459-475 Hose Assemblies
459-475 Hose Assemblies
459-475 Hose Assemblies
In order to obtain the best service from any particular hose application, two important conditions must be fulfilled. 1) Select the right hose for the job. 2) Make sure that it is fitted correctly and used in the proper manner. Carefully consider the application requirements. A helpful guide is the S.T.A.M.P.E.D. process. S.T.A.M.P.E.D. is an acronym and stands for the seven major information areas required to provide a quality hose assembly.
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
S SIZE I.D., O.D., and length of the assembly T TEMPERATURE includes temperature of fluid conveyed and the climatic conditions A APPLICATION the conditions of use, including abrasion, flexing and routing M MATERIAL type of material conveyed, including composition and concentration P PRESSURE hose assembly working pressure and surge or back pressure E ENDS definition of the fitting, including thread type, gender, bent tube, swivel and orientation D DELIVERY time allowed for delivery, including testing, quality assurance and packaging
To assist in obtaining and conveying information regarding the application, a copy of the S.T.A.M.P.E.D. application form is included in this catalog. This inquiry sheet can be sent to any Goodyear Engineered Products authorized distributor for a hose recommendation. Please Note: A hose should always be selected based on its rated working pressure. Do not use minimum burst pressure as a guideline in selecting the hose. Minimum burst pressure decreases over the use and life of the hose. A hose should be selected based on its rated working pressure to provide a normal service life. In addition, always select a hose by giving consideration to its recommended temperature limits. Hose service life is reduced if the temperatures of the fluids being conveyed or ambient temperatures exceed the recommended limits.
459
O.D.
TEMPERATURE
of Material Being Conveyed (high, low, ambient)
Impulse
APPLICATION(S)
Indoor and/or Outdoor Use Intermittent or Continuous Use Flexibility Required (min. bend radius) Movement (static, vibrations, flexing) External Conditions: Abrasion
DELIVERY
Lead Time
Oil
Quantity Solvents Stock/Nonstock Acid Ozone Electrical/Static Conductive Oil Resistance: Tube Customer: Cover Customer No.: Flame Resistance Noncontaminating Materials Hose Currently in Use Service Life Desired Ship To: Bill To: Telephone: Fax: Special Print Special Packaging
OTHER INFORMATION
ASSEMBLIES ASSEMBLIES Date:
460
ADAPTERS
QUICK COUPLINGS
Velocity Tolerances
FITTINGS
SIZE
PRESSURE(S)
HOSE
S.T.A.M.P.E.D. FORM
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
Male Ends
Dash No. -2 -3 -4 -5 -6 -8 -10 -12 -14 -16 -20 -24 -32 -36 -40 -48 -56 -64 -72
mm in 3.2 4.8 6.4 3/16 7.9 1/4 9.5 5/16 12.7 13/32 15.9 1/2 19.0 5/8 22.2 25.4 7/8 31.8 1 1/8 38.1 1 3/8 50.8 1 13/16 57.6 63.5 2 3/8 76.2 88.9 101.6 115.2
Flange Ends
* SAE Dash Size equals O.D. of the tubing, which has approximately the same I.D. as the hose, expressed in 1/16.
461
The C cut-off factor can be obtained from the fitting product tables. An example is shown below.
Part No. Hose Thread Hose I.D. Dash Size (in) (mm) Size (in-TPI) 3/8 9.5 -6 9/16-18 Thread C Cut-Off Stem Dash Factor Hex Size (mm) (mm) -6 26.3 17
The following illustration shows the clockwise angle separation between a close fitting and a far fitting. The close fitting would be defined as the fitting closer when looking at an assembly end to end. The far fitting would be defined as the fitting on the far end of the assembly when looking at an assembly end to end. The far end is used as the reference point and the close end establishes the angular difference.
Knowing the overall length of the assembly desired, you subtract the C cut-off factor for each fitting from the overall length to obtain the hose cut length.
C2
Close End
Far End
462
APPENDIX
ASSEMBLIES ASSEMBLIES
ADAPTERS
QUICK COUPLINGS
The hose cut length for a hose assembly is calculated by subtracting the cut-off factor (distance from the bottom of the ferrule or collar to the end of the fitting or an internal sealing surface), denoted as C cut-off in the tables, from the actual assembly length required.
The offset angle between two fittings is the number of degrees measured in a clockwise direction between the fitting nearest the viewer and the farthest end fitting. Tolerances on the offset angle are +/- 3 degrees for assemblies up to 24 inches long and +/- 5 degrees for assemblies 24 inches and longer.
