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8 tips you can do to make sure your mast hose stays in good condition

8 tips you can do to make sure your mast hose stays in good condition

A mast hose is an important thing to pay attention to when routine inspections are carried out on equipment used to handle materials. If there are problems with the mast how at an industrial facility, it’s highly likely that malfunctions and down time will result.

All of this inevitably leads to avoidable decreases in productivity. But the productivity issues are not the only consequence of a faulty mast hose that is poorly maintained. Perhaps an even more important consequence that needs to be avoided is safety issues. A man hose that is failing or not operating properly can spill out oil. Spilled oil on a site can make it possible for dangerous and costly slip and fall accidents to occur. Avoiding this type of accident is a priority for any employer.

The way to avoid issues and keep a mast hose in the best possible condition over time is to conduct regular inspections. Inspections should involve looking out for faulty parts that need to be replaced. Replacing parts when necessary will lead to money savings over time. It will also ensure that a work environment remains safe and worksite injuries are avoided.

The following are eight things that need to be done as part of routine mast hose inspections:

  • Occasionally go over the manual on how the hose works- It’s easy to forget some of the information that is provided in the manual. For this reason, occasionally revising the manual as you inspect the hose is important.
  • Make sure that there are no cracks on the exterior bend radius of the hose- The exterior bend radius portion of a mast hose is one of the areas in the hose where cracks are most likely to develop. This is especially true where hoses are used at very low temperatures. Look out for cracks that form perpendicular to the hose. If you need to use your mast hose at unusually low temperatures, you may need to find a product that has a lower temperating rating.
  • Look over the hose from tip to tip- Inspecting the hose from tip to tip is important for looking out for any jacket portions that are missing from the assembly.
  • Make sure that the hose exhibits proper tension- It’s fairly typical for mast hoses to be sold after they’ve already been set to the proper tension. You can consult the owner’s manual of your hose to look for what the proper tension should be and adjust your mast hose accordingly during inspections.
  • Check the jacket for gouges- Over time, parallel cuts can develop on the jacket of a mast hose. Replacing jacket that is gouged out is especially important in situations where the hose reinforcement has been altered in some way.
  • Make sure that wires are not broken- Broken wires are especially likely to develop and are especially problematic in situations where rubber hoses are being used. Broken wires can break out of the rubber and stick out of the jacket. Be careful not to cut your hand or fingers when inspected for broken wires that are protruding from hoses.
  • Check where hose sides meet sheaves- If a mast hose is unusually wide, it’s possible for the jacket to wear out at places where the hose sides come into contact with the sheaves. In this case, it might be a good idea to look for a mast hose that offers a lower profile.
  • Make sure there are no leaks at connections- Leaks are particularly likely to develop at the hose ends and at the connections that join together two hose ends. Connections need to be tight. In the event that a leak is detected, the hose and fittings can possibly be sealed. If damage is excessive, parts may need to be replaced entirely and repair will not be possible.

Keeping the importance of sheave width in mind when replacements are necessary

The key factor to consider when you need to replace one of your mast hoses is sheave width. Excessive sheave width often means that additional wear will be likely to occur so that the hose will have to be replaced sooner than necessary.

Mast hoses should ideally not fit too tightly into the sheave. In situations where hoses are too tight when the hose is not pressurized, hoses can become too tight during use and could possibly come loose out of the sheave. The best way to find a hose with the appropriate sheave width is to have mast manufacturers install a new hose according to the “stretch of the hose” measurement.

Why choose a thermoplastic material over rubber if replacement is necessary

The material choices available out there for mast hoses are typically either thermoplastic or rubber. Generally speaking, it’s probably a good idea to choose thermoplastic hoses over rubber hoses. When thermoplastic hoses are chosen, minimal stretching occurs upon the application of tension. Also, thermoplastic tends to be more durable and lasts longer than rubber because of the following three factors:

  • There is no delamination when thermoplastic hoses are used. If rubber hoses are used, delimitation can be expected whenever an over-the-sheave application is carried out.
  • Thermoplastic mast hoses are able to handle lower temperatures generally speaking than rubber hoses. If your facility relies upon operation at low temperatures due to either cold weather or use of freezers, thermoplastic is definitely the way to go.
  • Thermoplastic hoses ensure that there is no fatigue in the fiber reinforcement that is in use. Constant flexing motion means that fiber reinforcement is important and shouldn’t wear out or deteriorate over time.
Tips for a Successful Hydraulic Hose Assembly

