit description 46 Super Staple-lock Male 48 Staple-lock Connection 59 Flush-fit Female
Fourth digit 1 = Straight
Fifth digit 0 = Male/Flush-fit Female
MANULI PART NUMBERING SYSTEM
digit “2” The numbers stated in this position refer to the gender andgeometry of the ends.
One End/Accessories 0 Male plug 1 Female plug
99
0 5 6 7 8- - 9 1021 3 4
TWO ENDS
1st end 2nd end geometry
0 male male straight1 female female straight2 male female straight3 male male 45° elbow
4 female female 45° elbow
5 male female 45° elbow
6 male male 90° elbow
7 female female 90° elbow
8 male female 90° elbow
THREE ENDS
1st end 2nd end 3rd end
0 male male male1 male male female2 male female male3 female female female 4 female female male5 female male female6 male 1 male 2 male 17 female 1 female 2 female 18 male 1 male 1 male 29 female 1 female 1 female 2
1st end 2nd end 3rd end
Y female female female
1 2
3
1 2
3
FOUR ENDS
1st end 2nd end 3rd end 4th end 0 male male male male1 male 1 male 1 male 1 male 22 male 1 male 2 male 1 male 23 male male male female4 male female male female5 male female female female6 female female female female7 female 1 female 1 female 1 female 28 female 1 female 2 female 1 female 29 male male female female
1 2
4
3
Digit “3”-“4” The numbers stated in these positions indicate the first endtype (see table “Termination Ends Type and Priority”).When male and female ends are present, the male is alwaysthe first end. When all the ends are male or female, one endtakes priority respect to the other one following the tables“Termination Ends Type and Priority”.
Digit “5”-“6” The numbers stated in these positions indicate the second end.
Digit “7”-“8” and “9”-“10” When the ends are part of the same family, the first size is the small-est. The size sequence is the same of the ends sequence (the first sizeindicates the first end, the second size indicates the second end).
Special adaptors (3-ways and 4-ways)When two ends are part of the same family, the family is indi-cated only one time. When three or four ends are part of thesame family, the family is repeated twice.When all the ends are part of different families, all the familiesand all the relative sizes are indicated.
Special suffix The special suffix allows the identification of special featuresnot included in the standard coding.The special suffix must be placed at the end of the code.
Termination Ends Type and Priority 03 BSP Banjo (Female) / BSP Male Parallel Thread O’R Flat Face
(ISO 1179-3) 04 BSP Fixed Female GAS DIN 3852-2 “form X” - ISO 1179-1 05 BSP Parallel Thread (60° cone BS5200) 06 BSP Male Parallel Thread Flat face 28 NPTF Male SAE J476a 30 Male O-ring Boss (Non-Adjustable Light) SAE J1926-3 31 Male O-ring Boss (Adjustable Light) SAE J1926-3 44 BSP Male Parallel Thread Flat face for bonded washer 46 Super Staple Male / Super Staple Fixed Female 48 Staple Male / Staple Fixed Female 59 Flushfit Female / Flush-fit Fixed Female 64 BSP Male Front Seal 72 Female Swivel Super Staple-lock Connection82 Female Swivel Staple-lock Connection
100
0 5 6 7 8- - 9 101 3 42
0 3 4 7 8- - 9 101 5 62
0 3 4 - -1 2 7 8 9 105 6
X L
L
EXTRA LONG BODY
LONG BODY
101digit “0” J Accessories
digit “1” L Staplesdigit “2”-“3” These digits identify the Termination End of the family to whomstaples are referred.See “Termination Ends Type and Priority”.
digit “4” This digit specifies the material used.
0 Standard 1 Stainless
digit “5” This digit specifies the surface.
0 Standard 1 Zinc Plated 2 Spring Steel Black Phospate
digit “6” The number stated in this position indicate the section’s shape.
S Standard T Flat topF Flat D Form “D”
digit “7” The number stated in this position indicate the length.
S Standard L Long
digit “8”-“9” The number stated in this position indicate the nominal boredash size.
digit “0”-“1” AV means always Valves
digit “2”-“3”-“4” These digits identify the series. I.e.: M (Mining) S (Staple-lock) 1 (Design 1)
0 1 8 9-2 3 4 5 6 7
10 8 9-2 3 4 5 6 7
0 8 9-2 3 4 5 6 71
1 40 8 9-2 3 5 6 7
41 50 8 9-2 3 6 7
541 60 8 9-2 3 7
6541 70 8 9-2 3
65410 8 9-2 3 7
8 9-2 3 5 6 70 1 4 10 11-
8 9-5 6 70 1 4 10 11-2 3
MINING STAPLES PART NUMBERING SYSTEM
MINING BALL VALVES PART NUMBERING SYSTEM
digit “5” Gender M Male - MaleF Female - FemaleB Male - Female
digit “6” This digit identify the handle type.
1 Single HandleL Single Long HandleX Single Extra Long HandleP Single Pad Lock Handle 2 Double Handle 3 Hexagon Handle 5 Safety Handle 6 Safety Pad Lock Handle
digit “7” This digit identify the handle color.
N Natural R Red W White G Green B BlueO Orange
digit “8”-“9” and “10”-“11”
The numbers stated in these positions indicate the ends’ size.When male and female ends are present, the male is alwaysthe first end.When all the ends are male or female, one end takes priorityrespect to the other one following the tables “Priority of theEnds”.When ends are part of the same family, the first size is thesmallest.When ends have the same size, the second size is omitted.
102
MS Mining Valves Series Staple Lock 1 MS1 Cubic Shaped; Female-Compact FemaleMS Mining Valves Series Staple Lock 2 MS2 Hexagonal Shaped; Female-Compact FemaleMS Mining Valves Series Staple Lock 3 MS3 Cylindrical Shaped; FemaleMS Mining Valves Series Staple Lock 4 MS4 Cubic Shaped; Male-Compact FemaleMS Mining Valves Series Staple Lock 5 MS5 Hexagonal Shaped; Male-Compact FemaleMS Mining Valves Series Staple Lock 6 MS6 Cylindrical Shaped; Male-Female
MH Mining Valves Series Super Staple Lock 1 MH1 Cubic Shaped; FemaleMH Mining Valves Series Super Staple Lock 2 MH2 Cylindrical Shaped; FemaleMH Mining Valves Series Super Staple Lock 3 MH3 Cubic Shaped; Male-FemaleMH Mining Valves Series Super Staple Lock 4 MH4 Cylindrical Shaped; Male-Female
8 9-5 6 70 1 4 10 11-2 3
5 8 9-6 70 1 4 10 11-2 3
65 8 9-70 1 4 10 11-2 3
65 8 9-0 1 4 10 11-2 3 7
Quick Couplings
INTRODUCTION
A quick-coupling is a mechanical device, made up of both amale and female part, used when frequently connecting anddisconnecting two or more lines of a hydraulic or pneumaticsystem. This device also guarantees the sealing in both con-nected and disconnected conditions.The Manuli quick-couplings range - range - has beenspecifically developed and engineered for hydraulic systems.
The common hydraulic applications for Q.Safe are: tools foragriculture and construction equipment, braking systems ofagriculture trailers, diagnosis devices of hydraulic circuits, sys-tems for industrial applications (steel mills industry and plas-tic/rubber machinery industry).
If two or more parts of ahydraulic circuit have to be con-nected or disconnected severaltimes during the operation, theuse of quick-couplings willreduce both set-up time andcost. In addition the loss of oilfrom the circuit is drasticallyreduced.
104
fig. 1 - Example of hydraulic circuit
APPLICATIONS
fig. 2 - Agriculture fig. 3 - Earth movement
fig. 5 – Connections of quick-cou-plings
fig. 4 - Steel mills
A quick-coupling is always made by two different parts con-necting to each-other: the female part (coupler) and the malepart (nipple).Both the coupler and the nipple are equipped with a shut-offvalve that guarantees hydraulic sealing in uncoupled condi-tion, usually through a gasket.When connecting the two parts, both the shut-off valvesmove back allowing the flow. In coupled condition thehydraulic sealing between coupler and nipple is guaranteedby an O-ring placed in a dedicated groove of the couplertogether with a back-up ring to increase the resistance againstO-ring extrusion.
A quick-coupling can be primarily distinguished according tothe type of locking system between coupler and nipple andthe type of shut-off valve.
105
STRUCTURE OF A QUICK-COUPLING
fig. 6 – Quick-release coupling structure
fig. 7 – Examples of Locking systems
Main types of locking systemsQ.Safe range currently comprises of two different types of lock-ing systems:1) Latching ball system The connection between the two parts is provided by a num-ber of balls held by the sleeve of the coupler and the externalgroove of the nipple.
2) Screw-on latching system The connection occurs by screwing a sleeve, machined withfemale thread, to a mating male thread machined on theother part.
106
a. Uncoupled condition
b. Connection: pulling back the sleeve the latching balls canfall in the nipple groove
c. Coupled condition: the latching balls are held in the nip-ple groove by the sleeve which returns in initial position
a. Uncoupled condition
b. Connection: when the two halves start to engage, sealingbetween male and female is guaranteed by an O-ring
c. Coupled condition
The main types of shut-off valveQ.Safe range currently comprises of three different types ofshut-off valve system.1) Poppet valve: the sealing occurs through a prominent valve
placed inside the nipple and the coupler.When the quick-coupling is disconnected the sealing is guar-anteed by a moulded shaped seal.
In order to increase the resistance against seal wash-out incase of high flow, the Q.Safe poppet valve is made by threedifferent parts:• the body of poppet valve• the gland• shaped seal
2) Ball valve: the sealing occurs through a ball valve placedinside the nipple and the coupler.When the quick-coupling is disconnected the sealing is guar-anteed by a metal-to metal sealing.Ball valve was the first type of shut-off system introduced inthe market, but in comparison to the poppet valve it is lessconvenient mainly due to the following reasons:
• higher pressure drop of the quick-coupling• lower burst pressure of the quick-coupling and then lower
working pressure.
3) Flush valve: this type of shut-off system avoids the loss of fluidduring the operation of connection and disconnection.Because of the complicated architecture, the manufacturingcosts of flat face quick-coupling are quite high. However,when dust reduction and environment protection are themain concerns, flush valve solution is the most effective one.The sealing is guaranteed by a moulded shaped seal. Inorder to prevent the seal wash-out in case of high flow andto increase the resistance against wear due to dirt and anddust inclusion, Q.Safe flush valve is made in Polyurethanewith a special shape.
107
fig. 8 – Poppet valve quick-coupling
shaped seal
gland
poppet valve
fig. 11 – Flush-valve (or “Flat-face”) quick-coupling
fig. 9 – Components of a poppet valve
fig. 10 – Ball valve quick-coupling
108
The Q.Safe range consists of the following product families:
Depending on the typical applications, main internationalstandards and engineering specifications, Q.Safe range canbe divided as shown in the following tables.
PRODUCT RANGE
fig. 1 – MQS-A series: ISO-AMQS-N series: Standard
fig. 2 – MQS-B series: ISO-B
fig. 3 – MQS-AF series: Push-pull fig. 4 – MQS-F series: Flat Face
fig. 5 – MQS-SG, -SC, -ST series: Screw to connect
fig. 6 – MQS-VB, -VS series: Braking Circuit Valve
fig. 7 – MQS-CV series: Check valves
fig. 8 – Accessories & Service Kits
Poppet and ball valves quick-couplings for agriculture andindustrial applications
1) MQS-A, MQS-AP, MQS-AF and MQS-AFP families undertaketo ISO 7241-A standard that defines the main performancesand the geometry of connection area of nipple and coupler.ISO 7241-A standard was introduced to guarantee theworldwide interchangeability of quick-release couplings.
• MQS-A (ISO A ) nipple and coupler connection occurspulling back the coupler sleeve and pushing the nipple intothe coupler. The disconnection occurs pulling back the cou-pler sleeve and pulling out the nipple.
• MQS-AF refers to push-pull coupler, widely used in low andmedium tractors.When bulkhead mounted on the outside sleeve, the connec-tion occurs just pushing the MQS-A nipple into the push-pullcoupler. The disconnection occurs just by pulling out the nipple.
An important feature of a push-pull coupler is the breakwayfunction that allows the automatic disconnection to preventdamage of the quick-release coupling or the hose in case ofaccident (i.e. a towed implement becomes unhitched). Thisfeature is ruled by ISO 5675 standard.
• MQS-AP and MQS-AFP are recommended in case of con-nection under pressure (i.e. residual pressure due to thermalexpansion).The connection is allowed through to a micro-valve placedon the top of poppet valve capable to spill oil from the cir-cuit and then reducing the pressure.
109
MQS-A
MQS-AP
MQS-AF
MQS-AFP
MQS-N
MQS-B
ISO A
ISO Aunder pressure
PUSH-PULL
PUSH-PULLunder pressure
STANDARD
ISO B
Q010
Q013
Q015 –
Q032
Q033
Q024
Q006
–
Poppet
Poppet
Poppet
Ball
Poppet
Q008
Q009
Q002
Q003
Q029
Q030
Q021
Poppet
Ball Pull backthe sleeve
Push-pull
Pull backthe sleeve
Pull backthe sleeve
Latchingballs
Latchingballs
Latchingballs
Latchingballs
ISO 7241-A
ISO 7241-A
–
ISO 7241-B
Series Description Female ref Male refShut-off
valveConnection
DisconnectionLockingsystem
Specifications
fig. 9 – Example of Push-Pull coupler
fig. 10 – Example of breakaway functionwhen Push-Pull is wall-mounted
fig. 11 – Micro valve of MQS-AFP
2) MQS-N quick-coupling refers to the oldest series introducedin the market, still very common in agriculture applications.The ½” inch size of this series is completely interchangeablewith ½” inch size of MQS-A series. Therefore Q.Safe rangedoes not include MQS-N ½” size.
