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  • HOSE ASSEMBLY ASSURANCE MANUAL

    HOSE ASSEMBLY ASSURANCE MANUAL

    REV.                    QUALITY ASSURANCE                 SIGNATURE

    OF                                     QAS

                                              PRODUCTION                           SIGNATURE

                                               PRODS     

    APPROVED BY          ENGINEERING MGR.              SIGNATURE

    COPY TO                                                   UNIT

    1. GOAL
    2. APPLICATION FIELD
    3. ABBREVIATIONS
    4. RESPONSABILITIES
    5. CONTENTS OF HOSE ASSEMBLY ASSURANCE MANUAL

    Phase 1                        Hose Type
    Phase 2                       Cut Length/Interaxle Length
    Phase 3                       Out Side Skive
    Phase 4                        Inside Skive
    Phase 5                        Inside/Outside Skive Control
    Phase 6                        1st Fitting/2nd Fitting
    Phase 7                        Orientation
    Phase 8                        Crimping Diameter and Crimping Diameter Control
    Phases 9                      Manufacturing Date Marking
    Phase 10                      Proof Test (if requested)
    Phase 11                      Hose Flushing (if requested)
    Phase 12                     Capping (if requested)

    SHEETS OF REFERENCE

    1. MANUFACTURING AND CONTROL SHEET
    2. INTERNAL ORDER
    3. INTERAXLE LEGTH INERPRETATION
    4. FITTING ORIENTATION
    5. CRIMPING DIAMETER CHART
    6. INSTRUCTIONS P32/FP110
    7. HOSE FLUSHING – REGOLATION MACHINE CHART
    8. PROOF TEST REPORT

    1.0 GOAL
    Hose Assembly Assurance Manual defines assembly process in order to garantee and assure that all operation of assembly productions are made following requirements requested by Customer Specifications e by Manuli Specifications.
    2.0 APPLICATION FIELD
    Work and control phases described in this Manual are applicable only to the activity of Hose Assembly production.
    Each assembly phase is numbered with reference to Manufacturing and Control Sheet
    3.0 ABBREVIATIONS
    STOS              :           STORE SUPERVISOR
    PROD             :           PRODUCTION
    PRODS           :           PRODUCTIONE SUPERVISOR
    QAS                :           QUALITY ASSURANCE SUPERVISOR
    NC                  :           NON CONFORM PRODUCT
    MF/C               :           MANUFACTURING AND CONTROL SHEET
    4.0 RESPONSABILITY
    PRODS

    • Issue MF/C with reference to internal order and give to production.
    • Operate swaging machine. At this operation, PRODS has to assure on every hose assembly that they are made following MF/C.

    PROD

    • Has the responsibility to assembly and to control along the manufacturing process following what is written in SF/C.

    QAS

    • Operate test pressure machine and report test result.
    • Issue NON CONFORM PRODUCT SHEET of NC

    PHASE 1                                       HOSE TYPE

    OPERATIONS MACHINE SHEET OF REFERENCE
    Take from the storage the type of hose with the same code indicated on MF/C
    Write the hose lot# on M/FC
    Attention: to facilitate traceability of hose assembly, the type of hose used to manufacture a single lot of hose assembly must possibly be of the same lot

    PHASE 2                      CUT LENGTH / INTERAXLE LENGTH

    OPERATIONS MACHINE SHEET OF REFERENCE
    Cut length is indicated in MF/C. If it is not specified, operate as follow:
    n     consider interaxle length “L” of assembly indicated in MF/C;
    n     subtract from the measure of interaxle length “L”  the sum of fittings length “x”, considering the measure from the abutting end of rubber hose to the fitting interaxle
    n     subtract to the result obtained the extension obtained  during the crimping phase (5mm for braided hose and 8mm for spiralled hose)    		  
     
    L
     
    Cut Length - InterAxle Length
     
     
     
     
     
    x
    Set the hose cut measure steel ruler
    Attention: cut must be perpendicular to the hose
     