Tips for a Successful Hydraulic Hose Assembly

It is an understatement to say that hose is merely an essential part of a hydraulic system. This is because over the years, the complexity of hydraulics has substantially increased. Hose dimensions have become smaller to accommodate tighter spaces, but at the same time, pressures are getting higher. A broad range of hydraulic hose featuring various styles are offered by numerous manufacturers. There are also thousands of fittings from which to choose. Although this wide variety of products can be advantageous, it can also make it difficult to determine which fittings and hoses are best. Below are some important aspects to which thought should be given when building a hose assembly:

The Application’s Dash Size or Inside Diameter

Hydraulic hoses are measured by their inside diameter– I.D.–which is also referred to as the dash size. Diameter is measured in sixteenths of an inch. In most cases, this measurement can be found on the hose’s layline, but can also be manually measured. The dash size is required in order to determine the system’s proper flow velocity. Too high of a flow will cause hose leakage, system damage, and pressure drops, while a sluggish performance can be expected if the flow is not fast enough.

Fortunately, your application’s proper hose I.D. can be determined with our flow capacity nomogram. Parker’s Hose Products Division has a full line of hose to fit various flow rates, ranging from size four to size forty.

Temperature

Temperature is a critical factor when choosing a hose for your application, and you must consider both media and ambient temperature when making this decision. The temperature outside the hose is ambient temperature, while media temperature is the phrase used to describe the hose’s internal temperature. The hose’s overall temperature rating should not exceed the higher of the two. When selecting a hose, you should also give thought to the media type. This is because the temperature may be increased or decreased by certain media types. Therefore, some Parker hoses feature different fluid and temperature ratings. Both high and low temperature hoses are offered by Parker for specific applications.

Every Application is Different

When choosing a hose, thought must be given to how it will be used. The following questions are helpful when making this determination:

• Are there routing requirements?
• Must the assembly bear mechanical loads?
• Are there any environmental factors?
• What type of equipment is involved?

Specific requirements are set according to industry standards, including requirements for impulse cycles, burst pressure, tolerances, size and construction type. Parker is dedicated to meeting or exceeding standards set forth by the following organizations:

• International Organization for Standardization– ISO
• Deutsches Institute für Normung– DIN
• European Norm– EN
• Society of Automotive Engineers– SAE

Parker products are also manufactured according to government agencies’ requirements. Such agencies also regulate standards for ABS, the US Coast Guard, and other industries and organizations. The Parker hose line must not only meet the application’s functional requirements, but also the legal requirements set forth by the aforementioned agencies.

Bend Radius Requirements

A hose’s minimum bend radius refers to the smallest radius at which the hose may be bent without stopping the system from running at maximum pressure. Bending radius eases routing and enhances flexibility. Nevertheless, if the hose is bent below the minimum bending radius, possible hose failure may occur due to loss of mechanical strength. As a general rule, a minimum straight length of 1 1/2 times the hose’s outer diameter is allowed between the point where the bend starts and the hose fitting. For applications that require a tight bend radius Parker offers two products, the 797 and the 787 hose, both of which feature half the bend radius of a traditional SAE 100R15 hose.

Abrasion

The risk of abrasion is an important factor when choosing hose. To make a proper decision, you must consider the application’s external conditions and determine whether or not there is a risk of abrasion. The outside of most hoses feature neoprene; however, if it is inevitable that the hose will rub against machinery, materials, or against the boom or jib, a high abrasion carcass is the best choice. This is because hoses often wear through and ultimately fail when they continuously rub on the outside. Naturally, when this happens, pressure can no longer be contained in the hose and it will simply burst. Arguably, the number one cause of hose failure is external abrasion. Tough Cover–TC– is what Parker recommends for harsh environments, and for extremely abrasive environments, SuperTough–ST– is recommended.

Media Compatibility

Always consider media compatibility when selecting hose. The media being conveyed should be compatible with the hose’s inner tube, but it is also important to ensure compatibility with the O-rings, fittings and cover. Several problems to hydraulic systems and hose assemblies will occur if incompatible media is used. Avail yourself of our chemical resistance chart to check hose compatibility and prevent hose failures.