3) MQS-B quick-couplings are very similar to MQS-A series, butundertaking to ISO 7241-B standard that defines the mainperformances and the geometry of connection area of nip-ple and coupler.MQS-B is the reference series for industrial applications.Beside carbon steel version, brass and stainless steel versionsare very common as well.
Screw-on quick-couplings for heavy duty applications
In case of severe working conditions with pressure impulses,latching balls system can suffer in terms of reliability and dura-bility because of BRINELLING.In these working conditions screw-on quick-couplings are themost effective solution due to the large surface contactbetween male and female part. Therefore the mechanicalstress can be reduced.In addition screw-on quick-coupling allow the connectionunder pressure.There is no international standard referring to the performanc-es and the interchangeability of any screw-on quick-couplingtype.
1) MQS-SG series was originally introduced into the German mar-ket, but now is used worldwide. This has helped to resolvesome issues related to pressure impulses and vibrations onheavy duty applications.
110
MQS-SG
MQS-SC
MQS-ST
SCREW forGerman market
SCREW forhydraulic cylinders
SCREW for trucks
Q056
Q058
Q055
Q057
Ball
Poppet
Q052 Q051 Poppet
Screw-onScrew-onlatchingsystem
–
–
–
Series Description Female ref Male refShut-off
valveConnection
DisconnectionLockingsystem
Specifications
fig. 12 – MQS- SG series (Screwfor German Market)
fig. 13 - Application on hydraulichammer
2) MQS-SC quick-coupling is specifically designed for very highpressure applications in steady conditions like hydrauliccylinders
3) MQS-ST series is commonly used in truck trailer applications.Usually the sleeve of coupler is wing-shaped which enableseasier connection to the male and female.
Flat-face quick-couplings
MQS-F was originally designed for construction equipment appli-cations in the North American market. Later ISO 16028 standardswas introduced to define the main performances and the geom-etry of connection area of the nipple and the coupler.Main features of flat-face couplings are:• no fluid loss during disconnection• reduced air inclusion during connection• easy cleaining of mating surfaces
111
fig. 14 – MQS- SC series (Screw forHydraulic Cylinders)
fig. 15 - Application on hydrauliccylinders
fig. 16 - MQS – ST series (Screw forTrucks)
fig. 17 – Application on trucks
fig. 18 – MQS – F series (Flat-face) fig. 19 – Flat-face application onearth moving machines
MQS-F FLAT FACE Q041 Q039 FlatPush the male
Pull back the sleeveLatching
ballsISO 16028
HTMA (3/8” only)
Series Description Female ref Male refShut-off
valveConnection
DisconnectionLockingsystem
Specifications
112
An optimized internal design of MQS-F quick-release couplingguarantees to reduce the flow distorsion, therefore minimaz-ing the pressure drops.
Braking circuit valves
1) MQS-VB series undertakes to ISO 5676 and it’s specificallydesigned to connect the braking circuit of the trailer to thehydraulic system of the tractor.
2) MQS-VS valve has the same function of MQS-VB but withscrew-on locking system.
MQS-VB
MQS-VS
BRAKING CIRCUIT VALVE
AGRICULTURE VALVE
Q048
Q050
Q047
Q049
Flat
Flat
Pull back the sleeve
Screw-on
Latchingballs
Screw-onlatchingsystem
ISO 5676
–
Series Description Female ref Male refShut-off
valveConnection
DisconnectionLockingsystem
Specifications
fig. 20 – Braking circuit valve
fig. 22 – Tractor and trailer
fig. 21 – Agriculture valve
Q.Safe Part Numbering System
DIGIT “0”Q Quick-release coupling
DIGIT “1”0 Hydraulic
DIGIT “2” – “3”Quick-release coupling
1136 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
02
03
06
08
09
10
13
15
29
30
32
33
39
41
47
48
49
50
51
52
55
56
57
58
Male according to ISO 7241-1 standards, series A - Poppet valve
Male according to ISO 7241-1 standards, series A - Ball valve
Male according to ISO 7241-1 standards, series A - Connectable under pressure
Female according to ISO 7241-1 standards, series A - One-way release, poppet valve
Female according to ISO 7241-1 standards, series A - One-way release, ball valve
Female according to ISO 7241-1 standards, series A - One-way release, connectable under pressure
Female according to ISO 7241-1 standards, series A - Two-ways release, poppet valve
Female according to ISO 7241-1 standards, series A - Two-ways release, connectable under pressure
Male interchangeable with series 4000 - Poppet valve
Male interchangeable with series 4000 - Ball valve
Female interchangeable with series 4000 - One-way release, poppet valve
Female interchangeable with series 4000 - One-way release, ball valve
Flat-Face male according to ISO 16028
Flat face female according to ISO 16028 - With safety sleeve
Male for hydraulic braking circuit according to ISO 5676
Female for hydraulic braking circuit according to ISO 5676
Screw-type male for hydraulic braking circuit
Screw-type female for hydraulic braking circuit
Screw-type male for German market
Screw-type female for German market
Screw-type male for hydraulic cylinder
Screw-type female for hydraulic cylinder
Screw-type male for truck
Screw-type female for truck
Series Description
DIGIT “4”
It indicates the material 1 steel2 AISI 3163 AISI 3034 Brass5 Aluminum
DIGIT “5”
It indicates the sealing material 0 no seal1 NBR2 HNBR3 FKM (viton, FPM)4 CR (neoprene)5 EPDM6 FFPM (Kalrez)7 PTFE8 VMQ (silicone rubber)9 AU (polyurethane)
DIGIT “6” – “7”
It indicates the termination end type
114 6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
04
05
11
12
14
19
23
28
30
34
37
77
82
87
BSP male bulkhead / Fixed female BSP DIN 3852-2 “form X” - ISO 1179-1
BSP parallel thread (60° cone BS5200)
Male metric thread (24° cone light type DIN 3861)
Male metric thread (24° cone heavy type DIN 3861)
Metric male DIN 3852-11 “form E” / Metric fixed female DIN 3852-1 “form X” and “form Y”
Metric male (adjustable + non-adjustable heavy) ISO 6149-2 / Metric fixed female ISO 6149-1
JIC thread (37° cone) bulkhead
NPTF male SAE J476A / NPSM swivel female
Male O-Ring boss (non-adjustable light) SAE J1926-3 / Female port SAE J1926-1
NPTF fixed female SAE J476A
Flange (A/C and refri application) / Metric male 60° cone superlight DIN 3863 bulkhead
Male bulkhead DIN (24° cone light type)
Male bulkhead BSP
Male bulkhead DIN (24° cone heavy type)
Series Description
DIGIT “8”
It indicates the thread gender 0 male1 female
DIGIT “9”
It indicates a customized version
DIGIT “10” – “11”
It indicates the quick coupling size
DIGIT “12” – “13”
It indicates the thread size
1156 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
6 7 -4 5 8 9 10 11 - 12 131 2 30
Refrigeration
REFRIGERATION APPLICATIONS
Refrigeration line in Manuli concerns with Air Conditioningand Mobile refrigeration.
A/C Air conditioning + Mobile refrigeration
Manuli REFRIGERATION product range.
They are both systems that exchange heat with the environ-ment cooling or freezing the environment itself..
Manuli Refrigeration marketManuli Refrigeration market consists of:
Air Conditioning (A/C) and Refrigeration system cycleThe basic rrefrigeration cycle makes use of the boiling and con-densing of a working fluid, the refrigerant, to mmove heat fromone place to another. Fig. 1 provides a schematic diagram of the components of atypical one-stage vapor-compression refrigeration system.Starting at the compressor (which is basically a pump that rais-es the pressure, so it will move the refrigerant through the sys-tem), the refrigerant is compressed and sent out of the com-pressor as a high temperature, high pressure, superheated gas(it is said to be on the ‘high side’ of the system). The refriger-ant travels to the condenser, that changes the refrigerant froma high temperature gas to a warm temperature liquid: as itcondenses, it gives up heat to the outside air. As the refriger-ant leaves the condenser, it is cooler, but still under pressureprovided by the compressor. It then reaches the expansionvalve (Thermal Expansion Valve, TXV, or throttling valve). Theexpansion valve meters the proper amount of refrigerant intothe evaporator and allows the high-pressure refrigerant toflash through becoming a lower pressure, cooled mix of liquidand gas (saturated gas). This saturated gas enters the evapo-
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A/C big buses A/C small & medium buses
Trucks mobile refrigeration A/C Off-high way
|\/
rator where it is changed to a cool dry gas: as it evaporates, itabsorbs heat from the warm, moist “room air” blown acrossthe evaporator, changing its state from liquid to vapor. Thecool dry gas, then, re-enters the compressor to be pressurizedagain and to re-start the cycle.So, in summary, during the refrigeration cycle, refrigerant cir-culates through the system changing temperature, pressureand physical state (liquid & vapor). This allows heat to beabsorbed from air entering the passenger compartment andcarried to the condenser where it is released. The compressorprovides the pumping action necessary to move the refriger-ant and together with the expansion valve create the pressurechanges. Flexible hoses are integral part of the system: theirduty is to transfer thermal power conveying the refrigerantfrom one side to the other side of the system.In fig. 1 are also indicated the average working conditionswith the two most common used refrigerants for air-condition-ing and transport refrigeration applications, respectively R134aand R404A. The main difference between the two applicationsis the temperature of the cabin to refrigerate, that has to besensibly lower in transport refrigeration: different temperaturescan be obviously obtained by means of different refrigerants,due to their different thermodynamic properties.Anyhow, the real observed working conditions depend on a lotof factors, among which above all the refrigerant type and thesystem dimensioning type. For the example refrigerants maxi-mum extreme peak values of discharge temperature and pres-sure (superheated gas) are in the range of 140°C and 35bar.
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fig. 1 - Main components and processes - General indication [Referential Refrigerants: R134a (A/C);R404A (Refrigeration)].
The temperature in the cabin to refrigerate is lower in transportrefrigeration application than in air conditioning application.
Different temperature can be obtained with different refriger-ants (see fig. 2). Transport refrigeration is higher demandingsystem than air conditioning.
For refrigeration application are recommended hoses withthermoplastic inner layer, like type D and type E (see hosesclassification in the next paragraph).
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The components of the system are connected by HOSES andFITTINGS assembled.
To clarify further:
fig. 2 - Difference between A/C and Refrigeration system
HOSES AND FITTINGS
fig. 3 - Main structure of refrigeration hose
fig. 4 - Detailed structure of refrigeration hose
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HosesDifferent possible types of hoses, according to specification:
• SAE J2064 types A Elastomeric, textile reinforced• SAE J2064 types B Elastomeric, wire reinforced• SAE J2064 types C Barrier, textile reinforced• SAE J2064 types D Thermoplastic, textile reinforced, elastomeric cover• SAE J2064 types E Veneer, textile reinforced• SAE J2064 types F Veneer, Barrier, Thermoplastic Liner
The following details explain the hose structure.
SAE J2064 types A Elastomeric, textile reinforcedThe hose is made using a suitable seamless synthetic elas-tomeric tube. The reinforcement does consist of textile yarn,cord, or fabric adhered to the tube and cover. The outer coverhas a heat and ozone resistant synthetic elastomer.
SAE J2064 types B Elastomeric, wire reinforcedThe hose is built with a suitable seamless synthetic elastomer-ic tube. The reinforcement consists of steel wire adhered tothe elastomeric tube. The cover consists of a heat-resistanttextile yarn impregnated with a synthetic elastomeric cement.
SAE J2064 types C Barrier, textile reinforced The hose has a suitable thermoplastic barrier between elastomericlayers. The reinforcement consists of suitable textile yarn, cord, orfabric adhered to the tube and cover. The outer cover has a heatand ozone resistant synthetic elastomer.
SAE J2064 types D Thermoplastic, textile reinforced, elas-tomeric coverThe hose has a suitable thermoplastic tube. The reinforcementconsists of suitable textile yarn, cord, or fabric adhered to thetube and cover. The outer cover has a heat and ozone resist-ant synthetic elastomer.
SAE J2064 types E Veneer, textile reinforcedThe hose has a suitable thermoplastic veneer lining the insidediameter with an elastomeric tube outer layer. The reinforce-ment consists of suitable textile yarn, cord, or fabric adhered tothe tube and cover. The outer cover has a heat and ozoneresistant synthetic elastomer.
SAE J2064 types F Veneer, Barrier, Thermoplastic LinerThe hose has a suitable thermoplastic veneer liner with a ther-moplastic barrier between elastomeric layer. The reinforcementconsists of suitable textile yarn, cord, or fabric adhered to thetube and cover. The cover has a heat and ozone resistant syn-thetic elastomer.
FittingsShown here below, the most common termination ends usedin Refrigeration.
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fig. 3 - 24° DIN flare O-ring ogivalfemale
fig. 4 - O-ring female - Rotalock(size 11)
fig. 5 - Short drop O-ring female fig. 6 - ORFS (flat seat) female
fig. 7 - Flange fig. 8 - SAE male 45° cone fig. 9 - O-ring male seat
fig. 11 - Termination end forexpansion valve
fig. 10 - O-ring male
fig. 1 - 45° SAE female fig. 2 - O-ring female
The liquid circulating in the system is an emulsion of refriger-ant and lubricant:• the refrigerant is related to thermodynamic process;• the lubricant is to lubricate the mechanical components of
the system.The international market is now ready for new environmental-ly friendly solutions.The most common current refrigerants and lubricants areshown the in the following tables.
