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Competence Development Planning

TF 001
Hose and Fitting

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 Mobiles off (or on silent)

 Times

 Domestics – Fire & Toilets


OUTPUT REQUIRES INPUT
 Participate, ask questions &
enjoy !

 Documentation
 Any questions?

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TUJUAN
- Mengerti dan Paham jenis jenis Hose dan fitting
- Mengetahui standarisasi hose dan fitting
- Dapat mengidentifikasi kode hose dan fitting
- Dapat Menggunakan Part book Gates dan Hydraulink
- Dapat membedakan ferrule
- Dapat mengidentifikasi adaptors
- Dapat mengidentifikasi steel pipe
- Dapat mengidentifikasi Quick release couplingbenar
- Dapat menggunakan tool dengan benar
- Dapat melakukan Assembly Hose dengan
- Dapat mengidentifikasi seal atau perapat yang di gunakan
- Mengetahui maintenance Inspection pada Hose & Fitting

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Course contain
• Pengenalan
• Kontruksi hose
• Hose selection
• Sifat-sifat Fluida
• Convertion
• Jenis Hose
• Common Hose Standard
• Identification jenis Hose
• Jenis Ferrule
• Jenis Connector / Fitting dan Identification jenis Connector
• Jenis Adaptors dan Identifikasi Adaptors
• Jenis Steel Pipe dan Identifikasi Steel Pipe
• Jenis Quick Release coupling dan Identifikasi Quick Release
Coupling
• Assembly to Hose
• Tool
• Type Seal / Perapat
• Inspection Hose & Fitting
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Apa itu Hose ?

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Kontruksi hose

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Type Reinforcement

 Braided Reinforcement

 Spiral Reinforcement

 Helical Reinforcement

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Hose Selection

FACTOR

Rates of flow
Fluid (or material)
(Volume and
to be conveyed
densty)

Operating
Aplication Pressure

Condition Temperature

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Sifat-Sifat Fluida

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Principle Liquid and Gas

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Pascal Law

F = Force
P = Pressure
A = Area

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Conversion
Length (Panjang) Pressure (Tekanan)
 1 Cm = 0.393 inch  1 bar = 14.0537 psi
 1 inch = 2.54 Cm  1 bar = 100000 Pascal
 1 M = 39.370 inch  1 bar = 0.1 Mpa
 1 M = 3.280 Feet  1 bar = 100 Kpa
 1 pascal = 0.001Kpa
Volume  1 pascal = 0.000001 Mpa
 1 litre = 0,219976 gal (UK)  1 psi = 0.0068 Mpa
 1 gallon (US) = 3,78533 litre  1 psi = 6.894 Kpa
 1 litre = 0,264177 gal (US)  1 psi = 6894.757 pascal

Velosity Flow Rate


 1 foot per second = 0,3048 m / s  1 litre per minute = 0,219976 gal / min. (UK)
 1 metre per second = 3,28084 ft / s  1 gallon per minute (US) = 3,78533 l / min.
 1 gallon per minute (UK) = 4,54596 l / min.  1 litre per minute = 0,264178 gal / min. (US)

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Membaca ukuran dalam Inch

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Rumus merubah celcius ke fahrenheit= (Celcius x 1,8) + 32
Rumus merubah celcius ke fahrenheit= (Celcius x 1,8) + 32
Competence Development Planning

Temperature
Celcius Ke Kelvin
100°C 212°F 80°R 373°K
= Celcius + 273.5
Celcius ke rheamur
= Celcius x 0.8
100 Skala 180 Skala 80 Skala 100 Skala Rheamur ke Celcius
= Rheamur x 1.25
Fahrenheit ke celcius
= (Fahrenheit - 32) / 1,8
0°C 32°F 0°R 273°K celcius ke fahrenheit
= (Celcius x 1,8) + 32
rheamur ke fahrenheit
= (Rheamur x 2,25) + 32

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Nomografic Chart

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High Pressure HYPRESS 4SP


(G2)