FITTINGS
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
6. Push and seat hose into the fitting. It is essential that the fitting be mated with a compatible hose style. Check fitting compatibility in hose or fitting product tables. To determine the insertion depth of the hose coupling, first measure the distance from the bottom of the fitting to the end of the ferrule where the hose is to be inserted. Mark a line on the hose cover at the distance from the end of the hose that equals the insertion depth. This becomes the visual check to determine if the hose was fully inserted in the fitting.
Cut-off saw. Use caution when operating power equipment. Follow the proper safety measures per manufacturer suggestions.
It is sometimes difficult to insert a fitting into hydraulic hose. If necessary, it is recommended using a liquid soap or a water/soap solution as a lubricant. Use the lubricant sparingly. When installing elbow fittings, point elbow towards curvature of the hose, unless specified otherwise. When installing elbow fittings on both ends, see the previous section on Measuring the Offset Angle. If the insertion mark was correctly applied, you should now be able to determine if the coupling has been completely inserted. The depth mark will be aligned with the end of the ferrule. In the case of a skived assembly, check that no skive shows and that couplings are on straight.
90
3. Ensure hose is cut squarely. 4. Contaminated hose may reduce the service life of hydraulic systems. Always clean the hose bore after cutting, using air and/or flush with a compatible fluid.
463
8. Place hose and fitting into the crimp machine. Crimp ferrule to predetermined diameter. Refer to the Goodyear Engineered Products Crimp Specifications Manual for proper crimp diameters and the crimper operators manual for further instructions on how to properly and safely operate the crimper.
7. Before crimping hose fitting, verify the tooling setup and install the proper die set. Read the Crimp Chart, per Goodyear Engineered Products recommendations, and dial in the correct crimp diameter.
464
APPENDIX
ASSEMBLIES ASSEMBLIES
9. Remove assembled end and check crimp diameter with caliper or micrometer. Crimp diameter should be measured at the center of the ferrule. Measure the smooth portion of the ferrule and not the ridges. Visually check for cracked, cocked or damaged fittings.
ADAPTERS
QUICK COUPLINGS
FITTINGS
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
Cut-off saw. Use caution when operating power equipment. Follow the proper safety measures per manufacturer suggestions.
90
465
6. The 2-piece crimped fitting consists of a ferrule and a stem insert. It is essential that the fitting be mated with a compatible hose style. Check fitting compatibility in hose or fitting product tables. Screw and/or push ferrule onto the hose until hose bottoms into the ferrule.
Always verify proper die set.
466
APPENDIX
ASSEMBLIES ASSEMBLIES
7. Push the stem insert into the hose I.D. Shoulder of the stem should make contact with ferrule. It is sometimes difficult to insert the stem into hydraulic hose. If necessary, it is recommended using a liquid soap or a water/soap solution as a lubricant. Use the lubricant sparingly. When installing elbow fittings, point elbow towards curvature of the hose, unless specified otherwise. When installing elbow fittings on both ends, see the previous subtopic on Measuring the Offset Angle.
ADAPTERS
QUICK COUPLINGS
5. In certain situations, skiving may be required. Skiving is the process of removing the portion of hose cover that lies directly under the coupling ferrule. This allows the metal fitting to be coupled directly on the hose reinforcement. Skiving is further discussed in the following section under the subtopic of Internal and External Skiving.
FITTINGS
4. Contaminated hose may reduce the service life of hydraulic systems. Always clean the hose bore after cutting, using air and/or flush with a compatible fluid.
8. Before crimping hose fitting, verify the tooling setup and install the proper die set. Read the Crimp Chart, per Goodyear Engineered Products recommendations, and dial in the correct crimp diameter.
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
Refer to the Final Inspection Checklist and Recommended Inspection Equipment previously listed in Hose Assembly Instructions Using a 1-Piece Crimped Fitting. Insert hose assembly into crimper die set.
10. Remove assembled end and check crimp diameter with caliper or micrometer. Crimp diameter should be measured at the center of the ferrule. Measure the smooth portion of the ferrule and not the ridges. Visually check for cracked, cocked or damaged fittings.
Cut-off saw. Use caution when operating power equipment. Follow the proper safety measures per manufacturer suggestions.