     
         		 Hose Cut Measurement cut section
    YES
    NO
    Switch on the machine and wait until the number of cycles is stable. cutting machine
    Rule downward speed of blade (knife) depending on type of hose to be cut. A wrong regulation of downward speed can break the blade. For spiralled hose : minimum speed for all other types : normal speed. cutting machine
    Speed can be regulated with the handle on the left of cutting machine.  Turning the handle anticlockwise speed increases and viceversa.
     
     
         		 cutting machine Front side
    Cutting Machine Front Side
    handle
    Control cut rubber hose length and writ it on MF/C. Steel ruler

    PHASE 3                                                    OUTSIDE SKIVE

    OPERATION MACHINE SHEET OF REFERENCE
    Take the pin guide of the same diameter of hose to be skived (see marking on the pin).
    Set the pin as the skive length indicated on MF/C measuring with caliper the distance between the abutting  of pin and the knife. Skive machine
    Set the phase inverter to wheel the mandrel to anticlockwise
    Switch the skive machine with the foot -switcher
    Insert the hose in the mandrel to skive.
    Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
    Be careful not to leave rubber dross, shavings on the hose.
    Attention: skive has to be done just on hose with metallic reinforce.

    PHASE 4                                                              INSIDE SKIVE

    OPERATIONS MACHINE SHEET OF REFERENCE
    Spiralled hose must be skived inside.
    Take the guide pin of the same diameter of the hose to be skived (see marking on the pin).
    Set the ghiera as the skive length indicated on MF/C measuring the distance between the ghiera abutting and the knife. Skive machine
    Set the phase inverter to wheel the mandrel to clockwise
    Switch the skive machine with the foot -switcher
    Insert the hose in the mandrel to skive.
    Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
    Be careful not to leave rubber droll, shavings inside the hose.

    PHASE 5                                           INSIDE/OUTSIDE SKIVE CONTROL

    OPERATIONS MACHINE SHEET OF REFERENCE
    Control the skive length with caliper as indicated in MF/C. Caliper
    Operator must also consult with skiving chart for the skive length in order to prevent too long/to short skive. Skiving Chart
    If skive is out of the range, put the assembly hose in a NC area, QAS to fill the Non Conformity product sheet. Non Conformity Product Sheet

    PHASES 6                                1ST FITTING / 2ND FITTING

    OPERATIONS MACHINE SHEET OF REFERENCE
    Fittings are stored boxes identified with the product code which recorded in stock cards and/or computer.
    Take fittings indicated on MF/C of the same box.
    Put in the fittings to the hoses as indicated on MF/C.

    PHASE 7                                           ORIENTATION

    OPERATIONS MACHINE SHEET OF REFERENCE
    Block fittings in the vice. Vice
    Turn manually the other fitting, following the chart enclosed, till the value indicated on MF/C is visible on goniometer Goniometer

    PHASES 8                          MANUFACTURING DATE MARKING

    OPERATIONS MACHINE SHEET OF REFERENCE
    Use electric pen to mark
    date-month-year on the ferrule of the assembly hose.
     
    Example : 30/12/43    		       Electric Pen

    PHASES 9                   CRIMPING DIAMETER AND CRIMPING DIAMETER  CONTROL

    OPERATIONS MACHINE SHEET OF REFERENCE
    The crimping diameter is indicated on MF/C.
    Consult crimping diameter chart to choose the set of dies required for the crimping diameter requested. P32/FP 110 Crimping Diameter Chart
    Be sure the machine is turned off.
    Put in the correct dies. Make sure that all dies are completely sit on the master dies.
    Operator must also consult with the crimping diameter chart in order to prevent the out of range of crimping diameter. Crimping Diameter Chart
    Switch the machine on. P32/FP 110 Instructions P32/FP110
    Set the right crimping diameter with the diameter setting device. “ Instructions P32/FP110
    Push the press button to crimp the hose. “ Instructions P32/FP110
    Control the crimping diameter with caliper. Operator must measure the crimping diameter in every change of diameter setting
    If crimping diameter is out of range, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet. Non Conformity Product Sheet