REFRIGERANTS AND LUBRICANTS
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PAG = POLYALKYLENE GLYCOLPOE = POLYOL ESTER
Specifications may be sudivided into International standardsand OEM’s specifications, as follows:The SAE J2064 represents the basic standard requirements forA/C fluids hose assemblies.
Specifications from A/C systems manufactures and OEMsinclude tests and requirements similar to SAE J2064, some-times additional specifications are requested.The customers’ homologation process generally requires fieldtests.
Specification SAE J2064Application: Automotive field and involves tests using R134a +PAG (lubricant) -30° ÷ 125°CTests on assembly hoseSAE J2064 is neither for design, nor for dimensions.It prescribes some tests, describes how to perform them andthe performance results.If the hose assemblies pass the tests it is according to SAEJ2064.
R134a
the most common gas for automotive applications and
off-highway machine.
PAG/POE
A/C fluid Remarks Lubricant
R404A
R407C
fluid for industrial applications, buses and
mobile refrigeration.
fluid for industrial applications, buses and
mobile refrigeration.
PAG/POE
PAG/POE
Refrigerationfluid
Remarks Lubricant
SPECIFICATIONS
Tests according to SAEIn the following table, the main tests listed according to theinternational specification (SAE J 2064).
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1
2
3
4
5
6
7
8
9
10
11
12
Permeation test
Coupling integrity test
Aging test
Cold test
Vacuum flattening
Length change
Bursting strength
Proof test
Extraction test
Ozone test
Cleanliness test
Moisture ingressionclass
indication of the loss of refrigerantthrough the hose wall.
indication of the loss of refrigerantthrough the coupling fitting-hose. It isalso a very good indication of productreliability
indication of the performance of thehose under aging conditions
indication of the performance of thehose under cold conditions.
indication about the reduction of theexternal diameter of the hose in inter-nal vacuum conditions
indication of the % change in length ofthe hose under pressure
indication of the burst pressure
indication of the sealing
indication about particles extractedfrom the hose internal surface byrefrigerant/lubricant mixture
indication of the ozone resistance ofthe cover
indication of the contamination degreeinside the hose
indication of the ingression of moisturethrough the hose wall
Test Meaning
Hose assembly
HOSE ASSEMBLY DATA
How to describe hydraulic hose assemblies?When you have to build or order a hydraulic hose assembly,the following information must be clear:
• Hose description from catalogue (hose type and size)• First and second coupling termination end style and dash
size• Offset angle or orientation of couplings if both couplings
contain elbow ends• Assembly overall length• Quantity of assemblies required.In order to support assemblers and OEMs in this activity,Manuli offers a complete set of tools for assembling drawingon the web (visit: www.manuli-hydraulics.com).
Hose cutting1. To determine the “cut hose length”, from the “overall assem-
bly length” deduct the cut-off length “A” of both end fittings.Consult the fitting catalogue for “A” dimensions;
2. Cut the hose square, using a proper sharp blade disk withfine-tooth;
3. Clean hoses with compressed air
Hose assembly instructionsFollow the procedure and recommendations reported on thecurrent edition of the Manuli assembly instructions document,yearly updated for assembly fabrication.In addition, a dedicated training presentation on assemblyprocess is available on www.manuli-hydraulics.comCaution: follow safety procedures.
Orientation of offset elbows fittingsFitting orientation is necessary when a hose assembly requirestwo elbow couplings at both the extremities: in this case fittingsmust be oriented to each other to ensure proper installationwith minimal stress due to hose twisting.
the selection of hose and proper fittingsshould always be determined consider-ing the working pressure of the applica-tion, including any surge or pressurepeak. The hose will guarantee normalservice life before replacement if correctlyused at a pressure level within its ratedworking pressure.
Caution
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EQUATOR / 2
Cut hose lenght (mm)
Assembly overall lenght (mm)
Assembly drawing - www.manuli-hydraulics.com
FLUID CONNECTORSPRODUCT RANGE
ENGLISH/ESPAÑOL
Assembly instructions
Fitting orientation is measured from the centreline of the firstcoupling held in a vertical position and looking at the assem-bly towards the second end by measuring the angle in acounter clockwise direction (or clockwise depending on thecustomer drawing).
The orientation angle tolerance should be within:± 3 degrees for assembly lengths up to 610mm,± 5 degrees for assembly lengths over 610mm.Backing off to get desired angle should be avoided afterhaving crimped the fittings.Try to avoid the use of double elbow hose assemblies: twistingof the hose during installation may occur. In fact the relativelocation of the natural curvature in the hose may induce atwist during pressure cycling and the twisted hose may reducethe life of the assembly.
Safety recommendationsFor safety reasons and to underline the relevance of the hosefitting compatibility study, carried out by Manuli with severequalification programs, to highlight the need to avoid the “mixand match” of hose and fittings from different manufacturers,it is recommended to read the par. 6 of the SAE J1273 specifi-cation, well describing these subjects.
Hose-fitting compatibility is a very delicate aspect of the assem-bly design, where the proper study and testing of the hose-fit-ting area is the critical part of the whole project: that’s why it isabsolutely necessary to use the original components with therecommended assembly prescriptions.There is also a relevant aspect of industrial liability to consider,in fact it is responsibility of the assembler to check properly thecompatibility of hose and fittings for the assemblies producedand released to the end user.For the proper procedure to carry out assembly operation,please refer to the Manuli Assembly instructions documentupdated yearly.
Refer to SAE J1273 par. 6 for further details on hose assembly fabrication.
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J1273Recommended Practicesfor Hydraulic HoseAssemblies
CLEANING, INSPECTION, TESTING
Additional operations for assemblies preparation
• CleaningAssemblies can be cleaned by blowing out with clean com-pressed air.Assemblies may be rinsed out with dedicated fluids if thetube stock is compatible, otherwise hot water at 55°C to65°C max. See Manuli Rubber Industries catalogue for spe-cial cleaning equipment.
• InspectionExamine hose assembly internally for cut or bulged tube,obstructions, or other abnormalities. Check that the cou-pling is correctly swaged, that the ferrule neck is exactlyinside the fitting latch area, fitting is aligned with the hose. Check for proper gap between nut and socket: nuts shouldswivel freely.Check the branding of the hose to be sure that the assem-bly is not twisted. Cap the ends of the hose with plastic cov-ers to keep clean.
• Proof pressure testThe hose assembly can be requested to be hydrostaticallytested. The procedure for proof pressure testing is clearlyspecified in International Standard ISO 1402. The test is gen-erally carried out at twice the recommended working pres-sure of the hose.Test pressure should be held for at least 30 seconds asrequested (proof pressure test is not a destructive test).When test pressure is reached, visually inspect hose assem-bly for:• eventual leaks or signs of weakness• possible movements or abnormalities of the coupling in
relation to the hose.Any of these defects are cause for rejection.
Warning: testing should be conducted inapproved test stands with adequate guards toprotect the operators (see also the equipmentmanual for proper use of the test bench).
fig. 1 - Cleaning machine
fig. 2 - Proof pressure test
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Proper hose installation is essential for satisfactory performance.If hose length is excessive, the appearance of the installationwill be unsatisfactory, the configuration can create problemsdue to contacts with external bodies.If hose assemblies are too short to allow adequate flexing anddeformation in length due to pressure, hose service life will bereduced.The diagrams supplied in the previous chapter show properhose routing which provide maximum performance andsafety conditions. These are examples suggesting generalguidelines studying new hose installations .
Let’s focus here on the assembly installation tips:Before installing hydraulic hose assemblies, review the safetyprecautions included in this manual as well as the sys-tem/equipment user manual. Installation varies based on cou-pling configurations, use of adaptors and routing.
The following sequence of operations is a general procedurefor the correct installation of hose assemblies, in conformitywith safety and technical requirements.a. clean the surrounding area where connections are to be
made. Make sure no dirt or contamination gets intohydraulic openings;
b. install adaptors into ports (if used);c. lay the hose assembly into operating position to verify
length and correct routing;d. screw one end of hose assembly onto port (or adaptor). If
the hose assembly uses an elbow fitting, always install it firstto ensure proper positioning;
e. screw other end of the assembly without twisting the hose.Use a spanner on the backup hex of the fitting while tight-ening;
f. properly torque both ends at the recommended torquevalues;
g. run the hydraulic system to circulate oil under low pressureand reinspect for leaks and potentially damaging contacts.Circulation also purges air (bleed) from the system that cancause sluggish performance and possible damage topumps and other components.
Tips for coupling installationLet’s consider the three main cases of male fittings, flanges andswivel female connections.
1) Male fitting to port connectionsMale fitting to port connections can be made using threetypes of configurations:• solid male;• swivel male;• block-style adaptors with locknuts.
HOSE ASSEMBLY INSTALLATION TIPS
fig. 1 - Flanges installation tip
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Solid male fittings are installed by rotating the entire hoseassembly as you screw the male into the port, since hose rota-tion is necessary, never use two solid males on the sameassembly. If an O-ring is used, lubricate it with a light oil beforeinstallation: a dry O-ring will stick and pull away from the seal-ing area resulting in a poor seal. Once hand-tightened, use awrench on the hex to properly torque the fitting. PTFE tapecan be used on tapered threads to ease installation and sealbetter.
Swivel males installation does not require hose rotation.Simply screw the male into the port and use a spanner totorque properly. Since the hose does not rotate, you can easilyorientate the hose curvature to assist in routing.Be aware that male swivels have internal O-Rings that must becompatible with the fluid used.
Block-style adaptors generally use locknuts to orientate fitting.Rotate the block and thread fitting into port. When nearlytight, hold block in position needed and tighten locknutagainst port.
2) Flanges (figure 1)Are installed using split flange clamps or one piece clamps.
For proper flange fitting installation:• put a small amount of oil on the O-Ring and place it in the
fitting groove. Oil will prevent the O-Ring from falling out;• place fitting over port;• install clamp over flange head and screw in bolts by hand;• use wrench to tighten using crossing pattern sequence;• tighten to correct torque figure.
3) Female swivel connectionsFemale swivel connections are made by rotating the swivel nutover the solid male threads on the port. Never use a swivelfemale with a swivel male. Once hand tightened and use awrench to hold the backup hex (if present) while tighteningthe swivel nut to proper torque. This will prevent insert rotationand hose twist.Bent tube and block-style fittings must be held in position byhand while tightening.
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HOSE PROTECTION
Many accessories and additional components are sometimesused with hose assemblies in order to protect them from abra-sions, extreme temperatures and irradiation, for safety reasons,for fire protection, etc.Let’s see the most common types of protection the selectioncriteria and the methods used to solve routing and protectionproblems.
Bundling (fig. 1).When installing hose assemblies, various bundling techniquescan improve space utilisation, appearance and hose life. Hereare some tips:• Group and bundle similarly constructed and sized hose
together using clamp blocks, nylon straps or nylon sleevingor plastic spring guards;
• Always consider mechanical movement when bundling.Allow sufficient slack without pulling on a fitting or anotherhose. Bundles (like individual hoses) should bend in oneplane only;
• Avoid to bundle high-pressure hoses with low-pressurehoses: under pressure, they can work against each other;
• Bundling rubber hose with thermoplastic or PTFE hoseshould be avoided.
SleevingThere are numerous sleeving types used today. The most com-mon is nylon (fig. 2), which is typically used for one or moreof the following applications:• to protect hose from abrasion;• for use in bundling;• to protect equipment and operators from injury due to hose
failure (fluid jet dispersion).
Spring guardThere are many type of spring guards: flat armour, plated wire,plastic, etc. They can be used to bundle hoses or provide sta-bility and/or protection against abrasion. Tightly wound platewire guards can also be used as bend restrictors to ease stresson the hose (fig. 3).
Bend restrictorsBend restrictors typically are PVC or steel sleeves which areinstalled near the coupling during hose assembly. They reducebending stress in the hose near the coupling to prevent dam-age (fig. 4).
ClampsClamps are used to fix the assemblies to the system/equipmentand avoid potential contacts with high temperature surfaces,reduce vibration and risk of unintended movements (fig. 5). A wide range of clamp types and quality is available on the
fig. 1 - Bundling
fig. 2 - Sleeving
fig. 3 - Spring guard
fig. 4 - Bend restrictor
fig. 5 - Clamps
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market: with rubber hoses, the use of special clamps withinternal soft rubber rings in contact with the hose cover isadvisable. These clamps considerably reduce the risk of abrasionon the hose cover, even in presence of vibrations, dust, etc.
Manuli Rubber Industries has experience with some of the topquality level of clamps (fig. 6); contact Manuli Rubber Industriesfor detailed recommendations.Some useful tips for the installation of clamps and assembliesare the following:• choose clamp bore close to the hose OD, without crimping it:
- the hose should “breath” under pressure;- the hose should adjust its configuration.
• for safety reasons, position the clamps to reduce the possi-bility of “whiplash” in case of fitting blow-off;
• “soft” rubber insert between clamps structures is alwaysadvisable to reduce vibrations transmission and cover wear(the rubber insert has to be “sacrificial”).
Safety restraint systems (whipcheck and guards/shields)Restraint systems such as whipchecks and protection shieldsare used to fulfil the safety requirements of the hydraulicsystems and equipment, in particular when there is risk of injuryto operators and personnel working near the equipment.Restraint systems are used:
• in hydraulics applications when there are safety aspectsinvolved in a potential failure of the assembly, mainly blow-off of the fitting: we recommend STOPFLEX type;
• always with compressed air and with gas applications ingeneral (e.g. EQUATOR hose with compressed air), due tothe hazard connected with the potential “whiplash” of thehose disconnected from the fitting, we recommendedWHIPCHECK type, double connection rings.
When the equipment-designers identify an hazardous condi-tion where the risk can be contained using restraint systems orshields, different International Specification can be followed asreference.