Premoflex Medium Pressure


(Megatech 1000)

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Specifikasi Hose
HIGH PRESSURE HOSE
G2
TWO WIRE BRAID HOSE
BRAIDED WIRE REINFORCED HOSE - SAE 100R2 Type AT

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PREMOFLEX
Premoflex® MULTI-PURPOSE HOSE
TWO YARN SPIRAL REINFORCED INDUSTRIAL
HOSE

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Hypress 4 SP
Internal Hose : synthetic rubber,
Reinforcement : 4 steel wire spiral.
External Covering : Anti-Abrasive synthetic rubber,
resistant to oils,fuel and atmospheric condition.
MSHA cover.

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MEDIUM PRESSURE HOSE


ACR
HIGH TEMP. OIL/AIR RETURN
BRAIDED WIRE REINFORCED HOSE

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Industrial Standard
• SAE : Society of Automotive Engineers, North American Origin
• EN : European Norm, Central Europe origin – becoming the
global norm
• ISO : International Standards Organization, International
Standard-Central Europe origin-not widely used
• DIN : Deutche Industrial Normen, German Origin – generally
superseded by EN standard
• Proprietary : Manufactures In-house Standard

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Cara membaca kode Hose

Hose branding di atas memiliki arti sebagai berikut :


•Gates Connected = Product Gates
•24G1 = Angka Part Number Awal yang akan menentukan jenis hose
Dan menjelaskan tentang ukuran hose dalam satuan Dash Number
•1-1/2” = Ukuran diameter dalam hose dalam satuan Inch
•38.0 mm = Ukuran diameter dalam hose dalam satuan mm
•R1/1SN = banyaknya layer atau kawat reinforcement (1 layer atau 1 kawat)
•EN853 = common hose standards ( Europan )
•725 PSI = Max allowed preassure( safe limit ) dalam satuan PSI
•5,0Mpa = Max allowed preassure (safe limit ) dalam satuan Mpa
•Flame resistant = Characteristic dari type hose tersebut

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Fitting

Two Pieces One Pieces

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FERRULE
• Skive

• Non Skive

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Non-Skive
MULTISPIRAL FERRULES
S6KXN
SPIRAL HOSE SWAGE FERRULE
NON-SKIVE SWAGE FERRULE FOR G6K G5K & G4K HOSE

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Skive
MULTISPIRAL FERRULES
S6KXS
SPIRAL HOSE SWAGE FERRULE
SKIVE SWAGE FERRULE FOR G6K G5K & G4K HOSE

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JENIS CONNECTOR / FITTING

 Swage

 Re-usable

 Push On

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Crimped

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Re-usable (Field Attachable)


Connector

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BASIC PRINCIPLES OF RE-USABLE


CONNECTORS

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Push On

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Identifikasi Swage Hosetail


Sistem penomoran spare part hydraulink adalah deskripsi singkat produk dalam
bentuk kode, nomor spare part terdiri dari 4 modul sebagai berikut :

Module 1 : Prefix letter


S : Swage
R : Field attachable (Reusable)
P : Push-on
R5 : Field attachable (Reusable) to suit SAE 100R5 hose
SU : Suction tail

Module 2 : Series Code


Menandakan Coupling end menggunakan thread atau menggunakan metode
sealing
Contoh:
Series Code #51 menandakan BSPP swivel nut female in a swept 90° configuration.
Series Code #29 menadakan JIC female swivel nut in a compact 90° configuration.

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Module 3 : Coupling & Size


Ukuran diexpresikan seperti berikut :
English/American threads; diexpresikan 1/16 dengan satuan inch menandakan
diameter kunci .
Contoh : 08 = 8/16 = 1/2” dan 19 = 19/16”

Module 4 : Hosetail outside diameter


Ukuran diexpresikan seperti berikut :
1/16 dalam satuan inch.
Contoh : 06 = 6/16 = 3/8” dan 20 = 20/16”

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Contoh
Type Swage

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Type Field attachable (Reusable)


to suit SAE 100R5 Hose

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Type Push-on

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Type Field attachable (Reusable)

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Identification Fitting
Part Number : R555 1208

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Imformation-R5 Field Attachable

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R5 Field Attachable Coupling index

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T = Drop Length

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SUCTION HOSETAILS

Apa itu Suction Hosetails ?

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Identifikasi Suction Hosetail

Menyatakan  Awalan
Module 1 SU = Suction tail.

Menyatakan  Thread form atau sealing method


Module 2
(coupling end) dan sudut dari hosetail

Menyatakan  Coupling end size, biasanya dinyatakan


Module 3 dalam imperial dan metric

Menyatakan  Menandakan ukuran O.D dari hose tail


dan I.D hose yang sesuai, ukuran
Module 4 biasanya dinyatakan dalam kenaikan
1/16 inch

Menyatakan  Special sudut, Contoh : SU12-1216-90


Module 5
denotes a BSP parallel male (#12) size
3/4” (12/16) with a 1” (16/16) hosetail in
a compact 90° configuration.

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Steel Suction Coupling

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SERIES CODES AND DESCRIPTIONS


HOSETAILS
Part Number : SU 15 – 12 08

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Suction Coupling Index

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Adaptors

Apa itu Adaptor ?

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Type adaptors

 Straight adaptor

 Angled adaptor

 Tee adaptor

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Identifikasi Adaptors

Sistem penomoran spare part hydraulink adalah deskripsi singkat produk dalam
bentuk kode, nomor spare part terdiri dari 2 modul sebagai berikut :

Menyatakan  Type ujung dari adaptor menggunakan


Module 1 thread form atau sealing method (end
type).

Menyatakan  Ukuran dari end type, biasanya dinyatakan


Module 2 dalam American thread (inch) dan metric.

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 Straight Adaptor

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 Angled Adaptor

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 Tee Adaptor

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Imformation - Carbon Steel Adaptors


Part Number : A-G – 08-12
SERIES CODES AND DESCRIPTIONS - ADAPTORS

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Picture Index

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STRAIGHT ADAPTORS
A-G- 37°

MALE BSPT X JIC STRAIGHT


BSPT MALE WITH 60° CONE X JIC MALE 30°

WITH 37° CONE

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Steel Pipe and Tube

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Type Steel pipe

Hydraulic tube Pre-Formed Tube Bends

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Identifikasi Steel Pipe


(Hydraulic tube)
Menyatakan
 ST (Carbon Steel)
Module 1
 SST (Stainless Steel Tube)
 STP (Trivalent Plated carbon Steel tube)
Menyatakan
Module 2  Ukuran diameter luar pipa, biasanya
dalam Imperial (inch) atau Metric
(milimeter)

Menyatakan
Module 3
 Ketebalan pipa, biasanya dalam
imperial (Gauge) dan metric (mm)

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Part Numbering System

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Identifikasi Steel Pipe


(Pre-Formed tube bend)
Menyatakan
Module 1  TB (standard)
 TBH (Heavy wall tube)
Menyatakan
Module 2  tube bend angle (configuration);
typically 45° or 90°.

Menyatakan
Module 3  Ukuran diameter luar, biasanya dalam
imperial (inch).

Akhiran EXT ditambahkan ke nomor bagian untuk menggambarkan kaki panjang (kaki
diperpanjang) bend.

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Part Numbering System

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Picture Index

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Quick Release Coupling

Fungsi quick release coupling?

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Type Quick Release Coupling


Sering kita
jumpai

Screw Together Flat Face

Push to Connect

Diagnostic Pneumatic

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Push to Connect

Features and Options


 Temperature Range:-25°C to 125°C
 Most commonly found on agricultural applications and reffered to as a “Pioneer
coupler”
 Comes with NBR seals, but Viton, Neoprene, and EPDM are also available
 Comes standard with NPTF. Can be special ordered in ORB, Metric and BSPP ISO
567

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Dimensi

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Flow chart

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Working Pressure

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Picture Index

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STANDARD SERIES
QNV
POPPET SEAL COUPLINGS
INTERCHANGE WITH ISO 7241-1 PART A IN 08 SIZE

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Instruksi Perakitan Hose


Langkah ke 1 : Mengukur Panjang Hose

 Panjang Keseluruhan

Catatan : Selalu lakukan pengukuran panjang keseluruhan


Hose saat ingin melakukan pergantian. Karena hose
tail bisa berbeda setiap product terutama dari
manufacture yang berbeda

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 Panjang Pemotongan Hose

Catatan :
Pemotongan hose tidak termasuk hose tail dan Ferrule

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Menghitung Panjang pemotongan


Hose

Panjang Hose = Panjang keseluruhan – ( C1+ C2 )

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panjang keseluruhan
adalah 12.5”

data hose : 3/8” G1


1/2”Male Pipe ( 6G-
8MP ) dan 3/8”
Female JIC (6G-6FJX)

pberarti pajang hose


yang akan di potong:
12.5”- (1.36”+1.19”)

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Toleransi pemotongan hose


berdasarkan SAE
• Panjang hose 0 sampai dengan 12” ± 1/8 “
• Panjang hose 12” sampai dengan 18” ± 3/16”
• Panjang hose18” sampai dengan 36” ± 1/4 “
• Panjang hose di atas 36 “ ± 1 % dari
panjang yang
di ukur
sampai
mendekati
1/8”
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Langkah ke 2 : Pemotongan Hose

 Berikan tanda (Garis) pada hose yang ingin dipotong


 Hose harus di press/dijepit
 Pemotongan hose tidak boleh melebihi sudut 5°
 Setelah hose terpotong, periksa hasil pemotongan

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 Memastikan kedua pin dukungan Hose ditempatkan jarak yang sama dari
mata gergaji.
 Jangan terlalu melekuk (Overbend) hose, karena dapat menyebabkan sudut
pemotongan hose melebihi syarat pemotongaan.
 Gunakan tekanan yang konstan.
 Pastikan tidak ada sisi beban ditempatkan pada pisau saat memotong.

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Langkah 3: membersihkan Hose

 Pembersih hose sebelum dan sesudah fabrikasi sangat


dianjurkan,karena membersihkan hose akan mengurangi kontaminasi
didalam sistem.

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Langkah ke 4 : Fit End Connections

 Masukkan hose ke dalam ferrule, lalu tarik ferrule sedikit


menyisakan celah sekitar 4 mm antara bagian ferrule (kerah) dengan
hose end atau bila ferrule mempunyai kerah ganda tekan hose
sampai menyentuh bagian dalam ferrule(kerah).

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 lumasi tailpiece dengan oli dan dorong masuk ke dalam hose. Dorong sampai
belakang hex dari tailpiece kontak dengan ferrule. pada titik ini, ferrule dan
tailpiece akan keduanya bergerak bersama dengan kerah yang kontak dengan
tailpiece hose end. metode ini secara otomatis menempatkan tailpiece dan
mengunci kerah ferrule dalam posisi yang benar.

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Langkah ke 5 : Recheck panjang Hose

 Dianjurkan untuk memeriksa kembali panjang perakitan sebelum crimping


baik dengan mengukur atau meletakkan perakitan baru dengan yang akan
digantikan, jika tersedia. tujuan ini untuk menghindari hilangnya dua koneksi
akhir jika hose telah sengaja dipotong untuk panjang yang salah

Langkah ke 6 : Pengaturan Crimper

 Combination hose dan ferrule harus cocok seperti yang disediakan


hydraulink crimp chart atau instruksi perakitan.
 Lihat hydraulink crimp chart untuk dimensi crimp yang benar.
 Lihat crimper chart dari manufactur crimper untuk memilih crimper dies
dan penyetelan offset untuk hasil yang diinginkan .

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Crimper Operation

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• Switch Machine On

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• Select correct crimp specification

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• Select correct die set

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• Memasang die set


Ganti die set sesuai dengan yang diinginkan, tersedia juga option rak die yang
biasanya letaknya tidak jauh dari mesin,untuk memasang dan penggantiannya
dapat juga mengganti nya dengan (Quick change).

• Setting secara benar

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• Crimping
Pengoperasian Umum :
Tahan tombol crimping sampai dies menahan fitting hingga dies
menekan fitting.
• Tekan tombol crimping sampai dies berhenti.
• Buka dies dan lepaskan fitting/hasil crimpingan
• Check Crimping diameter

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Langkah ke 7 : Crimping
Crimp ujung pertama dan memeriksa diameter crimp akhir. Jika perakitan Hose
memiliki dua fitting siku,periksalah orientasi sudut sebelum Crimping fitting kedua.
Pengukuran ini kemudian di titik tengah dari ferrule antara pegunungan crimping.

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Langkah ke 8 : Cek hasil Perakitan


Cek hasil perakitan hose secara visual apakah posisi dari ferrule sudah.

Langkah ke 9 : Menutup rakitan hose


Bersihkan rakitan hose dari kotoran, jika sudah bersih tutup fitting dengan plug
untuk melindungi bagian dalam hose dari contaminasi dan agar aman pada saat
kita menyimpan hose.

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Langkah ke 10 : Memasang Hose Protection

Steel Armour - Coil Spring Type Plastic Armour - Coil Spring Type

Steel Armour - Coil Sleeve Type Protective Sleeve - Woven Nylon Type

 Pelindung hose misalnya: steel armour (Coil spring type) atau steel
armour (coil sleeve type), Plastic armour (Coil spring type) atau
Protective sleeve (Woven nylon type).

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Skive Style
(Skive 1 & 2 Wire & Multispiral Hose)

 Potong hose

 Lakukan pengukuran menggunakan hose


dan ferrule dan berikan tanda.

 Lalu kupas cover hose tersebut sampai


terlihat reinforcement, dan jangan sampai
merusak reinforcementnya

 Step selanjutnya sama seperti Non skive


dari step 2-5

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Non skive Re-usable

 Potong hose

 Posisikan hose menyentuh bibir dari


ferrule lalu putar kekiri sampai hose
masuk kedalam ferrule.

 Lumasi fitting dengan oil lalu


masukkan kedalam ferrule

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Skive Re-usable

 Potong hose

 Lakukan pengukuran menggunakan


hose dan ferrule dan berikan tanda.

 Lalu kupas cover hose tersebut sampai


terlihat reinforcement, dan jangan sampai
merusak reinforcementnya

 Step selanjutnya sama seperti Non skive


dari step 2-5

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Push On
 Potong hose

 Lumasi dengan oil hose tail nya

 Dorong masuk hose tail fitting kedalam


hose hingga menyentuh plastic dust cap

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Hose Assembly Measurement

Static Installation Dynamic Installation


Panjang = 2K + 3.142R Panjang = 2K + 3.142R + T

Note :
K = Jarak
Off-Set Angle Measurement R = Min bending
T = jarak pergerakan hose

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Hose Intallations

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Terminology
B.S.P.T British Standart Pipe Taper
B.S.P.P British Standart Pipe Parallel
N.P.T.F National Pipe Taper (Fuel)
N.P.S.M National Pipe Taper Mechanical
J.I.C Joint Industrial Conference
O.R.F.S O-ring Face Seal
D.I.N Deutsche Industrial Normen (German Industrial Standart)
Code 61 Standart Pressure SAE Flange Connection
Code 62 High Pressure SAE Flange Connection
U.N Unified National Thread
J.I.S Japanese Industrial Standart
O.D Outside Diameter
I.D Inside Diameter
E.N European Norm

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TYPE SEAL / PERAPAT

1. Thread Interference

2. O- ring

2. Mated Angle or
mechanical Joint

4. Mated Angle with


O-ring

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Tools

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TYPE COUPLING / CONNECTOR &


PERAPAT / SEAL
1. NORTH AMERICAN TREAD TYPES
– NPTF (National Pipe Tapered Tread Fuel )

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– JIC ( 37o Flare ) Joint Industrial Conference

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– SAE ( 45o Flare )

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– O-Ring Boss

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– O-Ring Face Seal ( ORFS ) – J1453

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2. BRITISH
– B.S.P.P
British Standard Pipe Parallel

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Ada beberapa model perapat O-ring di type BSPP ini, antara lain

1. Dowty seal
2. O-ring + Retaining Ring
3. O-Ring

Training Division
Fluids service, February 2014
Competence Development Planning

3. FRENCH
– GAZ 24o

Training Division
Fluids service, February 2014
Competence Development Planning

5. JAPANESE
– Japanese 30o Flare Parallel

Training Division
Fluids service, February 2014
Competence Development Planning

– Komatsu Style Flange Fitting

Training Division
Fluids service, February 2014
Competence Development Planning

Standarisasi ukuran dari kode 61 , kode 62 dan


caterpillar style refence

Training Division
Fluids service, February 2014
Competence Development Planning

Maintenance

Training Division
Fluids service, February 2014
Competence Development Planning

Jadwal pemeriksaan

• Stationary Setiap 3 bulan sekali

• Alat yang berjalan Setiap 3 bulan sekali atau


400 – 600 Hours

• Keadaan di sekitar Sesering mungkin (1 Minggu)


yang extream

Training Division
Fluids service, February 2014
Competence Development Planning

Masalah yang biasa terjadi pada hose


Problem: Hose Abrasion
Solution: Rute ulang hose untuk tetap jauh
dari sumber abrasif (gesekan) atau
menjaga hose dengan hose guard

Problem: Hose Burst Away from Hose Ends


Solution: Periksa tekanan operasi sistem dan
pilih hose yang memenuhi atau melebihi
tekanan maksimum sistem. Coba rerouting
hose untuk mencegah ketekuknya hose secara
berlebihan atau peletakkan hose melebihi
radius tikungan minimum.

Training Division
Fluids service, February 2014
Competence Development Planning

Problem: Hose Burst at Coupling


Solution: Menambah panjang hose pada
saat perakitan untuk mengakomodasi
kontraksi pada saat terjadinya tekanan,
meningkatkan radius tikungan hose atau
memasang tikungan pembatas (clamp),
atau mengganti perakitan hose dengan di
crimping dengan cara yang benar.

Problem: Leak at Thread End/Seat


Solution: Lepaskan connector dan lakukan
inspect.

Training Division
Fluids service, February 2014
Competence Development Planning

Problem: Hose Cracks


Solusi: Pilih hose yang memenuhi
persyaratan suhu dan aliran
aplikasi. Juga, mengidentifikasi sumber
panas dan mempertimbangkan
rerouting itu jauh dari sumber untuk
meminimalkan efek.

Problem: Cover Blisters


Solution: Ganti hose dengan yang
direkomendasikan sebagai yang kompatibel
dengan cairan yang digunakan.

Training Division
Fluids service, February 2014
Competence Development Planning

Problem: Rembes disambungan coupling


Solution: Pastikan pada crimping hose
sudah dimasukkan dengan benar
kedalam ferrule.

Problem: Hose Twist


Solution: Route ulang hose.

Training Division
Fluids service, February 2014
Competence Development Planning

Maintenance Inspection
Visual Inspection ( Hose and fitting) :
a. Leaks at fitting or in hose
b. Damage
c. Exposed reinforcement
d. Kinked, Crushed, flattened
e. Hard, stiff, heat cracked
f. Blistered, soft, degraded, or loose cover
g. cracked, damaged, or badly corroded fittings
H. Other signs of significant deterioration

Training Division
Fluids service, February 2014
Competence Development Planning

Training Division
Fluids service, February 2014

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