    PHASE 10                                         PROOF TEST (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    Supply the bench with connections conform to hose to be tested. Pressure bench Customer Specifications
    Switch on the bench and the computer.
    Select or create the recipe. Remember that the proof pressure is double the working pressure written on the rubber hose.
    Close the door and start the bench.
    When cycle is finished write results on MF/C.
    Print the report if requested by the Customer.
    If there is leakage along the rubber or on the fittings, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet. Non Conformity Product Sheet

    PHASE 11                               HOSE FLUSHING (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    THE USE OF GLOVES IN THIS PHASE IS COMPULSORY
    Control oil level with dipstick. If oil is under the half fill it up with oil. Dipstick
    Prepare the machine according to the hoses diameter, following the machine chart for the time and number of pumps FMX 150 MOD. MOT06
    Screw hoses on the rack in the correct way, being careful with long hoses, with wide bend radius (it is sufficient to screw two turns)
    Push the two buttons on the sides of the bench. Door closes and automatically cycle works.
         		                     Front side
    Test Bench Front Side Push Button
     
     
     
    buttons
    Door opens automatically, unscrew the hoses and put them on the rack to drip.
    Attention: fluid used in this phase is oil for spark erosion (BP/HP-0 FINA IT/11-004 FINA PARAPUR/1013) and pollution grade to specifics NAS 1638 is checked monthly in an outside laboratory.
    According to the analysis results: if the value of fluid is less or equal to 8 NAS can be used till the following month; if it is more or equal to 9 NAS must be changed by TEQ.

    PHASE 12                                                  CAPPING (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    Take caps according to hose type and diameter.
    Cap fittings when hoses are completely dry (if flushed).

    NOTE
    The handling of hoses from the cutting phase to the fitting assembly/crimping one and from the latter and the flushing phase, has to be done by racks which can garantee outside hose cleanliness and prevent abrasions due to trailing along the floor.

     

  • New era marketing for hydraulic hose workshops.

    DESIGN OF HYDRAULIC HOSE WORKSHOP

    HYD HOSE SERVIVE MINING _ Hose Layout Workhop
    EGAT Workshop No 300 Layout-001
    New era marketing for hydraulic hose workshops _ 18
    New-era-marketing-for-hydraulic-hose-workshops-_-19-1.jpg
    GENERAL / Tightening

    PERIODIC REPLACEMENT OF PARTS

    To ensure safe operation, be sure to conduct periodic inspection of the machine. In addition, the parts listed below, if defective, may pose serious safety/fire hazards. It is very difficult to gauge the extent of deterioration, fatigue, or weakening of the parts listed below simply by visual inspection alone. For this reason, replace these parts at the intervals shown in the table below. However, if any of these parts are found to be
    defective, replace before starting operation, regardless of the interval.
    Also, when replacing hoses, check the clamps for deformation, cracks, or other deterioration, and replace as necessary.
    Be sure to perform periodic inspection of all hoses, as shown below, and replace or retighten any defective parts found, as necessary.
    Consult your authorized dealer for correct replacement.

    Periodic Replacement Parts  – Replacement Intervals

    • Oil filter hose (Engine to oil filter) Every 2 years or Every 6000 hours
    • Fuel hose ( Engine Fuel tank to injection pump) Every 2 years or Every 6000 hours
    • Heater hose (Heater to engine) Every 2 years or Every 6000 hours
    • Pump suction hose Every 2 years or Every 6000 hours
    • Pump delivery hose Every 2 years or Every 6000 hours
    • Swing hose Every 2 years or Every 6000 hours
    • Travel hose Every 2 years or Every 6000 hours
    • Boom cylinder line hose Every 2 years or Every 6000 hours
    • Arm cylinder line hose Every 2 years or Every 6000 hours
    • Bucket cylinder line hose Every 2 years or Every 6000 hours
    • Pilot hose Every 2 years or Every 6000 hours

    NOTE: Replace seals, such as O-rings and gaskets,
    when replacing hoses.
    New era marketing for hydraulic hose workshops _ 01

    SAFETY

    PREVENT BURNS
    Hot spraying fluids:
    • After operation, engine coolant is hot and under pressure. Hot water or steam is contained in the engine, radiator and heater lines. Skin contact with escaping hot water or steam can cause severe burns.