• For example, refer to - International Standard ISO 3457(earth-moving machinery - guards and shields - definitionsand specifications) – Point 4.9: “Where hoses are used oper-ating to a pressure of at least 50 bar and/or at temperature ofat least 50°C, and are located within 0,5 m of the operator,deflecting shield should be provided to protect the operatorfrom thesudden hose failure. The shield should be sufficiently sturdy to stop or divert fluidsaway from the operator.”
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• ISO 4413 "Hydraulic fluid power - General rules relating tosystems" point 9.5.3 Protection against failure (of hoseassemblies) reports: "If the failure of a hose assembly consti-tutes a whiplash hazard, the hose assembly shall berestrained or shielded. If the failure of a hose assembly con-stitutes a fluid ejection or fire hazard, it shall be shielded." Theneed of restraint systems or shields on the hose assembliesdepends on the evaluation of the impact on safety of eachassembly in the equipment by the equipment designers.
• EN 982 "Safety of machinery - Safety requirements for fluidpower systems and their components - Hydraulics" is the“armonized” safety specification in Europe. Point 5.3.4.3.2Failure (of flexible hose assemblies) states: "If the failure of aflexible hose assembly constitutes a whiplash hazard, it shallbe restrained or shielded. If the failure of a flexible hoseassembly constitutes a fluid ejection hazard, it shall beshielded."
• EN 982 describes also the safety requirements for flexiblehose assemblies in the chapter 5.3.4.3:“Flexible hose assem-blies shall fulfil all performance requirements specified in theappropriate European and/or international standard(s)”. Thismeans that hose assemblies on a machines must meet theSAE, ISO and EN requirements and must have a record forqualifications and production control tests, to be complyingwith the European Machinery Directive 98/37/CE.
• Similar requirement and recommendations are reported bythe SAE J1273 specification, par. 4.2 Whipping hose (safetyconsiderations): "If a pressurised hose assembly blows apart,the fittings can be thrown off at high speed and the loosehose can flail or whip with great force. When this risk exists,consider guards and restraints to protect against injury." Alsoin this case the requirement of the restraint systems for hoseassemblies would be subjected to the system designer riskevaluation.
The restraint system with steel ferrule crimped on thehose are not recommended, due to the risk to involvehose deformation, cover bubbles, etc. since the hosebody must be free to “breath” under pressure. Manulirecommends the use of restraint systems with internalrubber ring in contact with the hose cover or steelcords (e.g. STOPFLEX).
fig. 6 - Clamp with rubber ring
fig. 7 - Whipcheck double eys
fig. 8 - Protective shields
Safety is of maximum importance when designing hydrauliccircuits, especially when considering the high pressure lines.In Europe the reference legislation is the European MachineryDirective 98/37/CE, that requires at the point 1.5.3. “Wheremachinery is powered by an energy other than electricity (e.g.hydraulic, pneumatic or thermal energy, etc.), it must be sodesigned, constructed and equipped as to avoid all potentialhazards associated with these types of energy.”
The European standard EN 982 - “Safety of machinery - safetyrequirements for fluid power systems and their components -hydraulics,” lists possible hazards associated with the use ofhydraulic power in a machine:• mechanical hazards (e.g. coupling blow-off, whipping
hose, hose burst, pinhole in hose);• thermal hazards (e.g. fluid high temperature) can heat
metal parts such as couplings and adaptors, causing severeburns when touched by someone;
• unintended movements caused by electromagnetic fields;• hazards resulting from contact with, or inhalation of, harmful
fluids, gases, mists, fumes and dusts;• fire or explosion hazards;• hazards caused by failure of energy supply, breaking down
of machinery parts and other functional disorders (e.g.falling or ejecting of moving parts or pieces held by themachinery, unexpected start, etc.).
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EUROPEAN LEGISLATION ON SAFETY AND CONCLUSION
Maintenance
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MAINTENANCE
A proper preventive maintenance program for fluid connec-tors used in hydraulic system/equipment is the key successfactor to guarantee a reliable equipment in service and avoidpotential injury to personnel.
That’s why in this section we suggest criteria to implement acorrect preventive maintenance program and to identify prob-lems and defects on fluid connectors in field, proposing thenecessary corrective actions.
The SAE J1273 par. 8 “Maintenance inspection” is suggested asone of the main guideline existing in the sector.
Refer to SAE J1273 par. 8 specification for further details on maintenanceinspection. J1273
Recommended Practicesfor Hydraulic HoseAssemblies
137
Prior to conducting any inspection of your hydraulic system, itis important to know how the equipment sounds, looks andfeels during normal operation. Any noticeable difference in itsdaily operation may indicate a problem. Take time to check itout thoroughly.
Frequency of inspectionBecause this varies by type of equipment, refer to the machineor equipment reference manual for recommendations.
Always follow the manufacturers inspection recom-mendations. If they are not available, a good rule is:
• for mobile equipment: every 400-600 service hours orthree months, whichever occurs first
• for stationary equipment: every 800-1000 service hoursor every three months whichever occurs first.
In addition, the following factors influence how often youneed to inspect your hoses:• critical nature of the equipment;• operating temperatures;• operating and safety procedures;• environmental factors;• type of usage (rugged, high vibrations, infrequent or long
lasting operating time, etc).
Of course the direct experience with each specific equip-ment/machine is often the best guide to understand when toconduct inspections. The past history of each machine typeand model is a source of information to fix the inspection fre-quency.
If we consider a rugged and high pressure hose applicationoperating 24 hours a day, seven days a week, it will requiremore frequent inspections than a hose used in a mild environ-ment at ambient temperature that is only pressurised a fewtimes a day.
Specific functional problems, such as high heat sources, con-stant high temperature of the fluid being conveyed, localisedabrasions and/or severe hose configurations, for example withvery reduced bend radius near the couplings, etc. may needmore frequent inspections to avoid or detect potentially dam-aging situations.
Inspection methodologyThe use of a proper preventive maintenance checklist can helpto carry out inspections, aimed at maintainingmachines/equipment efficient and in conditions of maximum
PERIODIC INSPECTIONS
safety.Follow as a general guideline the next 3 steps:
Step 1Place the equipment/machine and components in a safe andneutral position, being sure that the components are notunder stress, holding a load or in mid-cycle position (this couldcause the equipment to be unstable or to move).Before starting the maintenance operations on the equipmentdrop eventual loads, retract cylinders, etc.Turn off equipment or machine power putting it in conditionsthat it cannot be restarted accidentally by an inattentive oper-ator. Consider the use of lock out tags to prevent accidentaloperation of the equipment.
Step 2Remove external protection panels and visually inspect hoseand fittings for damages or leaks.
In particular look for:
Leakages: leaking can occur in the hose body, at the hose-coupling interface and/or on the fitting end. Signs of leakagecan be simple oil humidity near the fittings, visible puddles offluid in or around the equipment, low level of fluid in reservoiror greasy/dirty hoses. In this case, it is important carefully lookaround to locate the leak. If leaks are detected on the hose
assembly, it is necessary to replace it.
Warning: never check for leaks by running thehands over hose or hydraulic connections, on thecontrary clean the area, determining where theleak originates. Visual inspection of the otherhydraulic components, like valves, pumps, cylin-
ders, etc., for leaks and damages is also advisable.
Hose cover and other abnormalities: if the cover is dam-aged, the reinforcement could be deteriorated as well. Visualinspection of the cover for signs of abrasion, blisters, cracks,nicks, cuts and/or hardened conditions, is a first check to bedone. Also the whole system around needs to be checked inorder to find eventual direct causes of the damages (for exam-ple abrasions or heat sources).
If the hose is particularly hot, the operating temperature maybe excessive: the systems has to be checked for unefficiencies
138
139If the hose wire reinforcement is clearly visible in some parts, itis necessary to replace the hose: for other criteria of hosereplacement, refer to the following list of abnormalities:
• leaks at hose fitting or in hose• damaged, cut or abraded cover• exposed reinforcement• kinked, crushed, flattened, or twisted hose• hard, stiff. heat cracked, or charred hose• blistered, soft, degraded, or loose cover• cracked, damaged, or badly corroded fittings• fitting slippage on hose• leaking ports• damaged or missing hose clamps, guards or shield• excessive dirt and debris around hose• other signs of significant deterioration.
If any of these conditions exist, evaluate the hose assem-blies for correction or replacement.
Hose configurations (routings): proper hose routing is criti-cal in preventing early hose failure.It is recommended to carry out a rough analysis to check thathoses do not rub against each other or against metal parts,that the bend radii of the configurations are not lower thanthe minimum recommended in all the possible configurations,that twisting or kinking are not present, that there is enoughslack to allow for length deformation under pressure, etc.Also check that hoses are not located close to a high heatsource for potential cover cracks or hardening.
Step 3Reinstall the external protection panels and restart the sys-tem/equipment.Control the whole system behaviour under normal workingconditions, check for smell of burning oil, signs of excessiveheat, vibrations, strange noises, etc.
If any step in the inspection indicates a potential or a clearproblem, it is recommended to check it out and repair imme-diately.It is also necessary to keep a detailed logbook of inspectionsand maintenance activities, complete with service informa-tion. This can be used also to identify and prevent recurrentproblems of the system/equipment type, fix the frequency ofinspection, list the necessary component substitution recom-mendations, etc.
HOSE ASSEMBLY TROUBLESHOOTING GUIDE
The following list of troubleshooting is a useful guideline torecognise the hose field problems and identify faults, causesand correct solutions. It is also a useful training session withprevention targets, based on the field experience.Even if not exhaustive, this list highlights the main problems ofcommon use, installation, maintenance of hose assemblies,fittings, adapters, etc.
When selecting a component for a new application, theknowledge of potential failure modes is a suitable guideline todrive the selection of hose and fittings and to develop theproper assembly solution considering the functional parame-ters of the application/equipment.
When replacing a failed hydraulic hose assembly it is impor-tant to understand why the assembly being replaced failed.This is to ensure that the replacement assembly is “fit for pur-pose” and that premature failure can be avoided.
Failure of assemblies can be avoided by implementing regularinspection and monitoring deterioration. Hydraulic hoseassemblies can then be replaced before a failure occurs.Failure of hose assemblies can cause danger to personnel,possible machine damage, a fire hazard and environmentalpollution.
We will now take a look at the faults that can be identified asa reason for failure or increase the risk of failure, the causes ofthese effects and remedies to prevent future failure resulting inextended hose assembly service life.We can categorise failure faults, as follows:
• visible faults on the external hose & connectors:- hose has burst – critical failure!- hose cover shows signs if deterioration- fluid spray from hose cover (pin hole) – critical failure!- connectors become detached – critical failure!- leakage from connectors- weapage at the rear of the ferrule
• non-visible faults from within the hose & connectors:- internal tube material fault- internal tube deterioration.
140 Before attempting to replace or inspect ahydraulic hose assembly on an applica-tion first ensure that the machine isturned off and all moving parts aresecured and lowered to the ground.Ensure that the assembly is depressurisedbefore attempting to un-install. Theassembly and internal fluid may be hot,therefore, allow to cool down beforehandling. Wear personal protectionequipment. Never place a hand or otherbody part near a high pressure fluid jet. Athrough risk assessment should be carriedout prior to working on machinery andsites.
Caution
141
Hose has burstThe reason for this occurrence may have been one of thefollowing:• The peak pressure of the hydraulic system is too high for
the hose type utilised this is generally due to poor know-ledge of the application or of an application function butalso to component faults (fig.1).
• The hose has been bent past its minimum bend radius,damaging the wires, weakening the assembly and resultingin a pressure burst failure at the centre of the hose bend.
• The hose cover has been abraded by external causes, thereinforcement is corroded in the location of the burst:external protections for the hose can be necessary or specialcover materials are recommended (fig. 2).
• A hose burst close to the connector may be due to coni-cal stress caused by wire fatigue. This can be the result ofstarting the bend too close to the connector (fig. 3) or a veryflexible hose that has been allowed to whip, creating the“elephant ear effect” (fig. 4). A hose bend restrictor can beused. The hose assembly has been damaged causing aninstant failure or a failure due to a damage induced weaken-ing of the hose assembly (fig. 5).
• High-frequency, intense pressure spikes fatigued boldreinforcement: it is advisable to check the severity of pressurespikes. The selection of robust hose types (e.g. with wirespiral architecture instead of wire braided reinforcement).Replace hose assembly with properly crimped assembly.
• Pressure exceeded strength of the hose and/or the hosebold is twisted during attachment to ports and movementopened gaps in reinforcement. In this case it is necessary tocheck pressure rating output of the system, eventually use ahose with a higher pressure rating, and improve the routing,maybe with swivel couplings, studying the flexing configura-tions so that the hose remains always in the same plane (it is notrecommended to bend the hose in more than one plane).
Hose cover shows signs of deteriorationHose cover deterioration will involve a reinforcement decaydue to corrosion, etc. and could eventually lead to a criticalassembly failure. The cause of deterioration may be one of thefollowing:
• Hose cover abrasion, as a result of hose assemblies rub-bing against each other or as a result of contact with sharpedges or rough machine components, will expose the hosereinforcement allowing wire corrosion to take place. Severeabrasion may have damaged the reinforcement, weakeningthe hose. With synthetic fibre reinforced hose types the abra-sion weakens the hose’s ability to withstand the internal pres-sure. All instances will eventually lead to a critical hose failure(fig. 6-7).
fig. 1
fig. 2
fig. 3
fig. 4
fig. 5
142
• Cracks may be observed on the hose cover. This may bedue to natural ageing or as a result of accelerated ageingdue to ozone attack or use of the assembly at extreme rangeof temperature (fig. 8).