467
90
4. Contaminated hose may reduce the service life of hydraulic systems. Always clean the hose bore after cutting, using air and/or flush with a compatible fluid. 5. A Field-Grip fitting consists of a socket and stem assembly. |t is essential the fitting be mated with a compatible hose style. Check fitting compatibility in hose or fitting product tables. Place the socket in a vice. The socket will fit over the hose cover. To determine the insertion depth for the hose, first measure the distance from the bottom of the socket to the end of the socket where the hose is to be inserted. Transfer this insertion depth to the hose cover by measuring from the end of the hose. Mark a line on the hose cover at the distance from the end of the hose that equals the insertion depth. This becomes the visual check to determine if the hose was fully inserted in the socket.
6. Lightly lubricate hose cover with a mild soap solution. Screw end of hose counterclockwise until hose reaches the marked insertion depth and then back off 1/2 turn. If the insertion mark was correctly applied to the hose, you should now be able to determine if the socket has been correctly applied to the hose by using the insertion depth mark on the hose cover as a reference along with a visual check inside the socket.
468
APPENDIX
ASSEMBLIES ASSEMBLIES
ADAPTERS
QUICK COUPLINGS
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
469
Skiving is the process of stripping and removing the hose cover to allow the proper installation of crimped hose ends and to ensure the best possible hose assembly. 1. At the point of skiving, the hose has been cut to the proper length. See Steps 1 and 2 in the previous hose assembly instructions. 2. Obtain length of skive per Goodyear Engineered Products specifications. Mark hose with skive length.
3. Remove the hose cover to the wire, using care not to burn, fray or damage reinforcement wires. The cover of wire-braided hoses can be removed with a buffing wheel or a hand skiver. A manual, external skiving tool that uses a knife must be used with spiral hose. Mark the length of the cover to be removed, as noted in the Goodyear Engineered Products Crimp Specifications Manual, and set skiving depth on the manual skiving tool. Make sure the manual skiver is rotated in the counterclockwise direction for external skiving. Follow specific instructions on external skiving that would accompany the manual skiver.
Measure skive.
5. Check for the proper skive length. 6. Hoses should be checked for 100% of cover removal. If necessary, rebuff skived area to clean and remove hose cover. 7. A manual, internal skiving tool that uses a knife is to be used to remove the tube material of spiral hose for installation of the Dual-Grip fittings. Note the correct length of tube material to be removed from the Goodyear Engineered Products Crimp Specification Manual. Set the desired skiving depth on the internal skiving tool. Make sure the tool rotates in the clockwise direction for internal skiving. Verify that the correct length of tube material has been removed. Follow specific instructions on internal skiving that would accompany the manual skiver. 8. It is important to clean hose I.D. by brushing, blowing compressed air or flushing to remove any contaminants.
Cutting skive with buffing wheel. Follow manufacturers recommendation for the safe and proper use of the skiver.
Warning: Failure to completely remove the cover may result in serious personal injury or property damage due to hose ends blowing off, leakage or other failures.
470
APPENDIX
ASSEMBLIES ASSEMBLIES
ADAPTERS
QUICK COUPLINGS
FITTINGS
4. With the hose cover removed, check that the wire braid or spiral reinforcement has not been displaced, damaged or cut in the skiving process.
HOSE
INTERNALANDEXTERNALSKIVING
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
This will prevent the wire from flaring once the cut is made. If wire flare is allowed to occur, the ferrule will not slide onto the hose.
2. Slip ferrules on. Be sure they are in the correct direction. (i.e. flange side aims to the outside of the hose.) 3. Push in on stem on each end. 4. Remove the tape and slide the ferrule onto the stem.
471
472
APPENDIX
ASSEMBLIES ASSEMBLIES
ADAPTERS
QUICK COUPLINGS
FITTINGS
5. Crimp the fitting using proper die selection and setting. Be sure not to allow the ferrule to slip back onto the hose or ride up on the hub of the stem. The groove of the ferrule must line up with flange of the stem.
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
Special care should be taken when selecting the proper refrigerant hose and fittings. Goodyear Engineered Products Cool-Clip fittings should only be used with Goodyear Engineered Products Galaxy 4890 hose. Special care must be taken when working with refrigerant systems. Sudden escape of refrigerant gases may result in blindness or severe injury. Goodyear Engineered Products recommends adherence to guidelines and general practices as defined in SAE J2211 for the service containment of HFC-134a as well as all applicable EPA guidelines and procedures concerning the service of refrigerant systems.
4. Lubricate the fitting with a generous amount of the A/C systems lubricator oil. This is to lower the force of the insertion. 5. Insert the fitting into the hose. Ensure that the fitting is fully inserted so that there is no gap between the end of the hose, the clip retainer and the shoulder of the fitting.