    • To avoid possible injury from hot spraying water. DO NOT remove the radiator cap until the engine is cool. When opening, turn the cap slowly to the stop. Allow all pressure to be released before removing the cap.

    • The hydraulic oil tank is pressurized. Again, be sure to release all pressure before removing the cap.

    Hot fluids and surfaces:
    • Engine oil, gear oil and hydraulic oil also become hot during operation. The engine, hoses, lines and other parts become hot as well.
    • Wait for the oil and components to cool before starting any maintenance or inspection work.
    REPLACE RUBBER HOSES PERIODICALLY
    • Rubber hoses that contain flammable fluids under pressure may break due to aging, fatigue, and abrasion. It is very difficult to gauge the extent of deterioration due to aging, fatigue, and abrasion of rubber hoses by inspection alone.

    • Periodically replace the rubber hoses. (See the page of “Periodic replacement of parts” in the operator’s manual.)
    • Failure to periodically replace rubber hoses may cause a fire, fluid injection into skin, or the front attachment to fall on a person nearby, which may result in severe burns, gangrene, or otherwise serious injury or death.

    New era marketing for hydraulic hose workshops _ 02
    PREVENT FIRES
    Check for Oil Leaks:
    • Fuel, hydraulic oil and lubricant leaks can lead to fires.

    • Check for oil leaks due to missing or loose clamps, kinked hoses, lines or hoses that rub against each other, damage to the oil-cooler, and loose oil-cooler flange bolts.
    • Tighten, repair or replace any missing, loose or damaged clamps, lines, hoses, oil-cooler and oil-cooler flange bolts.
    • Do not bend or strike high-pressure lines.
    • Never install bent or damaged lines, pipes, or hoses.

    New-era-marketing-for-hydraulic-hose-workshops-_-03.jpg
    AVOID HEATING NEAR PRESSURIZED FLUID LINES
    • Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders.

    • Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials.
    • Pressurized lines can be accidentally cut when heat goes beyond the immediate flame area. Install temporary fire-resistant guards to protect hoses or other materials before engaging in welding, soldering, etc..

    New-era-marketing-for-hydraulic-hose-workshops-_-04.jpg

    GENERAL / Precautions for Disassembling and Assembling

    GENERAL / Tightening
    TIGHTENING TORQUE SPECIFICATIONS
    New era marketing for hydraulic hose workshops _ 06New era marketing for hydraulic hose workshops _ 05New era marketing for hydraulic hose workshops _ 06New era marketing for hydraulic hose workshops _ 08New era marketing for hydraulic hose workshops _ 07New era marketing for hydraulic hose workshops _ 08

    GENERAL / Tightening

    PIPING JOINTNew-era-marketing-for-hydraulic-hose-workshops-_-09-2728359931-1565132472712.jpg

    IMPORTANT:

    The torques given in the chart are for general use only.
    Do not use these torques if a different torque is given for a specific application.

    Union JointNew era marketing for hydraulic hose workshops _ 10

    Metal sealing surfaces (4) and (5) of adapter (1) and hose (2) fit together to seal pressure oil. Union joints are used to join small-diameter lines.
    IMPORTANT:

    1. Do not over-tighten nut (3). Excessive force will be applied to metal sealing surfaces (4) and (5),possibly cracking adapter (1). Be sure to  tighten nut (3) to specifications.

    2. Scratches or other damage to sealing surfaces (4) or (5) will cause oil leakage at the joint. Take care not to damage them when connecting/disconnecting.