• A hardening of the hose cover may be the result of anincorrectly specified hose type for the application systemtemperatures, internal or external. Excess temperature mayhave been generated by high friction of the fluid inside thesystem (e.g. closed circuits) or by external heat sources (e.g.engine compartment).
• A soft hose cover may be a result of an incorrectly cured rub-ber by the manufacturer or the effects of an incompatible fluidcoming into constant contact with the cover.
• A cracked and peeled hose cover may indicate an extremeabrasion contact, maybe in combination with a flexing ofthe hose close to the connector, during application causingfatigue. Another symptom can be fluid weeping from thesame area of the hose cover (fig. 9).
• Blisters observed on the hose cover may be a conse-quence of fluid leakage from inside the hose assembly orfluid being driven through the hose cover.This may be due to a manufacturing fault or the effects of anincompatible fluid (fig. 10).
• The aging and the effects of environmental conditions suchas heat, cold, ozone and sunlight, cause loss of performanceproperties and failure. The production date of the hose hasto be checked: hoses older than 5 to 7 years are due forreplacement to meet the application conditions.
Hose cover is cracked radially but the cover material is nothard or brittleThe hose has been exposed to extreme cold temperatures thatcaused radial cracks of the cover during the flexing move-ments. It is necessary to select a hose with characteristics thatmeet these conditions or to insulate the assembly with a suit-able protection.
Cracks in hose liner and cover result in leakage while tube andcover are still soft and flexible at room temperature: this is theevidence that flexing of hose during periods of extreme coldwhen liner and cover were brittle caused the failure.In this case it is important to check the minimum internal andexternal temperatures, in particular at the time of equipmentstart-up. Use a hose that remains flexible below the applica-tions lowest operating temperature.
fig. 6
fig. 7
fig. 8
fig. 9
fig. 10
143
Fluid spray from hose coverDanger! Do not attempt to put your hands near the spray. Thiscould result in serious injury!Fluid venting from the hose cover may be the result of wirereinforcement breakage due to hose damage or maybe as aconsequence of a hose tube manufacturing fault (fig. 11).It may also be the result of a hose tube failure due to the useof incompatible fluid, extreme temperatures or hose-tubefatigue.Incorrect assembly operation could be another cause of thistype of failure.
Connector has become detached (blow-off)The possible causes of such a severe failure can be:• Connector and hose are mix-matched between two differ-
ent manufacturers, therefore there is not the correct level ofconnector retention on the hose (fig. 12).
• The internal pressure, may be over the rated one, lateralstretch, axial twist or a combination of all the stress/strainresulted in a critical assembly failure.
• Connector has been incorrectly installed onto the hoseand/or not swaged/crimped according to the manufacturerprocedures (fig. 13).
• A connector may be damaged due to incompatible insertsand ferrules being used resulting in a material fracture.
• A ferrule may crack resulting in a hose assembly failure. Thismay be due to incorrect swaging assembly equipment or toa material fault (fig. 14).
Leakage is observed from connectorsConnector leakage can be linked to the following causes:• The connector may have become loose due to incorrect
tightening or as a result of machinery vibration. The fluidmay be seen leaking from the end of the connector orbehind the nut (fig. 15).
• The sealing surface of the connector and/or the mating sur-face may be incorrectly manufactured, old and/or corrodedor damaged (fig. 16).
• Where an O-Ring is specified, it may have been damaged oraged after a long period in service or simply was fallen outof the insert or mating surface allowing leakage (fig. 17).
• The connector nut, thread or clamp bolt thread may havebeen damaged misaligning the components while tighten-ing.
Leakage between the insert and the top of the ferrule(hose-fitting area)• This may be the result of incorrectly matched or assembled
hose and connectors, hose deterioration due to extremetemperatures, too high working pressure for the selectedhose type (presence of uncontrolled pressure peaks), vibra-
fig. 12
fig. 13
fig. 14
fig. 15
fig. 11
tions, hose stretch or twist (severe routing with reducedbend radius near the fittings or twist), chemical incompatibil-ity with the service fluid (fig. 18-19).
• This may also be caused by insufficient hose insertion duringassembly and/or undercrimping. Also excessive vibrationand flexing movements may weaken the interface andreduce the assembly ability to prevent fluid leakage.Whether it has been undercrimped or the insert and ferrulehave been improperly assembled, the hose assembly mustbe replaced with one properly assembled.
Hose leaks without burstingHigh fluid velocity or aggressive fluid erodes hose tube (inter-nal layer). Fluid velocity may be too high or a jet stream of fluidthrough an orifice may impact the tube in a concentratedarea. Contamination particles can add to the erosion. In thiscase it is necessary to consider a larger diameter hose to han-dle the flow rate at a lower velocity. Make sure that hosescome straight away from any port that has an orifice. Fluidshould be clean, check fluid and filters.
Hose tube failureTube is swollen and badly deteriorated, it could also be partiallywashed out. The fluid used may not be compatible with thehose tube; the effect of very high temperature of the fluid can bea concomitant cause too. In this case it is necessary to check theManuli fluid chart on the catalogue, verifying also details regard-ing the maximum temperature recommended. For further spe-cific assistance contact Manuli Rubber Industries (fig. 20).
Reinforcement failure: hose is flattened out in several areasand appears twisted.Hose was installed in a twisted position and when pressurisedtries to return to a neutral position causing the reinforcement totear apart. The twist of the hose can reduce the hose servicelife. The cause is an incorrect installation problem: using thehose branding as visual indication of proper installation it is pos-sible to realise a correct routing and installation of the assembly(eventually using also live swivel adaptors if necessary).
Leakage on a tapered male termination endThread has been re-used without proper installation proce-dure. The use of a proper sealant, like a PTFE tape or othersealant material on the threads is necessary.
The reuse of tapered fittings is not recom-mended, the use of a new fitting isadvised.
144
fig. 16
fig. 17
fig. 18
fig. 19
fig. 20
145
Fitting seal area leakage: SAE screw threads with 37 or 45degree flare sealsThe flare seat may be severely deformed and/or cracked. Thiscondition is due to over-tightening. The solution can be toreplace fittings and refer to the installation guide, following therecommended torques. The female flare or the male seat mayhave been damaged in transit or storage: in this case considerall flare fittings should be inspected for scratches or nicks priorto installation. Replace the fitting with a new one if damaged.
Remark: the 37 degree and 45 degree flare fittingare not interchangeable with each others. Thedegree of angle is different and will not producean adequate seal.
Fitting seal area leakage: O-Ring seal typesNew fittings with O-Ring seal can leak at start up due toimproper installation. The O-Ring must be lightly lubricatedprior to threading onto the fitting: this reduces axial frictionduring insertion which causes the O-ring to move out of theseal area and to be sheared. Do not exceed with the oil, risk-ing to lubricate also the threading requiring excessive torqueat the installation.
Fittings with O-Rings can leak after considerable service timedue aging of the rubber. O-Ring must be replaced after afixed service period (depending on the application).
In case of further leaks check system pressure and relief valvecondition and setting. In case the O-Ring seal is swollen or par-tially eroded, this phenomenon can be caused by fluid incom-patibility: it is necessary to replace the O-Ring with a materialrecommended for the fluid being used.
O-Ring material can be found hard, brittle and cracked byexposure, resulting in a leak. In this case it is necessary to veri-fy the presence of high fluid temperatures or vicinity to highheat sources. Eventually replace the O-Ring with a suitablematerial compatible with the system temperature (see photoof a typical aged O-Ring: fig. 17)
Bolts on flange head fitting not correctly tightened cause theO-ring to extrude out of the fitting: bolts must be tightenedcorrectly at the proper recommended torque values, followingthe correct procedure of installation.Wrong size O-Ring installed: check fitting manufacturersspecifications for proper O-Ring size and material (refer to thecoupling section of this technical manual).
Conclusions
146
Description of leaks: SAE J1176 (and ISO/TR 11340)In order to describe, register and communicate the gravity ofthe leak it is useful to refer to SAE J1176 specification.SAE J1176 establishes a guide for defining the degree of exter-nal leakage with 6 classifications for dusty (class 0D to class 5Dfrom no moisture to recurring fluid with a measurable streamof droplets) and 6 for dust-free conditions (class 0 to class 5from no moisture to recurring fluid with a stream of droplets).The choice of classifications is intended to be by visual meanand describes the state at the observation.
Pump cavitation: suction hose is flattened out or kinked inone or more areasIf the hose selected for a suction application does not have thecharacteristics to be suitable for vacuum resistance or routing isnot correct, exceeding the minimum bend radius, then the hosecan be partially collapsing and then fluid flow can be seriouslyrestricted. A more robust structure is necessary, Manuli offers awide range of hoses suitable for vacuum resistance applications.It is necessary to replace the assembly and re-route it, using even-tually elbow fittings to reduce the hose bend.
Considering the vast array of faults which can be identified asthe cause for an assembly failure or can increase for failure itcan now be understood why simply replacing a hydraulichose assembly with a similar type and installing it withoutinvestigating the reason for failure may only result in a shortservice life of the replacement assembly and/or a potential riskof injury to personnel.
"FAILURE RECOGNITION & PREVENTION" IS THE ONLYSAFE SOLUTION FOR REPLACING HYDRAULIC HOSEASSEMBLIES.
Manuli specialist assistance may berequired to determine the cause of thefailure. Consult your nearest dealer orcontact Manuli Rubber Industries foradvice.
Note
The procedure in case of different faults and causes is as follows:• should material or assembly manufacture faults be
suspected then the assembly should be returned with allapplication details to the manufacturer for analysis andreporting;
• should the fault be the result of incorrect hose or con-nector selection then refer to the hose selection part ofthis manual to carry out a correct hose and fittings selec-tion after having evaluated the application;
• should the fault be considered the result of incorrectinstallation then refer to the criteria recommended inthe hose assembly routing section in this manual;
• should it be suspected the fault could be the result of afaulty application then consult with the machine useror manufacturer.
Appendix
The following tables show the most common units of measu-rements and conversion charts used in the hydraulic sector.
