KOMATSU—__4&*=— Training Aid @ HIGH PRESSURE HOSE FOR HYDRAULIC SYSTEM A hydraulic pump to the hydraulic system is equivalent to the heart to the huatian body. If So, piping to the hydraulic system corresponds to the artery to the human body. Holding a high pressure hose by hand as a hand-rail or treading down on it with a shoe will cause serious damage to the hose. CONSTRUCTION OF HIGH PRESSURE HOSE \ Tubing Rubber Covering Wie Lay The above photograph shows a cutaway view of a high pressure hose. As can be noted from it, various layers are laid on one another to form a high pressure hose. The innermost tubing is of molded oil and heat resistant synthetic rubber to prevent oil from leaking. Therefore, if should the eubing is made of a material that is vulnerable cool or heat, the hose will prematurely be rendered useless due to permeation of oil. The outer side of the tubing is covered with a knitting layer or layers consisting of small gauge wires ranging from 0.3mm to 0.6mm (0.012 in.to 0.024 in.) in dia., depending on the application involved. This wire layer is adapted to protect the tubing ffom being bursted by hydraulic pressure, ot from bei Enobell by teamest-peegrure, 11 she hoor coeaies af s slices leyer, baacalel “single wire braid”, while if it consists of two layers, it is called “2-wire raid”. As greater the numbers of wire-braid, higher the hose resistance to pressure, this layer is the very life of the high pressure hose. The wires used are intertwined at a proper angle to provide the highest possible resistance to pressure. Therefor; the serious bending or ewistng ofthe .0se will change the angle of the intertwined wires and consequently reduce its pressure resistance, thus causing premature hose breakdown. The wire layer is covered with rubber layer to protect it against wear or external injuries. ‘On the some types of hoses, another wire is wound around the outer side of the hose to prevent exposuring of the wire layers if itis apprehended that there is danger of scratching the rubber layer or rock falling on it. The high pressure hose above explained is of the wire braid construction. Another high pressure hose is of the spiral wire construction, of which internal layers act the same functions as those of the wire blade type above mentioned. >The spiral wire layer is consists of a set of layers comprising a clockwise wound layer and a counterclockwise wound layer. SN METAL: FITTINGS Wite blade layer covered on top of spiral wire ayer. The high pressure hose is fastened to a metal fitting at each end. The fittings can be classified into the flanged type and the threaded type as shown below. Various methodo of fasesning Ptiags are avadable, However, if any impropee method is employed, a hose fitting will come off the hose, oF oil leaks out. Two types of fittings shown in the figure are sdopred by KOMATSU. In there structure the hose is tightly fastened to the fitting by closing the outer sleeve on a press.If the hose is not tightened ‘enough, the hose will come off out of place due to hydraulic pressure; if it is tightened too firmly, the hose will be bursted, thereby causing oil leakage. Since it is very difficult to tighten the fitting properly, this should be entrusted to the specialist. ‘Threaded type fiting PRECAUTIONS TO USE HOSE Keep Oil Temperature low: Too high oil temperature will cause the oil to sink into the innermost tubing of the hose to expend the hose, thus causing premature hose deterioration. It is advisable to maintain oil temperature at Somewhat less than 80°C (176°F), Absolutely avoid to allow ol temperature rise to anywhere in excess of 100°C (212°F) Do not Use Low Pressure Resistant Hose: It is necessary to consider that far higher shock pressure than normal operating pressure can be exerted on the hose. Komatsu makes it a rule to conduct a sampling inspection by picking up several pieces of hoses at random from each production lot. The sampling pieces are subjected to one million times of pressure resistance test under shock pressure 1.5 times greater than the normal operating pressure. ‘Normal pressure at which the hose is usable can be found by first five digits of the part number of each hose. Besides, on actual hoses, the following color codes are adopted to distinguish easily their normal pressure: 07100— or 07101 for normal pressure to 10kg/cm? (Orange) 07102— or 07103. for normal pressure to 30kg/cm? (Green) 07104— or 07105. for normal pressure to 70kg/em? (White) 07106— of 07107 sn. for normal pressure to 10Skg/em? (Red) 07108— or 07109. 07114— or 07115. Do not use any hose other than as specified in the part list even if it is equipped with the same fitting as that of the specified one. “" }for normal pressure to 140kg/em? (Yellow)CARE TO INSTALL THE HOSE Prior to installation of a hose equipped with che threaded type fitting, first make sure that the tapered portion of the fitting is completely free from dirt and dust or scratches. Then, fasten a pair of fittings each other to a specified torque to prevent oil from leaking out. Tightening the fitting too firmly will cause deformation of the tapered portion or a crack, thereby spoiling the fitting useless. When installing a hose equipped with the flanged type fitting make sure that no dust and dirt, or scratches, exist on the O-ring or its contacting area. Improper fitting of the hose will ‘shorten the life of it to one-tenth, or even to one-hundredth. * Do not use a short hose. Employ a specified hose. ‘Too sharp bend will cause undue stain at Provide slack inline any given point inthe hose to. compensate for hose length change. pee # Do not install the hose in twisted position. Any twisting can be found by 2 checking the marking on the hose Ifthe hose is installed even though the pipe Paced deways the hve wil be ote 4 shown by an _attow. Ideally, the hoes © Avoid to install the hose as shown below. *0w!d move within the same plane, * ‘This poine wil be injured, In such a condition, the middle of the hose must be. clamped. with allowance for the Tength; otherwise, ie will bent to a serious ‘extent when pressure is applied to it nt when a © Do not install hoses in contact with each other. Hoses contact here ‘This area is wearing,TROUBLE SHOOTING GUIDE SYMPTOM: Oil oozes out form a swelled portion on the rubber hose. This condition often occurs nearby the fit- ting or within 500mm from it. PROBABLE CAUSE: The fitting and hose are not properly joined, or the tubing is ruptured due to sharp bend of the hose. SYMPTOM: Hose ruptured near fitting, ‘© When the wire layer is ruptured slantingly. PROBABLE CAUSE: This condition occures due to sharp bend of the hose near a fitting in most cases. It is important to note that the hose which is in a gently bent condition when no hydraulic pressure is being applied will be sharply bent upon application of hydraulic pressure. (See the * marked illustration in the preceding Page.) # When wire layer is rupcured in direction of hose axis. PROBABLE CAUSE: The hose is installed in a twisted condition, or undue pressure is exerted on the hose nearby the fitting. SYMPTOM: Hose ruptures at middle portion of its length. ‘@ When the wire layer is rupeured slantigly. PROBABLE CAUSE: The hose may not be suitable for high pressure applications, or it is being installed in a sharply bent condition. © When wires are ruptured with numerous cracks. PROBABLE CAUSE: The hose may be heavily fatigued in most cases. High shock pressure may be another probable cause. Locate such a strong shock source. SYMPTOM: Oil spurting out from middle of hose. PROBABLE CAUSE: This condition is often caused by defective tubing. If any external damage cxists, the cause of such trouble should be eliminated Ruptured wire layer Ruptured wire layer Ruptured wire layer 70=7 _1000(04)