    New era marketing for hydraulic hose workshops _ 11

    GENERAL / Tightening

    Screw-In Connection New era marketing for hydraulic hose workshops _ 12

    Depending on types of screw and sealing, different types of screw fittings are used.
    IMPORTANT:
    Be sure to confirm that the thread pitch and thread type (tapered or straight) are the correct type before using any screw-in connection.
    New era marketing for hydraulic hose workshops _ 13

    Seal Tape Application New era marketing for hydraulic hose workshops _ 14

    Seal tape is used to seal clearances between male
    and female threads, so as to prevent any leaks between threads.
    Be sure to apply just enough seal tape to fill up thread
    clearances. Do not overwrap.
    • Application Procedure
    New era marketing for hydraulic hose workshops _ 15
    Confirm that the thread surface is clean and, free of dirt or damage.
    Apply seal tape around threads as shown. Wrap seal tape in the same direction as the threads.

    Low-Pressure-Hose Clamp Tightening Torque

    Low-pressure-hose clamp tightening torque differs depending on the type of clamp. New era marketing for hydraulic hose workshops _ 16
    T-Bolt Type Band Clamp:
    4.4 N⋅m (0.45 kgf⋅m, 3.25 lbf⋅ft )
    Worm Gear Type Band Clamp:
    5.9 to 6.9 N⋅m (0.6 to 0.7 kg⋅m, 4.3 to 5.1 lbf⋅ft)

    GENERAL / Tightening

    Connecting HoseNew era marketing for hydraulic hose workshops _ 17

    CAUTION:

    When replacing hoses, be sure to use only genuine Hitachi service parts. Using hoses other than genuine Hitachi hoses may cause oil leaks, hose rupture or Separation of fitting, possibly resulting in a fire on the machine.

    Do not install hoses kinked. Application of high oil pressure, vibration, or an impact to a kinked hose may result in oil leaks, hose rupture or separation of fitting. Utilize Print marks on hoses when installing to prevent hose from being kinked.

    If hoses rub against each other, wear to the hoses will result, leading to hose rupture. Take necessary measures to protect hoses from rubbing against each other.

    Take care so that hoses do not come into contact with moving parts or sharp objects.

    Workshop Shape Design

    New era marketing for hydraulic hose workshops _ 18New era marketing for hydraulic hose workshops _ 19

     

  • HOSE ASSEMBLY ASSURANCE MANUAL

    HOSE ASSEMBLY ASSURANCE MANUAL

    REV.                    QUALITY ASSURANCE                 SIGNATURE

    OF                                     QAS

                                              PRODUCTION                           SIGNATURE

                                               PRODS     

    APPROVED BY          ENGINEERING MGR.              SIGNATURE

    COPY TO                                                   UNIT

    1. GOAL
    2. APPLICATION FIELD
    3. ABBREVIATIONS
    4. RESPONSABILITIES
    5. CONTENTS OF HOSE ASSEMBLY ASSURANCE MANUAL

    Phase 1                        Hose Type
    Phase 2                       Cut Length/Interaxle Length
    Phase 3                       Out Side Skive
    Phase 4                        Inside Skive
    Phase 5                        Inside/Outside Skive Control
    Phase 6                        1st Fitting/2nd Fitting
    Phase 7                        Orientation
    Phase 8                        Crimping Diameter and Crimping Diameter Control
    Phases 9                      Manufacturing Date Marking
    Phase 10                      Proof Test (if requested)
    Phase 11                      Hose Flushing (if requested)
    Phase 12                     Capping (if requested)

    SHEETS OF REFERENCE

    1. MANUFACTURING AND CONTROL SHEET
    2. INTERNAL ORDER
    3. INTERAXLE LEGTH INERPRETATION
    4. FITTING ORIENTATION
    5. CRIMPING DIAMETER CHART
    6. INSTRUCTIONS P32/FP110
    7. HOSE FLUSHING – REGOLATION MACHINE CHART
    8. PROOF TEST REPORT

    1.0 GOAL
    Hose Assembly Assurance Manual defines assembly process in order to garantee and assure that all operation of assembly productions are made following requirements requested by Customer Specifications e by Manuli Specifications.
    2.0 APPLICATION FIELD
    Work and control phases described in this Manual are applicable only to the activity of Hose Assembly production.
    Each assembly phase is numbered with reference to Manufacturing and Control Sheet
    3.0 ABBREVIATIONS
    STOS              :           STORE SUPERVISOR
    PROD             :           PRODUCTION
    PRODS           :           PRODUCTIONE SUPERVISOR
    QAS                :           QUALITY ASSURANCE SUPERVISOR
    NC                  :           NON CONFORM PRODUCT
    MF/C               :           MANUFACTURING AND CONTROL SHEET
    4.0 RESPONSABILITY
    PRODS

    • Issue MF/C with reference to internal order and give to production.
    • Operate swaging machine. At this operation, PRODS has to assure on every hose assembly that they are made following MF/C.

    PROD

    • Has the responsibility to assembly and to control along the manufacturing process following what is written in SF/C.

    QAS

    • Operate test pressure machine and report test result.
    • Issue NON CONFORM PRODUCT SHEET of NC

    PHASE 1                                       HOSE TYPE

    OPERATIONS MACHINE SHEET OF REFERENCE
    Take from the storage the type of hose with the same code indicated on MF/C
    Write the hose lot# on M/FC
    Attention: to facilitate traceability of hose assembly, the type of hose used to manufacture a single lot of hose assembly must possibly be of the same lot

    PHASE 2                      CUT LENGTH / INTERAXLE LENGTH

    OPERATIONS MACHINE SHEET OF REFERENCE
    Cut length is indicated in MF/C. If it is not specified, operate as follow:
    n     consider interaxle length “L” of assembly indicated in MF/C;
    n     subtract from the measure of interaxle length “L”  the sum of fittings length “x”, considering the measure from the abutting end of rubber hose to the fitting interaxle
    n     subtract to the result obtained the extension obtained  during the crimping phase (5mm for braided hose and 8mm for spiralled hose)    		  
     
    L
     
    Cut Length - InterAxle Length
     
     
     
     
     
    x
    Set the hose cut measure steel ruler
    Attention: cut must be perpendicular to the hose
     
     
         		 Hose Cut Measurement cut section
    YES
    NO
    Switch on the machine and wait until the number of cycles is stable. cutting machine
    Rule downward speed of blade (knife) depending on type of hose to be cut. A wrong regulation of downward speed can break the blade. For spiralled hose : minimum speed for all other types : normal speed. cutting machine
    Speed can be regulated with the handle on the left of cutting machine.  Turning the handle anticlockwise speed increases and viceversa.
     
     
         		 cutting machine Front side
    Cutting Machine Front Side
    handle
    Control cut rubber hose length and writ it on MF/C. Steel ruler

    PHASE 3                                                    OUTSIDE SKIVE

    OPERATION MACHINE SHEET OF REFERENCE
    Take the pin guide of the same diameter of hose to be skived (see marking on the pin).
    Set the pin as the skive length indicated on MF/C measuring with caliper the distance between the abutting  of pin and the knife. Skive machine
    Set the phase inverter to wheel the mandrel to anticlockwise
    Switch the skive machine with the foot -switcher
    Insert the hose in the mandrel to skive.
    Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
    Be careful not to leave rubber dross, shavings on the hose.
    Attention: skive has to be done just on hose with metallic reinforce.

    PHASE 4                                                              INSIDE SKIVE

    OPERATIONS MACHINE SHEET OF REFERENCE
    Spiralled hose must be skived inside.
    Take the guide pin of the same diameter of the hose to be skived (see marking on the pin).
    Set the ghiera as the skive length indicated on MF/C measuring the distance between the ghiera abutting and the knife. Skive machine
    Set the phase inverter to wheel the mandrel to clockwise
    Switch the skive machine with the foot -switcher
    Insert the hose in the mandrel to skive.
    Skive depth must unwrap rubber to void damage till metallic reinforce is visible.
    Be careful not to leave rubber droll, shavings inside the hose.