SYSTEM OF UNITS AND CONVERSIONS
148
Inches
MillimetersDecimalsFraction
17.46317.85918.25618.65319.05019.44719.84420.24120.63821.03421.43121.82822.22522.62223.019 23.416 23.813 24.209 24.606 25.003
.6875.703125.71875.734375
.750.765625.78125.796875.8125
.828125.84375.859375
.875.890625.90625.921875.9375
.953125.96875.984375
11/1645/64 23/32 47/64 3/4
49/64 25/32 51/64 13/16 53/64 27/32 55/64 7/8
57/64 29/32 59/64 15/16 61/64 31/32 63/64
Inches
MillimetersDecimalsFraction
9.128 9.5259.92210.31910.71611.11311.50911.90612.30312.70013.09713.49413.89114.28814.68415.08115.47815.87516.27216.669
.359375.375
.390625 .40625 .421875.4375
.453125.46875.484375
.500.515625.53125.546875.5625
.578125.59375.609375
.625640625.65625
23/643/8
25/64 13/32 27/64 7/16 29/64 15/32 31/64
1/2 33/64 17/32 35/64 9/16 37/64 19/32 39/64
5/8 41/64 21/32
Inches
MillimetersDecimalsFraction
.397
.7941.1911.5881.9842.3812.7783.1753.5723.9694.3664.7635.1595.5565.9536.3506.7477.1447.5417.938
.015625 .03125 .046875
.0625 .078125 .09375 .109375
.125.140625.15625.171875
.1875.203125.21875.234375
.250.265625.28125.296875
.3125
1/641/323/64 1/16 5/643/32 7/64 1/8
9/64 5/32
11/64 3/16
13/64 7/32
15/64 1/4
17/64 9/32
19/64 5/16
Decimal and Millimeter Equivalents of Fractions
R5 hosedash size
ISOMetric size
SAEdash size
Nominal hose I.D.inches
decimalfraction
-4 -5 -6 - -8 -10 -12 -
-16 -
-20 -
-24 -
-32-----
5 6.3 8 10 -
12.5 16 19 -
25 -
31.5 -
38 -
51 63 76 89 102
-3 -4 -5 -6 - -8 -10 -12
- -16
- -20
- -24
- -32 -40 -48 -56 -64
.1875 .250 .3125 .375
.40625 .500 .625 .750 .875 1.000 1.125 1.250 1.375 1.500 1.8125 2.000 2.500 3.000 3.500 4.000
3/16 1/4
5/16 3/8
13/32 1/2 5/8 3/4 7/8 1
1 1/8 1 1/4 1 3/8 1 1/2
1 13/16 2
2 1/2 3
3 1/2 4
Hose size identification numbers
149
Bar(Bar)
0.7 1.4 2.1 2.8 3.4 4.1 4.8 5.5 6.2 6.9 13.8 20.7 27.6 34.5 41.4 48.3 55.2 62.1 68.9 137.9 206.8 275.8 344.7 413.7 482.6 551.6 620.5 689
1,379 2.068 2,758
Mega Pascals(MPa)
Kilo Pascals(kPa)
Pounds perSquare Inch
(psi)
0.07 0.14 0.21 0.28 0.34 0.41 0.48 0.55 0.62 0.7 1.4 2.1 2.8 3.4 4.1 4.8 5.5 6.2 6.9 13.8 20.7 27.6 34.5 41.4 48.3 55.2 62.1 68.9 137.9 206.8275.8
68.9 137.9 206.8 275.8 344.7 413.7 482.6 551.6 620.5 689
1,379 2,068 2,758 3,447 4,137 4,826 5,516 6,205 6,895 13,790 20,684 27,579 34,474 41,369 48,263 55,158 62,053 68,948 137,895 206,843 275,790
10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 20,000 30,000 40,000
Pounds perSquare Inch
(psi)
14.5 29.0 43.5 58.0 72.5 87.0 101.5 116.0 130.5 145.0 290.1 435.1 580.2 725.2 870.2
1,015.3 1,160.3 1,305.3 1,450 2,901 4,351 5,802 7,252 8,702 10,153 11,603 13,053 14,504 29,008 43,511
Bar(Bar)
PSI to Metric( 1 psi = 6.89 kPa )
Metric to PSI( 1 kPa = .145 psi )
Mega Pascals(MPa)
Kilo Pascals(kPa)
1 2 3 4 5 6 7 8 9 10 20 30 40 50 60 70 80 90 100 200 300 400 500 600 700 800 900 1000 2000 3000
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10 20 30 40 50 60 70 80 90 100 200 300
100 200 300 400 500 600 700 800 900
1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000
10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000
100,000 200,000 300,000
Pressure Conversions
150 ConversionSI / ImperialUnitQuantity
1kg = 2,2046 lb1lb = 0,4535 kg1N = 0,2248 lbf1lbf = 4,4482 N1W = 0,7375 ft lbf/s1ft lbf/s = 1,356 W
1m = 3,2808 ft1mm = 0,03937 in1ft = 0,3048 m1in = 25,4 mm1m2= 1550 in2
1cm2 = 0,1550 in2
1in2 = 6,45 cm2
1m3 = 1000 liter1cm3 = 0,0610 in3
1in3 = 16,387 cm3
1gal = 4,5460 liter1gal = 3,785 liter1bar = 14,5035 psi1MPa = 145,035 psi1KPa = 0,1450 psi1psi = 0,0689 bar
1l/min = 0,2199 gallons (UK) per minute1l/min = 0,2642 gallons (US) per minute1gal/min = 4,546 l/min1gal/min = 3,785 l/min
kglbN (1N = 1kg m/s2)lbfW (1W = 1kg m2/s3)ft lbf/s
mmmftInm2
cm2
in2
m3
cm3
in3
GalGalbar (1bar = 105N/m2)MPa (1MPa = 10bar)KPa (1KPa = 0,01bar)lbf=psi
l/s (l/s = 0,001m3/s)l/m (l/min = 0,001m3/min)gal/mingal/mincSt (cSt = mm2/s)
Kilogrampound (UK)Newtonpound force (UK)Wattfoot pound forceper secondMeterMillimeterfoot (UK)inch (UK)square metersquare centimetersquare inch (UK)cubic metercubic centimetercubic inch (UK)gallon (UK)gallon (US)Barmega-pascalkilo-pascalpound-forceper square inchliters per secondliters per minutegallons per minute (UK)gallons per minute (US)Centistokes
mass
force
power
lenght
area
volume
pressure
flow rate
viscosity
Physical quantities, units and conversions
fromUnit
inmftmin2
m2
gallgalllbkgpsibarpsiMPakPabarMPabarft/sm/sgal/min.l/min.gal/min.l/min.°F°Clb/inNmlb/ftNm
to
minmftmm2
in2
lgal (UK)lgal (US)kglbbarpsiMPapsibarkPabarMPam/sft/sl/min.gal/min. (UK)l/min.gal/min. (US)°C°FNmlb/inNmlb/ft
1 inch1 meter1 foot1 meter1 inch2
1 meter2
1 gallon (UK)1 liter1 gallon (US)1 liter1 pound1 kilogram1 pound/inch2
1 bar1 pound/inch2
1 mega pascal1 kilo Pascal1 bar1 mega Pascal1 bar1 foot/second1 meter/second1 gallon/minute (UK)1 liter/minute1 gallon/minute (US)1 liter/minutedegree Fahrenheitdegree Celsius1 pound/inch1 Newton/meter1 pound/foot1 Newton/foot
Lenght
Area
Volume
Weight
Pressure
Velocity
Flow
Temperature
Torque
multiply by
0,025439,3700,30483,281645,1615504,5460,223,780,2640,4542,2050,0689514,50,006895145,0350,01100100,10,30483,2814,5460,223,780,2645/9 (°F-32)°C (9/5)+320,1138,851,3560,7374
.
Units and conversions
°FTemp°C
464 482 500 518 536554 572 590 608 626 644 662 680 698 716 734 752 770 788 806 824 842 860 878 896 914 932 950 968 986 1004 1022 1040 1058 1076 1094 1112 1130 1148 1166 1184 1202 1220 1238 1256 1274 1292 1310 1328 1346 1364 1382 1400 1418 1436 1454 1472 1490 1508 1526 1544 1562 1580 15981616
240 250 260 270 280290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 440 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 840 850 860 870 880
115 121 127 132 138143 149 154 160 165 171 177 182 188 193 199 204 210 215 221 226 232 238 243 249 254 260 265 271 276 282 288 293 299 304 310 315 321 326 332 338 343 349 354 360 365 371 376 382 387 393 399 404 410 415 421 426 432 438 443 449 454 460 465 471
°FTemp°C
122.0 123.8 125.6 127.4 129.2131.0 132.8 134.6 136.4 138.2140.0 141.0 143.6 145.4 147.2 149.0 150.8 152.6 154.4 156.2 158.0 159.8 161.6 163.4 165.2 167.0 168.8 170.6 172.4 174.2 176.0 177.8 179.6 181.4 183.2 185.0 186.8 188.6 190.4 192.2 194.0 195.8 197.6 199.4 201.2 203.0 204.8 206.8 208.4 210.2 212 203 248 266 284 302 320 338 356 374 392 410 413 428 446
50 51 52 53 5455 56 57 58 5960 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100110 120 130 140 150 160 170 180 190 200 210 212 220 230
9.910.411.111.512.112.613.213.714.314.815.6 16.1 16.6 17.1 17.7 18.2 18.8 19.3 19.9 20.4 21.0 21.5 22.2 22.7 23.3 23.8 24.4 25.0 25.5 26.2 26.8 27.3 27.7 28.2 28.8 29.3 29.9 30.4 31.0 31.5 32.1 32.6 33.3 33.8 34.4 34.9 35.5 36.1 36.6 37.1 38. 43 49 54 60 65 71 76 83 88 93 99 100 104 110
°FTemp°C
-166-148-130-112-94
-88.6-76
-72.4-58-40-22-7.6-414
24.832.0 33.8 35.6 37.4 39.2 41.0 42.8 44.6 46.4 48.2 50.0 51.8 53.6 55.4 57.2 59.0 60.8 62.6 64.4 66.2 68.0 69.8 71.6 73.4 75.2 77.0 78.8 80.6 82.4 84.2 86.0 87.8 89.6 91.4 93.2 95.0 96.8 98.6 100.4 102.2 104.0 105.8 107.6 109.4 111.2113.0 114.8 116.6 118.4 120.2
-110-100-90-80-70-67-60-58-50-40-30-22-20-10-40123 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 4344 45 46 47 48 49
-79.0-73.0-68.0-62.0-57.0-55.0-51.0-50.0-46.0-40.0-34.0-30.0-29.0-23.0-20.0-17.7 -17.2 -16.6 -16.1 -15.5 -15.0 -14.4 -13.9 -13.3 -12.7 -12.2 -11.6 -11.1 -10.5 -10.0 -9.4 -8.8 -8.3 -7.7 -7.2 -6.6 -6.1 -5.5 -5.0 -4.4 -3.9 -3.3 -2.8 -2.2 -1.6 -1.1 -0.6 -0-0.5-1.1-1.6-2.2-2.7-3.3-3.8-4.4-4.9-5.5-6.0-6.6-7.1-7.7-8.2-8.8-9.3
Temperature Conversion Chart151
5050
40
30
2010
0
10
20
30
40
5060
70
80
90
100
110
120
130140
150
160
170
180190
200
210
FAHR. CENT.
50
40
30
20
10
0
10
20
30
40
50
60
70
80
90
100
Fahrenheit in Centigrades:If degree °F are higher than zero;°C = (+ °F - 32) x 5/9If degree °F are lower than zero;°C = (- °F - 32) x 5/9
Centigrades in Fahrenheit:If degree °C are higher than zero;°F = °C x 9/5 + 32 = °C x 1,8 + 32If degree °C are lower than zero;°F = - °C x 9/5 + 32 = - °C x 1,8 + 32
Temperature
GLOSSARY
The following is a glossary of terms commonly used in the hose and fittings industry for the hydraulicsector. However, such words and expressions should not be intended as only with the precise meaningexposed in all the circumstances.
A
abrasion: a wearing away by friction.abrasion tester: a machine for determining the quantity of material worn away by friction underspeci-fied conditions.accelerated life test: a method designed to approximate in a short time the deteriorating effectsobtained under normal service conditions.accelerator: a compounding ingredient used with a curing agent to increase the rate of vulcanisation.acid resistant: having the capability to withstand the action of identified acids within specified limits ofconcentration and temperature.activator: a compounding ingredient used to increase the effectiveness of an accelerator.adapter: the accessory part which can complete the connection between a hose fitting and anotherfluid system component. Often, a tube fitting connected to a hose alloy: metal made of the fusion of two or more metals.annealing: thermal treatment process which consist of heating a metallurgical product at a sufficienttemperature to recover some or all of its structural and physical-chemical balance and then graduallycooling it.assembly rather than a tube assembly.adhesion: the strength of bond between cured rubber surfaces or between a cured rubber surfaceand a non-rubber surface.adhesion failure: the separation of two bonded surfaces at an interface by a force less than specifiedin a test method or the separation of two adjoining surfaces owing to service conditions.adhesive: a material which, when applied, will cause two surfaces to adhere.adhesive coating: a layer applied to any product surface to increase its adherence to an adjoiningsurface.aftercure: a continuation of the process of vulcanisation after the cure has been carried to the desireddegree and the source of heat removed.afterglow: in fire resistance testing, the red glow persisting after extinction of the flame.aging: changes in physical properties over a period of time.air cure: vulcanisation without the application of heat. See also: hot air cure.air oven aging: a means of accelerating a change in the physical properties of rubber compounds byexposing them to the action of air at an elevated temperature at atmospheric pressure.ambient temperature: the temperature of the atmosphere or medium surrounding an object underconsideration.angle of lay: the angle developed at the intersection of a structural element and a line parallel to itslineal axis.antioxidant: a compounding ingredient used to retard deterioration caused by oxygen.anti-ozonant: a compounding ingredient used to retard deterioration caused by ozone.anti-static: having the capability of furnishing a path for a flow of static electricity.armored hose: a hose with a protective covering, applied as a braid or helix, to protect from physicalabuse.assembly: hose assembly.autoclave: a pressure vessel used for vulcanising rubber products by means of steam under pressure.
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B
banbury mixer: a specific type of internal mixer used to incorporate fillers and other ingredients intorubber or plastic.band: a thin strip of metal used as a boltless clamp.bank: an accumulation of material at the opening between the rolls of a mill or calender.batch: the product of one mixing operation.bench marks (tensile test): marks of known separation applied to a specimen used to measure strain(elongation of specimen).bench test: modified service test in which the service conditions are approximated in the laboratory.bend: the curvature of a hose from a straight line.bending force: an amount of stress required to induce bending around a specified radius and hence,a measure of stiffness.bend radius: the radius of a bent section of hose measured to the innermost surface of the curvedportion.bleeding: surface exudation. See also: bloom.blister: a raised area on the surface or a separation between layers usually creating a void or air-filledspace in a vulcanised article.bloom: a discolouration or change in appearance of the surface of a rubber product caused by themigration of a liquid or solid to the surface.body wire: a round or flat wire helix embedded in the hose wall to increase strength or to resist collapse.bolt hole circle: a circle on the flange face around which the centre of the bolt holes are distributed.bore: an internal cylindrical passageway, as of a tube, hose or pipe; the internal diameter of a tube,hose or pipe.braid: a continuous sleeve or reinforcement of interwoven single or multiple strands of yarn or wire.braid angle: the angle developed at the intersection of a braid strand and a line parallel to the axis ofa hose.braid smash: a defect in a braided reinforcement caused by one or more of the ends of reinforcingmaterial breaking during the braiding operation.braided hose: hose in which the reinforcing structure presents braided configuration.braided ply: a layer of braided reinforcement.braider: a machine which interweaves strands of yarn or wire to make a hose reinforcement.brand: a mark or symbol identifying or describing a product and/or manufacturer, either embossed,inlaid or printed.breaker ply: an open mesh fabric used to anchor a hose tube or cover to its reinforcement and tospread impact.buckled ply: a deformation in a ply which distorts its normal plane.buffing: grinding a surface to obtain dimensional conformance or surface uniformity.burst: a rupture caused by internal pressure.burst pressure: the pressure at which rupture occurs.
C
calender: a machine equipped with three or more heavy, internally heated or cooled rolls revolvingin opposite directions, which is used for continuously sheeting or plying up rubber compounds, or fric-tioning or coating fabric with rubber compound.capped end: a hose end covered to protect its internal elements.carcass: the fabric, cord and/or metal reinforcing section of a hose as distinguished from the hose tubeor cover.cement: unvulcanised raw or compounded rubber in a suitable solvent used as an adhesive or sealant.cemented end: a hose end sealed with the application of a liquid coating.