6. Close both clips with the Goodyear Engineered Products clip pliers, PN GC-Pliers-0001. The pliers will automatically release when the clips have been completely closed. Start with the clip closer to the end of the hose.
90
2. Install two proper-sized clips into the clipholder. For ease of assembly, both clips should have the same orientation.
3. Place the clipholder with the two clips on the hose. Install the clipholder so that the end with the smallest hole touches the end of the hose.
If there are any questions as to what fitting should be used, Veyance recommends that you consult the local Field Representative or Goodyear Hydraulics Application Group for assistance.
473
1. Insert the pressure plate into the bottom flange of the crimper, making sure that it is seated completely into the bottom flange.
3. Place the compression ring loosely but evenly over the die set. Make sure die set is correctly aligned. 4. Slide the pusher in place.
6. Attach the coupling stop, included with your crimper, to the base of the crimper.
Be Sure To: Lubricate the contact surfaces: both bottom and outside edges of the die fingers, the inside of the compression ring and the pressure plate with the die lubricant provided with the crimper. Only use a molybdenum/graphite highpressure grease applied sparingly to the contact surfaces. Die lubricant can be obtained from Goodyear Engineered Products using part numbers PC900-Grease-3oz or PC900-Grease-1lb. An aerosol lubricant, PC900-AerosolLube, can also be used. Failure to lubricate the contact surfaces with the correct lubricant will cause the dies to seize in the compression ring, causing damage to the die set as well as possibly damaging the crimper.
8. Insert the hose end fully into the ferrule of the corresponding fitting. When completely inserted, the hose should be visible through the witness hole on the side of the ferrule.
474
APPENDIX
7. Select the appropriate Galaxy hose size and cut to the correct length using Goodyear Engineered Products Hose Cutting Tool (part #65090). Be sure the hose is cut squarely at a 90-degree angle to the hose.
ASSEMBLIES ASSEMBLIES
G4826-06 5/16 G4826-08 13/32 G4826-10 1/2 G4826-12 5/8 G4867-14 3/4
5. Set the micrometer to the setting as shown in the Goodyear Crimp Specification Manual for the combination of hose and fitting being crimped. The metric micrometer (readings of 0 to 10) is a direct reading micrometer. The setting on the micrometer is added to the number in millimeters etched on the die ring to obtain the final crimp diameter. The adjuster, set at 0, is the setting for the die set fully closed. For example, with a 34mm die and the micrometer set at 3.0, the finished crimp diameter would be 37.0mm (34mm + 3.0mm).
ADAPTERS
2. Select the correct die set for the Galaxy hose dash size/I.D. and AC fitting being crimped. Insert the two halves of the die set onto the pressure plate, making sure both halves are flat and level.
QUICK COUPLINGS
FITTINGS
HOSE
HOSE FITTINGS QUICK COUPLINGS ADAPTERS EQUIPMENT & ACCESSORIES ASSEMBLIES ASSEMBLIES INSTALLATION & MAINTENANCE APPENDIX
13. Check the completed assembly to be sure that the hose is still visible through the witness hole on the fitting. Also, the crimp grooves should be centered on the fitting ferrule.
CAUTION:The notches on the die set must be completely covered by the compression ring prior to starting the crimp. If the notches are showing, you must go to a larger die set. Crimping with an incorrect die size could result in personal injury. If the crimp grooves are too near the fitting end of the ferrule, or too near the hose end of the ferrule, the fitting may not seal properly and the assembly could leak. If your finished crimp assembly resembles either of the two examples shown below, the end of the ferrule was not properly positioned against the coupling stop foot, or the coupling stop foot was not resting on the top of the die set when crimped. A new assembly should be crimped, being sure to follow the procedures in Step 9.
Each die set has a limited range of diameters for which a satisfactory crimp can be obtained. Always consult the Goodyear Engineered Products Crimp Specification Manual for selecting the correct die set. 11. Recheck the fitting for the correct alignment in the die set and depress the start/stop switch. Hold the start/stop switch until the automatic stop switch shuts the pump off. Release the start/stop switch and allow the pusher to return to the retracted position. 12. Check the crimp diameter of the finished assembly with a caliper or micrometer to be certain that it is within the specifications as outlined in the Goodyear Engineered Products Crimp Specification Manual. The caliper measurement should be taken in the crimp groove between the ridges as shown.
475
Note: This service is not intended for secure transactions such as banking, social media, email, or purchasing. Use at your own risk. We assume no liability whatsoever for broken pages.
Alternative Proxies: