Certified Hose Fitting Technician Trainings
Certified Hose Fitting Technician Trainings
Hydroman Certified Hose Fitting Technician What is its Purpose?
To gain the Qualification of "Certified Hose Fitting Technician" to the technicians of companies that make Hose Fittings.
Ensuring that the Fitted Hoses to be manufactured are made in accordance with the Hose Fitting Installation Procedures recommended by Hidroman.
To ensure that candidates can apply for Hydroman Training Qualifications and obtain the "Hose Technician & Advanced Hose Technician" certificate.
Minimizing the risk of encountering liabilities for the company and MRI.
What Should You Do To Become A Hydroman Certified Hose Fitting Technician?
Upon successful completion of the Representative's Questionnaire (100% pass mark is required.), The person will conditionally have a “Certified Hose Fitting Technician” certificate.
Inspection will be organized by a Hydroman representative (by giving a temporary certificate for 3 months). After a successful inspection, a full "Certified Hose Fitting Technician" certificate will be issued, which will be valid for 3 years.
What Are The Hydraulic Hose Manufacturing Machines That Should Be Used?
A Hose turntable or special hose feeder should be used so that the hose can not be kept on the floor and the hose can be fed to the cutting machine without being buckled or damaged. Measuring the hose on a bench or on the floor may cause damage to the hose. It can be difficult to measure the cut length accurately as the hose cannot be kept straight during measurement.
Hose Cutting Machine:
This Machine can be foot / hand operated or auto-fed. The cutting blade should be Metallic and sharp. The power of the machine and the size of the cutting blade must be large enough for the type and size of the hose to be cut properly.
Abrasive cutting discs (Flex stone etc.) are definitely not recommended for cutting, as they will cause distortion in the cutting plane of the hose cutting and also leave contamination to the inside of the hose. Abrasive cutting discs can only be used if they are used with Coolant spray (can prevent heat dissipation and deterioration.), But is not recommended.
Hand band saw:
Not recommended for cutting. The cutting process is not clean due to the saw teeth or the hose will cause distortions in the cutting plane.
For Cutting Machines, “V” channel with adjustable stopping apparatus is recommended to determine length in hose measurement. This will ensure that the hose is kept properly for accurate measurement and the measurement is made precisely.
Measuring the hose on a bench or floor may result in damage to the Hose. It can be difficult to measure the cut length accurately as the hose cannot be kept straight during measurement.
Hydraulic Hose peeling machine:
Stripping can be done with a hand-held tool kit or an electric motor driven machine. The blade and / or blades of the Stripping Apparatus or Machine allow the rubber material in the fitting assembly section of the hose to be stripped from outside and / or inside without damaging the wire reinforcement.
Saws and blades are not recommended for stripping as they may damage the steel wire reinforcement in the hose and may not be stripped properly. Also, sharp-edged-rotary blade machines are not recommended as they may damage the steel wire reinforcement during stripping.
Stripping with a wire brush is also not recommended for stripping as it will cause a high level of pollution.
Inner and outer stripping mandrels: The smoothness of the surface and end planes of the inner and outer stripping mandrels will provide a smooth and smooth outer surface after stripping on the hose.
The uneven surface and end planes of the smooth Mandrels will cause distortion of the inside of the hose, to avoid this situation, the uneven Mandrels should be replaced before the operation.
Stripping with uneven Mandrels will result in smooth and unsuitable results that are not suitable for the hose stripping technique, which will result in improper assembly of the hose coupling and therefore may cause oil leaks and explosions in hydraulic hoses with fittings.
Recommended internal / external stripping length tolerances: tolerance is + 0.5mm.
In hoses that are stripped shorter than the required size, the hose coupling cannot be mounted properly, and consequently, oil leaks and explosions in the coupled hoses may occur.
In hoses that are stripped longer than the required size, after the assembly of the hose connector, the hose wire reinforcement parts will be exposed and in this case the life of the union hose will be shortened.
Hose Stripping length:
Hose stripping lengths for the section where the hose fitting will be mounted are given in the Hydroman Fitting pressing tables.
The recommended hose stripping lengths are calculated to ensure a good sealing and not to absorb any moisture or foreign matter from the outer rubber surface of the fitting socket and the hose wire reinforcements. The length of the hose stripping length is also very important for the proper installation of the hose fittings. The working time of the coupled hoses produced after the hose stripping different than the recommended values may shorten.
Hydraulic Hose Fitting assembly machine:
It is used to properly fit the hose fittings to the hoses and to prevent the hose reinforcement wires from being damaged during this installation. Striking the hose coupling with materials such as wood or metal will cause the hose union nut, flange surface or male threads to deteriorate during the installation of the hose coupling to the hose, and this is not recommended.
Hydraulic Hose Pressing machine:
Pressing machines should be able to press in desired dimensions within the tolerances of + 0.1mm according to the hose middle axis after the fitting pressing process.
With the frequently used statistical production control method, the pressing calibration accuracy of the pressing machine is monitored.
Pressing machines that are not constantly monitored for sleeve pressing accuracy may lose their ability to press according to the dimensions over time. Pressing die bearings may wear out over time depending on the use, and there may be cones and ovalities in the pressing process.This may cause pressing in inappropriate dimensions and thus shorten the working life of the coupled hoses, oil leakage and explosions.
Hydraulic Hose Pressing dimensions:
Recommended pressing dimensions are found in the "Hydroman Pressing Table".
Conditions suitable for fitting pressing procedures and recommended dimensions should be provided in pressing the sockets. Application is not allowed outside the recommended dimensions and procedures.
Hydraulic Hose Pressing dies:
The size and structure of the pressing dies should only provide the necessary dimensions after pressing in the sockets.
Pressing dies should be clean and their surfaces should not show rapid deformation.
If the size and structure of the pressing dies cause more deformation than the required size after pressing, there will be cracks in the sockets. Cracking in the socket may not occur during the manufacture of the union hose, but may occur under conditions where the coupled hose is subjected to pressure. This situation can cause injuries and even deaths in humans, as well as machine breakages and environmental pollution.
Pressing dies that are used with dimensional errors, broken, dirty surfaces will prevent the sockets from being pressed in appropriate sizes and in accordance with the procedures. This situation may cause pressing in inappropriate dimensions and thus shorten the working life of the coupled hoses, oil leaks and explosions.
Hydraulic Hose Pressing dies: The pressing dies must be long enough to cover the length of the sockets to be pressed. (Including special sockets and interlocking sockets etc.)
If two or more pressing operations of the pressing process of the socket are applied (such as pressing the front part of the socket first and then the remaining part), the working life of the coupled hose will be shortened. Many machine manufacturers produce longer pressing die sets, unlike standard sizes.
Hydraulic Hose Pressure Testing machine:
Trial test is the procedure of checking whether the hose with union is made in accordance with the procedures and dimensions and any invisible inconsistencies in the material, after the fitting is done. Performing trial testing is not a must but a recommended procedure.
Trial test pressure operation procedures: Trial test procedures are included in the Hydrostatic test list for rubber, plastic hoses and coupled hoses in ISO 1402 standard. Working pressure and Test pressure, bursting pressure rates are specified in ISO7751 standards for rubber, plastic hoses and coupled hoses.
Hydraulic Hose test is not compulsory in cases where international standards are not required and there is no special customer request.
The calibrations of the measuring clocks on the machines undergoing trial testing must always be complete, otherwise the accuracy of the measured pressure will be doubtful and in this case the customer request or legal obligations will not be met.
In-hose cleaning equipment:
Cleaning of the inside of the hose is carried out for the purpose of cleaning the dirt that will occur due to cutting, peeling and pressing processes in the hose during the manufacture of the hose with fittings and is a necessity.
In-hose cleaning equipment is carried out by passing sponges and similar materials through the hose with the help of a gun or flushing with fluid. Passing compressed air through the hose is not recommended as it will not remove contamination effectively.
Adjusting the angle of hose fittings:
A reliable system must be used to adjust the angles of the hose fittings to each other. This process can be done with the help of specially prepared apparatus or a calibrated angle gauge ruler.
Adjusting the angles of the fittings made by wall charts and other visual methods may cause buckling and unwanted twists after the assembly of the coupled hose, and in this case, it may lead to shortening of the working life, oil leakage and explosions.
Tolerances on the angle of the hose fittings to each other:
As specified in SAEJ517 standards, the acceptable tolerance in the angles of the hose fittings relative to each other is + 3 degrees for the coupled hoses up to 610mm length, and + 5 degrees for the hoses longer than 610mm.
Union hydraulic hose manufacturing procedures:
During manufacturing, it is mandatory to comply with all required fitting hose manufacturing procedures.
Hydroman trainings give the correct procedures to be followed in the production of coupled hose.
You can find the size change procedures inside the fitting in the Hydroman pressing tables.
Storage of Hydraulic Hose and Hydraulic hose fittings:
Hoses should be stored on shelves so that they do not come into contact with the ground and preferably in order to protect them from any impact or damage.
Hose ends should be closed in a way that no contamination can enter.
Storage conditions should be protected from dark, moisture-free environment and electrical current. (Otherwise, the ozone effect will occur in the hoses.)
Hose fittings are kept away from dust, dirt, etc. in a moisture-free environment and preferably in cardboard boxes.
Boxes should be kept closed so that no materials can enter and the o-ring material that may be on the fittings is protected from the ozone effect.
Traceability of hoses, hose fittings and coupled hoses: Quality complaint notifications or determination regarding the working life of hoses, hose couplings and coupled hoses
It is necessary to write the necessary records on the relevant materials.
Hose traceability can be done by recording the production date written on the hose label and on the hose.
Traceability of hose fittings and sockets can be achieved by recording the numbers written on the cardboard boxes where the materials are stored.
Traceability can be achieved by creating a unique number to be created for each coupled hose in coupled hoses or by writing a number to be created in the company records on the produced material in an indelible structure.
Calibration of Measuring devices used for Hydraulic Hose Manufacturing:
In order to be able to produce in accordance with the standards and required dimensions, it should be ensured that all measuring devices used during production are accurate and the measuring devices should be calibrated at necessary times.
Productions of coupled hoses to be made with measuring devices that do not have accurate measuring features may cause uncoupled hoses not to be made in appropriate sizes and sizes and to press in unsuitable dimensions, so this situation may shorten the working life of the coupled hoses, cause oil leakage and explosions.
Hydraulic Education system:
It is recommended that new personnel coming to an organization that performs hose fitting assembly process pass through the specified training system. The training in question should be given to the personnel who manufacture hoses with fittings and who perform assembly and disassembly of the coupled hose.
Documents, technical drawings and specification control: It should be ensured that the relevant personnel working with the latest and valid documents, technical drawings and manufacturing in accordance with Quality control procedures must be ensured.
Rejection of defective products: Products that are suspected of being defective, produced incorrectly and not manufactured in accordance with the standards and required specifications should be subject to the Rejection procedure before sending to the end user and should not be delivered to the customer. In order to detect non-conforming products, the exit Quality control procedure should be applied to the products.