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circular woven jacket: a textile reinforcing member produced on a circular loom for such types ofhose as fire hose.clamp: in hose, a metal fitting or band used around the outside of a hose end to bind the hose to acoupling, fitting or nipple.cold flexibility: the relative ease of bending following exposure to specified low temperature conditions.compound: the mixture of rubber or plastic and other materials which are combined to give thedesired properties when used in the manufacture of a product.compound ingredient: a material added to a rubber to form a mix.compression set: the deformation which remains in rubber after it has been subjected to and releasedfrom a specific compressive stress for a definite period of time at a prescribed temperature.conditioning: the exposure of a specimen under specified conditions, e.g. temperature, humidity, fora specified period of time before testing.concentricity: the uniformity of hose wall thickness as measured in a plane normal to the axis of thehose.conductive: a rubber having qualities of conducting or transmitting heat or electricity (generallyapplied to rubber products capable of conducting static electricity).copolymer: a polymer formed from two or more types of monomers.corrugated cover: a longitudinally ribbed or grooved exterior.corrugated hose: hose with a carcass fluted radially or helically to enhance its flexibility or reduce itsweight.coupling: a frequently used alternative term for fitting.cover: the outer component usually intended to protect the carcass of a product.cover wear: the loss of material during use due to abrasion, cutting or gouging.cracking: a sharp break or fissure in the surface. Generally caused by strain and environmental conditions.crazing: a surface effect on rubber articles characterised by multitudinous minute cracks.creep: the deformation, in either cured or uncured rubber under stress, which occurs with lapse oftime after the immediate deformation.Crimped-back nut: the method used to realise the mechanical connection of the nut on the fitting bymeans of a crimping operation of the neck of the nut.crimping: the act of forming a hose fitting with a surrounding series of die segments to compress thehose within the fitting.crosshead extruder: an extruder so constructed that the axis of the emerging extruded product is atright angles to the axis of the extruder screw.cross-link: chemical bond bridging one polymer chain to another.cross wrap: the overlapping layer or layers of narrow tensioned wrapper fabric spiralled circumferen-tially over the outside of a hose to obtain external pressure during vulcanisation.cure: the act of vulcanisation.cure time: the time required to produce vulcanisation at a given temperature.cut resistant: having that characteristic of withstanding the cutting action of sharp objects.
D
date code: any combination of numbers, letters, symbols or other methods used by a manufacturerto identify the time of manufacture of a product.denier: a yam sizing system for continuous filament synthetic fibres.design factor: a ratio used to establish the working pressure of the hose based on the burst strengthof the hose.dry: the absence of tack; no adhering properties.durometer: an instrument for measuring the hardness of rubber and plastic compounds.durometer hardness: a numerical value which indicates the resistance to indentation of the bluntindentor of the durometer.
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E
eccentricity: in hose, the condition resulting from the inside and outside diameters not having a com-mon centre.eccentric wall: in hose or tubing, a wall of varying thickness.elastic limit: the limiting extent to which a body may be deformed and yet return to its original shapeafter removal of the deforming force.elastomer: a macromolecular material which, in the vulcanised state at room temperature, can bestretched repeatedly to at least twice its original length and which, upon release of the stress, willimmediately return to approximately its original length.elongation: the increase in length expressed numerically as a fraction or percentage of the initiallength.end: a single strand or one of several parallel strands of a reinforcing material on a single package suchas a braider spool.endurance test: a service or laboratory test, conducted up to product failure, usually under normal useconditions.extruded: forced through the shaping die of an extruder. The extrusion may be solid or hollow crosssection.extruder (extrusion): a machine, generally with a driven screw, for continuous forming of rubber orplastic trough a die. It is widely used for the production of hoses.
F
fabric: a planar structure produced by interlaced yams, fibres or filaments.fabric impression: a pattern in the rubber surface formed by contact with fabric during vulcanisation(wrapped).fatigue: the weakening or deterioration of a material occurring when a repetitious or continuousapplication of stress causes strain.ferrule: a collar placed over a hose end to affix the fitting to the hose. The ferrule may be crimped orswaged, forcing the hose in against the insert.filler: any compounding material, usually in powder form, added to rubber in a substantial volume toimprove quality or lower cost;fitting: a device attached to the end of the hose to facilitate connection.flange-fitting: a circular ring, at the end of a hose for joining to another circular ring, generally bybolting.flat spots: flat areas on the surface of cured hose caused by deformation during vulcanisation.flex cracking: a surface cracking, induced by repeated bending and straightening.flexible mandrel: a long, round, smooth rod capable of being coiled in a small diameter. It is used forsupport during manufacture of certain types of hose.flex life: the relative ability of a rubber article to withstand cyclical bending stresses.flex life test: a laboratory method used to determine the life of a rubber product when subjected todynamic bending stresses.flow rate: a volume of fluid per unit of time passing a given cross-section of a flow passage in a givendirection.foreign material: any extraneous matter such as wood, paper, metal. sand, dirt or pigment thatshould not normally be present in the tube or cover of a hose.formula: a list of ingredients and their amount, used in the preparation of a compound.free hose length: the lineal measurement of hose between fittings or couplings.friction: a rubber adhesive compound impregnating a fabric, usually applied by means of a calendar(also used to intend the resistance to motion due to the contact of surfaces).
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G
grab test: a tensile test for woven fabric using specimens considerably wider than the jaws holdingthe ends of the test specimen.grain: the unidirectional orientation of rubber or filler particles resulting in anisotropy of rubber com-pounds.ground finish: a surface produced by grinding or buffing,gum compound: a rubber compound containing only those ingredients necessary for vulcanisation.Small amounts of other ingredients may be added for processability, colouring, and improving resist-ance to aging.
H
hardening: an increase in resistance to indentation.hardness: resistance to indentation.heat resistance: the property or ability to resist the deteriorating effects of elevated temperatures.helical cord: in hose, a reinforcement formed by a cord or cords wound spirally around the body ofa hose.helix: in hose, a shape formed by spiralling a wire or other reinforcement around the cylindrical bodyof a hose.hold test: a hydrostatic pressure test in which the hose is subjected to a specified internal pressure fora specified period of time.hose: a flexible conduit consisting of a tube, reinforcement, and usually an outer cover.hose assembly: a length of hose with a coupling attached to one or each end.hose clamp: a collar, band or wire used to hold hose on to a fitting.hose duck: a woven fabric made from plied yams with approximately equal strength in warp andfilling directions.hot air cure: vulcanisation by using heated air, with or without pressure.hysteresis: a loss of energy due to successive deformation and relaxation. It is measured by the areabetween the deformation and relaxation stress-strain curves.hysteresis loop: in general, the area between stress-strain curves of increasing and reducing stress, ameasure of hysteresis.
I
ID: the abbreviation for inside diameter.identification yarn: a yarn of single or multiple colours, usually embedded in the hose wall, used toidentify the manufacturer.impregnation: the act of filling the interstices of an article with a rubber compound. Generally appliesto the treatment of textile fabrics and cords.impression: a design formed during vulcanisation in the surface of a hose by a method of transfer,such as fabric impression or molded impression.impulse: an application of force in a manner to produce sudden strain or motion, such as hydraulicpressure applied in a hose.indentation: the extent of deformation by the indentor point of any one of a number of standardhardness testing instruments (sometimes used to intend a recess in the surface of a hose).inhibitor: an ingredient used to suppress a chemical reaction or a growing activity such as mildew.insert: optional term for nipple of a fitting (coupling).inspection block: a description on a drawing of the dimensional inspection to which a hose will besubjected.
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instantaneous modules: the slope of a stress-strain curve at a single point, employed when modulesvaries from point to point.interstice: a small opening, such as between fibres in a cord or threads in a woven or braided fabric.
J
jacket: a seamless tubular braided or woven ply generally on the outside of a hose.
K
kinking: a temporary or permanent distortion of the hose induced by bending beyond the minimumbend radius.knit fabric: a flat or tubular structure made from one or more yams or filaments whose direction isgenerally transverse to the fabric axis but whose successive passes are united by a series of interlockingloops.knit ply: a layer of textile reinforcement in which the yarns are applied in an interlocking looped con-figuration in a continuous tubular structure.knitter: a machine for forming a fabric by the action of needles engaging threads in such a manneras to cause a sequence of interlaced loops.
L
laminated cover: a cover formed to desired thickness from thinner layers vulcanised together.lap: a part that extends over itself or like part, usually by a desired and predetermined amount.lap seam: a seam made by placing the edge of one piece of material extending flat over the edge ofthe second piece of material.lay: the amount of advance of any point in a strand for one complete turn.layer: a single thickness of rubber or fabric between adjacent parts.latch area: are of the fitting to provide mechanical connection with the ferrule.lead cure finish: a type of exterior surface of hose, smooth or longitudinally corrugated, obtained bythe lead pipe method of vulcanisation (old method).leakage: a crack or hole in the tube which allows fluid to escape, or a hose assembly which allowsfluid to escape at the fittings or couplings.life test: a laboratory procedure used to determine the resistance of a hose to a specific set of destruc-tive forces or conditions.light resistance: the ability to retard the deleterious action of light.lined hose: term generally referring to fire hose having a seamless woven jacket or jackets and a tube.liner: a separator, usually cloth, plastic film or paper, used to prevent adjacent layers of material fromsticking together. Also used as synonym of internal tube of a hose.lining: internal tube layer.livering: a gelling in cement giving a liver-like consistency.loose cover: a separation of the cover from the carcass or reinforcements.loose ply: a separation between adjacent plies.loose tube: a tube separated from the carcass.lot: a specified quantity of hose from which a sample is taken for inspection.low temperature flexibility: the ability of a hose to be flexed, bent or bowed at low temperatureswithout loss of serviceability.low temperature flexing: the act of bending or bowing a hose under conditions of cold environ-ment.LPG: the abbreviation for liquefied petroleum gas.
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M
mandrel: a form, generally of elongated round section, used for size and to support hose duringfabrication and/or vulcanisation. It may be rigid for flexible.mandrel built: a hose fabricated and/or vulcanised on a mandrel.mandrel wrapped: a tubing, built up by wrapping a thick unvulcanised sheet around a mandrel.manufacturer's identification: a code symbol used on the hose to indicate the manufacturer.mass flow rate: the mass of fluid per unit of time passing a given cross-section of a flow passage in agiven direction.masterbatch: a preliminary mixture of rubber and one or more compound ingredients for such pur-poses as more thorough dispersion or better processing, and which will later become part of the finalcompound in a subsequent mixing operation.migration: in a rubber compound, the movement of more or less rubber soluble materials from apoint of high concentration to one of low or zero concentration. Migration is applied to the movementof accelerators, antioxidants, anti-ozonants, sulphur, softeners and organic colours. It is a form of diffusion.migration stain: a discolouration of a surface by a hose which is adjacent to but not touching the dis-coloured surface.mildew inhibited: containing material to prevent or retard the propagation of a fungus growth.mildew resistance: withstanding the action of mildew and its deteriorating effect.mill: a machine with two horizontal rolls revolving in opposite directions used for the mastication ormixing of rubber.minimum burst pressure: the lowest pressure at which rupture occurs under prescribed conditions.modules: in the physical testing of rubber, the load necessary to produce a stated percentage of elon-gation, compression or shear.moisture absorption: the assimilation of water by a rubber or textile product.moisture regain: the re absorption of water by textile.monomer: a low molecular weight substance consisting of molecules capable of reacting with like orunlike molecules to form a polymer.Mooney scorch: a measure of the incipient curing characteristics of a rubber compound using theMooney viscometer.Mooney viscosity: a measure of the plasticity of a rubber or rubber compound determined in aMooney shearing disc viscometer.MPa: MegaPascal a measure of pressure, 1 MPa equal to 145 psiMSHA: Mine Safety and Health Administration
N
necking down: a localised decrease in the cross-sectional area of a hose resulting from tension.nerve: a measure of toughness or recovery from deformation in unvulcanised rubbers or compounds.nip: the clearance between rolls of a mixing mill or calender.nipple: the internal member or portion of a hose fitting (insert).nominal: a dimensional value assigned for the purpose of convenient designation; existing in nameonly.nozzle end: an end of hose in which both the inside and outside diameters are reduced.
O
OD: the abbreviation for outside diameter.off gauge: not conforming to a specified thickness.oil proof: not affected by exposure to oil.oil swell: the change in volume of a rubber article resulting from contact with oil.
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open seam: a seam whose edges do not meet, creating a void.open steam cure: a method of vulcanising in which steam comes in direct contact with the productbeing cured.operating pressure: like working pressure or maximum working pressure.optimum cure: the state of vulcanisation at which a desired combination of characteristics is attained.overcure: a state of vulcanisation beyond the optimum cure.oxidation: the reaction of oxygen on a rubber product, usually evidenced by a change in the appear-ance or in physical properties.oxygen bomb aging: a means of accelerating a change in the physical properties of rubber com-pounds by exposing them to the action of oxygen at an elevated temperature and pressure.ozone cracking: the surface cracks, checks or crazing caused by exposure to atmosphere containingozone.ozone resistance: the ability to withstand the deteriorating effects of ozone (generally cracking).
P
peptizer: a compounding ingredient used in small proportions to accelerate by chemical action thesoftening of rubber under the influence of mechanical action, heat, or both.permanent fitting: the type of fitting which, once installed, may not be removed for use in anotherhose.permanent set: the amount by which an elastic material fails to return to its original form after defor-mation.pick: an individual filling yarn of a fabric or woven jacket.pin-hole: very small hole, present on the tube surface of a hose as defect.pin-pricking: the small holes made by means of pins on the hose cover for gas applications.pitch: the distance from one point on a helix to the corresponding point on the next turn of the helix,measured parallel to the axis.pitted tube: surface depressions on the inner tube of a hose.pitting: superficial fatigue effect on metallic surfaces creating surface depressions, corrosion.plain ends: the uncapped or otherwise unprotected, straight ends of a hose.plasticity: a measure of the resistance to shear of an unvulcanised elastomer; it is also used to indicatea property of vulcanised rubber to retain a shape or form imposed to it by a deforming force.plasticizer: a compounding ingredient which can change the hardness, flexibility, or plasticity of anelastomer.plastometer: an instrument for measuring the viscosity of raw or unvulcanised rubber.plied yarn: a yarn made by twisting together in one operation two or more single yarns.ply: a layer or rubberised fabric or a layer of reinforcement.ply adhesion: the force required to separate two adjoining reinforcing members of a hose.ply separation: a loss of adhesion between plies.pock marks: uneven blister-like elevations, depressions or pimpled appearance.polymer: a macromolecular material formed by the chemical combination of monomers having eitherthe same or different chemical composition.porous tube: the physical condition of a hose tube due to the presence of pores or a hose tube thathas low resistance to permeation.pre-cure: see semi-cure and scorch.pressure, burst: the pressure at which rupture occurs.pressure, operating: working pressure.pressure, proof: a specified pressure which exceeds the manufacturer's recommended working pres-sure applied to a hose to indicate its reliability at normal working pressure. Proof pressure is usuallytwice the working pressure.pressure, service: generally to intend working pressure.
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pressure, working: the maximum pressure to which a hose will be subjected, including the momen-tary surges in pressure which can occur during service, it is often abbreviated as WP.pricker mark: a perforation of the cover of a hose performed before or after vulcanisation.processability: the relative ease with which raw or compounded rubber can be handled in or onrubber processing machinery.proof pressure test: a non-destructive pressure test applied to a hose to determine its reliability at nor-mal working pressures by applying pressures which exceed the manufacturer's rated working pressure.Proof pressure is usually twice the working pressure.psi: the abbreviation for pounds per square inch.pulled-down tube: loose tube.pure gum: a rubber compound containing only those ingredients necessary for vulcanisation; par-ticularly applicable to natural rubber.
Q
qualification test: the examination of samples from a typical production run of hose to determineadherence to a given specification; performed for approval as a supplier.quality conformance inspection or test: the examination of samples from a production run of hoseto determine adherence to given specifications, for acceptance of that production run.
R
rag-wrap: for wrapped cure.recovery: the degree to which a hose returns to its normal dimensions or shape after being distorted.reinforcement: the strengthening members, consisting of either fabric, cord, and/or metal of a hose(sometimes intended as the non-rubber elements of a hose).reinforcing agent: an ingredient (not basic to the vulcanisation process) used in a rubber compoundto increase its resistance to mechanical forces.resin: a compounding material, solid or liquid in form, used to modify the processing and/or vulcani-sed characteristics of a compound.retarder: a compounding ingredient used to reduce the tendency of a rubber compound to vulcani-se prematurely.reusable coupling: reusable fitting.reusable fitting: the type of fitting which, by design, may be removed and reused.reversion: the softening of vulcanised rubber when it is exposed to an elevated temperature; a dete-rioration in physical properties; (extreme reversion may result in tackiness.).rise test: a determination of the distance a fire hose, under a specified internal pressure, lifts from thesurface on which is rests.roll ratio: the ratio of the surface speeds of two adjacent mill or calender rolls.rubber: a material, elastomer based, that is capable of recovering from large deformations quitequickly.rubber cement: generally adhesive cement, rubber based.
S
safety factor: design factor.sampling: a process of selecting a portion of a quantity of a hose for testing or inspection, selectedwithout regard to quality.scorch: premature vulcanisation of a rubber compound.
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screw-together reusable fitting: a type of hose fitting whose socket and nipple are threaded togetherin combination with the hose.seam: a line formed by the joining of the edges of a material to form a single ply or layer.seaming strip: a strip of material laid over a seam to act as a binder.self cure: vulcanisation without the application of heat.semi-cure: a preliminary but incomplete cure applied to a tube or hose in the process of manufacture tocause the tube or hose to acquire a degree of stiffness or to maintain some desired shape, service pressure.service test: or field test, a test in which the product is used under actual service conditions.set: the amount of strain remaining after complete release of a load producing a deformation.shank: that portion of a fitting, which is inserted into the bore of a hose.shear modules: the ratio of the shear stress to the resulting shear strain (the latter expressed as a frac-tion of the original thickness of the rubber measure, at right angles to the force); shear modules maybe either static or dynamic.shelf storage life: the period of time prior to use during which a product retains its intended perform-ance capability.shell: sometimes as alternative to the term ferrule.shock load: a stress created by a sudden force.simulated service test: test of field simulation.sink: a collapsed blister or bubble leaving a depression in a product.skim coat: a layer of rubber material laid on a fabric but not forced into the eave.skimmed fabric: a fabric coated with rubber on a calendar; the skim coat may or may not be appliedover a friction coat.skive: the removal of a short length of cover to permit the attachment of a fitting directly over the hosereinforcement.slip-on nut: method to block the nut on the fitting by means of a plastic slip.smooth bore hose: a wire reinforced hose in which the wire is not exposed on the inner surface ofthe tube.smooth cover: a cover having an even and uninterrupted smooth surface.socket: the external member or portion of a hose fitting, commonly used in describing screw-togetherreusable fittings.soft end: a hose end in which the rigid reinforcement of the body, usually wire, is omitted.spacing: the space between adjacent turns of helically wound wire.specification: a document setting pertinent details of a product, such as performance, chemical com-position, physical properties and dimensions, prepared for use in, or to form the basis for, an agree-ment between negotiating parties.specific gravity: the ratio of the weight of a given substance to the weight of an equal volume ofwater at a specified temperature.specimen: an appropriately shaped and prepared sample, ready for use in a test procedure.spider mark: a cleavage or weak spot caused by the failure of a compound to reunite after passing aspoke of the spider of an extrusion machine.spiral: a method of applying reinforcement in which there is no interlacing between individual strandsof the reinforcement.spiral lay: the manner in which a spiral reinforcement is applied with respect to angularity and leador pitch as in a hose or cylindrical article.splice: a joint or junction made by lapping or butting, and held together through vulcanisation ormechanical means.spread: a thin coat of material in solvent form applied on a fabric surface by means of knife, bar ordoctor blade.spread fabric: a fabric the surface of which is coated with a rubber solution and dried.spring guard: a steel or plastic helically wound protection applied externally to the hose to protectfrom abrasion or make bunches of hoses.
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standard: a document or an object for physical comparison, for defining product characteristics,products or processes, prepared by a consensus of a properly constituted group of those substantiallyaffected and having the qualifications to prepare the standard for use.staple: a steel fork used for special fittings connection.static bonding: use of a grounded conductive material to eliminate static electrical charges.static conductive: having the capability of furnishing a path for a flow of static electricity.static wire: a wire incorporated in a hose to conduct static electricity.stock: an uncured rubber compound of a definite composition from which a given article is manufac-tured.straight end: a hose end with an inside diameter the same as that of the main body of the hose.straight wrap: in a curing process, a wrap of lightweight fabric in which the warp threads of thefabric are parallel to the axis of the hose.stress relaxation: the decrease in stress after a given time at constant strain.stress-strain: the relationship of force and deformation of a unit area of a body during compression,extension or shear.stretch: an increase in dimension, an elongation.strike through: in coated or frictioned fabric, a penetration of rubber compound through the fabric;in woven fire hose, the penetration of the rubber backing through the jacket.strip test: in fabric testing, tensile strength test made on a strip of fabric ravelled down to a specifiednumber of threads or width of fabric.sulphur free: the sulphur in a rubber compound extractable by sodium sulphite after the normal vul-canisation process.sulphur total: all the sulphur present in a rubber compound, including inorganic sulphides andsulphates.sun checking: the surface cracks, checks, or crazing caused by exposure to direct or indirect sunlight.surge: a rapid and transient rise in pressure.swaging: the act of forming a hose fitting by passing it into a die, generally split, which is sized to yieldthe desired finished fitting diameter.swelling: an increase in volume or linear dimension of a material specimen immersed in liquid orexposed to a vapour.
T
tack: the ability to adhere to itself.tack rubber: a property of a rubber and rubber compounds that causes two layers of compounds thathave been pressed together to adhere firmly at the area of contact.tear resistance: the property of a rubber tube or cover of a hose to resist tearing forces.teeth: the tension filaments which appear between two adhering plies of rubber as they are pulled apart.tensile strength: the maximum tensile stress applied while stretching a specimen to rupture.tensile stress: a stress applied to stretch a test piece (specimen).termination end: the end part of the fitting, connection and sealing type of a fitting.test pressure: pressure used to perform a test (e.g. impulse test, proof test).tex: a yarn size system defined as the weight in grams of 1000 meters of yarn.thermoplastics: range of resins being easily softened under heat.thin cover: a cover, the thickness of which is less than specified; a wire braid hydraulic hose specificallymade with a thin cover to eliminate the need for skiving when attaching couplings.thin tube: a lining the thickness of which is less than specified (compact).thrust wire nut: method of mechanical connection of the nut on the fitting by means of a circular wire.tight braid: an unevenness in a braid reinforcement caused by one or more ends of the reinforcementbeing applied at a greater tension than the remaining ends; a localised necking down of the braidedreinforcement caused by a stop in the braiding operation.
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tolerance: the upper and lower limits between which a dimension must be held; the total range ofvariation, usually bilateral, permitted for a size, position or other required quantity.trapped air: air trapped during cure, which usually causes a loose ply or cover, a surface mark, depres-sion or void.tube: the innermost continuous all-rubber or plastic element of a hose.tubing: a non-reinforced, flexible, homogeneous conduit, generally of circular cross-section.twist: the turns about the axis, length of hose, of a fibre, etc; twist is usually expressed as turns perlength unit.
U
ultimate strength: tensile strength.undercure: a less than optimal state of vulcanisation, which may be evidenced by tackiness or inferiorphysical properties.
V
viscosity: the resistance of a material to flow under stress.void: the absence of material or an area devoid of materials where not intended.volume change: a change in linear dimensions of a specimen immersed in a liquid or exposed to avapour.vulcanisation: an irreversible process during which a rubber compound, through a change in itschemical structure (e.g. cross-linking), becomes less plastic and more resistant to swelling by organicliquids, and which confers, improves or extends elastic properties over a great range of temperature.volumetric expansion: the volume increase of hose when subjected to internal pressure. It is gener-ally reported in cubic centimetres per unit length of hose.
W
warp: the lengthwise yarns in a woven fabric or in a woven hose jacket; also the deviation from astraight line of a hose while subjected to internal pressure.water resistant: having the ability to withstand the deteriorating effect of water.wavy tube: a tube or lining with an inner surface having surface ripples formed by the pattern of thereinforcement.weathering: the surface deterioration of a hose cover during outdoor exposure, as shown by crackingor crazing.weft: a term used for filling.weftless cord fabric: a cord fabric either without filling yarns or with a few small filling yarns widelyspaced.wire braid: see braid.wire loop: in braided hose, a loop in the wire reinforcement caused by uneven tensions duringbobbin winding or braiding.wire reinforced: a hose containing wires to give added strength, increased dimensional stability, orcrush resistance.wire throw-out: in braided hose, a broken end or ends in the wire reinforcement protruding from thesurface of the braid;wire wound: having a single wire or a plurality of wires spiralled in one or more layers as a protectiveor reinforcing member.wire woven: woven with the wire reinforcement applied helically by means of a circular loom.
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working pressure: the maximum pressure to which a hose will be subjected, including the momen-tary surges in pressure which can occur an during service; frequently abbreviated as WP.woven fabric: a flat structure composed of two series of interlacing yarns or filaments, one parallel tothe axis of the fabric and the other transverse.WP: the abbreviation for working pressure.wrapped cure: a vulcanising process using a tensioned wrapper (usually of fabric) to apply externalpressure.wrapper marks: the impressions left on the surface of a hose by a material used during vulcanisation.
Y
yarn: a generic term for continuous strands of textile fibres or filaments in a form suitable for knitting,weaving, or otherwise interwining to form a textile fabric.
Z
Zinc-plating: traditional external treatment for corrosion resistance of steel components, applied tocouplings, adaptors, etc. with electrochemical methods.
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165
Some applications have strict requirements that are not codedin the Norms and Standrads. The requirements are coded by independent certificationbodies that have therefore specific acceptance criteria.Type Approvals are the certifications of appropriate characteris-tics. In particular FRAS, MSHA, LOBA and WUG are specific tomine applications, others are third party certifications for stan-dard hydraulic end/or marine applications.
ABSBVBWBDNVDGMSFRAS
GLMADI-CERTHBLINDIA MoDKRSLOBALRMAKNII
MSHARINA
MED
American Bureau of ShippingBureau VeritasBundesamt für Wehrtechnik und BeschaffungDet Norske VeritasDirectorate General of Mine Safety (India)Fire Resistant and Anti-Static (Australian Dept.Mineral Resources)Germanischer LloydGOST-R accreditation (Russian Federation and CIS)Houillers du Bassin de LorraineGovernment of India - Ministry of DefenceKorean Register of ShippingLandesoberbergsamt Nordrhein - WestfalenLloyd’s Register of ShippingState Makeyevka Research Institute of WorkSafety in Mining Industry (Ukraine)Mine Safety and Health AdministrationRegistro Italiano NavalePolish Safety Certification type “B” for miningMarine Equipment Directive (European Directive)
TYPE APPROVALS
For further details, please refer to the Manuli Fluid Connectors Catalogue.
Manuli Rubber Inustries assumes no responsibility or liability for any loss or damage, whether direct or indirect, consequential or incidental, which might arise from incorrect data
or incorrect interpretation of the data reported in the present Technical Manual, or in any similar documentation.
Trademarks, service marks and any product identification are Manuli Rubber Industries’ property at all times.
Printed in Italy, April 2009
© copyright by Manuli Rubber Industries S.p.A.
www.manuli-hydraulics.com - [email protected]
MRI
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