    PHASE 5                                           INSIDE/OUTSIDE SKIVE CONTROL

    OPERATIONS MACHINE SHEET OF REFERENCE
    Control the skive length with caliper as indicated in MF/C. Caliper
    Operator must also consult with skiving chart for the skive length in order to prevent too long/to short skive. Skiving Chart
    If skive is out of the range, put the assembly hose in a NC area, QAS to fill the Non Conformity product sheet. Non Conformity Product Sheet

    PHASES 6                                1ST FITTING / 2ND FITTING

    OPERATIONS MACHINE SHEET OF REFERENCE
    Fittings are stored boxes identified with the product code which recorded in stock cards and/or computer.
    Take fittings indicated on MF/C of the same box.
    Put in the fittings to the hoses as indicated on MF/C.

    PHASE 7                                           ORIENTATION

    OPERATIONS MACHINE SHEET OF REFERENCE
    Block fittings in the vice. Vice
    Turn manually the other fitting, following the chart enclosed, till the value indicated on MF/C is visible on goniometer Goniometer

    PHASES 8                          MANUFACTURING DATE MARKING

    OPERATIONS MACHINE SHEET OF REFERENCE
    Use electric pen to mark
    date-month-year on the ferrule of the assembly hose.
     
    Example : 30/12/43    		       Electric Pen

    PHASES 9                   CRIMPING DIAMETER AND CRIMPING DIAMETER  CONTROL

    OPERATIONS MACHINE SHEET OF REFERENCE
    The crimping diameter is indicated on MF/C.
    Consult crimping diameter chart to choose the set of dies required for the crimping diameter requested. P32/FP 110 Crimping Diameter Chart
    Be sure the machine is turned off.
    Put in the correct dies. Make sure that all dies are completely sit on the master dies.
    Operator must also consult with the crimping diameter chart in order to prevent the out of range of crimping diameter. Crimping Diameter Chart
    Switch the machine on. P32/FP 110 Instructions P32/FP110
    Set the right crimping diameter with the diameter setting device. “ Instructions P32/FP110
    Push the press button to crimp the hose. “ Instructions P32/FP110
    Control the crimping diameter with caliper. Operator must measure the crimping diameter in every change of diameter setting
    If crimping diameter is out of range, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet. Non Conformity Product Sheet

    PHASE 10                                         PROOF TEST (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    Supply the bench with connections conform to hose to be tested. Pressure bench Customer Specifications
    Switch on the bench and the computer.
    Select or create the recipe. Remember that the proof pressure is double the working pressure written on the rubber hose.
    Close the door and start the bench.
    When cycle is finished write results on MF/C.
    Print the report if requested by the Customer.
    If there is leakage along the rubber or on the fittings, put the assembly hose in a NC area, QAS to fill the Non Conformity Product Sheet. Non Conformity Product Sheet

    PHASE 11                               HOSE FLUSHING (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    THE USE OF GLOVES IN THIS PHASE IS COMPULSORY
    Control oil level with dipstick. If oil is under the half fill it up with oil. Dipstick
    Prepare the machine according to the hoses diameter, following the machine chart for the time and number of pumps FMX 150 MOD. MOT06
    Screw hoses on the rack in the correct way, being careful with long hoses, with wide bend radius (it is sufficient to screw two turns)
    Push the two buttons on the sides of the bench. Door closes and automatically cycle works.
         		                     Front side
    Test Bench Front Side Push Button
     
     
     
    buttons
    Door opens automatically, unscrew the hoses and put them on the rack to drip.
    Attention: fluid used in this phase is oil for spark erosion (BP/HP-0 FINA IT/11-004 FINA PARAPUR/1013) and pollution grade to specifics NAS 1638 is checked monthly in an outside laboratory.
    According to the analysis results: if the value of fluid is less or equal to 8 NAS can be used till the following month; if it is more or equal to 9 NAS must be changed by TEQ.

    PHASE 12                                                  CAPPING (IF REQUESTED)

    OPERATIONS MACHINE SHEET OF REFERENCE
    Take caps according to hose type and diameter.
    Cap fittings when hoses are completely dry (if flushed).

    NOTE
    The handling of hoses from the cutting phase to the fitting assembly/crimping one and from the latter and the flushing phase, has to be done by racks which can garantee outside hose cleanliness and prevent abrasions due to trailing along the floor.

     

G-2GCKRJZY3J