Pay Close Attention to Maximum Pressure Ratings

With regard to hose pressure, it is essential to consider the working pressure of the system, as well as spike pressures or surges. Such pressure should always measure below the hose’s designated maximum working pressure. Even though hydraulic hoses offered by Parker met a 4:1 pressure safety factor when tested, they are not designed for use at working pressures higher than those established for the assembly.

It is important to know the system’s exact maximum working pressure, which is that of its lowest rated component. For instance, even if the hose is rated to a pressure greater than the fittings, the entire assembly’s top working pressure is still that of the fittings.

Engineering specifications for pressure can be found on each hose, as well as on the hose’s laylines. We also offer a hose overview chart where you can find pressure specifications. For fittings, please see our Pressure Rating of Hose End Connectors chart.

The Complicated Process of Fitting Selection

The hose you choose must be compatible with the fitting-to-hose mechanical interface. Choose the appropriate mating thread to ensure leak-free sealing. The fittings that connect most hose types fall into one of two categories: field-attachable and permanent, the latter of which is primarily used in maintenance shops, by large-scale rebuilders, or by equipment manufacturers.

1. Permanent Fittings

Crimping machines are used to cold-form permanent fittings onto the hose. For this reason, permanent fittings are also sometimes referred to as crimped fittings. They are available for the majority of thermoplastic and rubber hoses and you can find a vast array of dependable connections for reasonable prices. Assemblies designed with portable machines in the field are typically uncomplicated systems that are both easy to operate and economical. Additionally, permanent fittings are not as difficult to install as other types.

2. Field-Attachable Fittings

Field-attachable fittings are categorized as clamp-type or screw-together. The screw-together fitting turns the outer coupling shell over the hose’s outside diameter, and thus attaches the hose to the fitting. The insert of the fitting must then be screwed into its shell. Thread type is another aspect to which thought must be given when selecting a fitting. Several thread types are available for hydraulic hose assemblies, including the following:

• Japanese fittings
• French Gas fittings
• British Standard Pipe–BSP
• German DIN hose fittings

In addition, one can choose from North American Thread Types, including those listed below:

• 4-Bolt Split Flange
• O-ring Face Seal–ORFS
• SAE O-rings–Boss Type
• Flange Fittings–Codes 61 and 62
• SAE 37⁰ JIC, SAE 45⁰ Flare
• Dryseal American Standard Taper Pipe Thread–NPTF

Ultimately, however, fittings are only as good as the person by whom they are installed. Each fitting style requires proper assembly procedures, and the level at which the assembler adheres to those standards is the difference between solid connections and future problems with the assembly. To ensure the correct identification is made, measure and compare the threads to the tables listed here.

Great resources are offered by Parker Hannifin for those in the market for hydraulic hose, equipment and fittings. These resources include information outlining proper techniques for hose assembly, as well as a mobile app called the Parker HoseFinder. The latter is another helpful tool for those with busy lifestyles who need assistance in selecting the appropriate fittings and hose for essentially any application.

7 Hydraulic Hose Safety Tips

When it comes to hydraulic hose systems safety is imperative. But safety involves more than the operation of hydraulic hose systems, however. The safety process also includes the selection and maintenance of the hoses. Safe hydraulic hoses are critical given the roles they play. Hoses are connected to a power-distributing cylinder. A hose failure can lead to accidents including injuries from a bucket on a loader failing. The consequences are exceptionally high in situations involving high-lift applications.

To many, creating a safe work environment through maintaining hydraulic hoses is common sense. Be that as it may, the best way to keep a safe work environment and avoid accidents is refreshing employees on the basics including hose maintenance routines, leak prevention, contamination, and temperature/pressure ratings. Adequately considering these factors can go a long way in providing a safe work environment.

Safety and Maintenance Tips

1) Create a maintenance routine

The first step to proper maintenance is keeping a regular inspection routine. Inspecting hoses each month will assist with catching hose failures and other issues before they can lead to a catastrophic outcome. Strictly following a maintenance schedule may not come second nature to some, but continually inspecting hoses will limit downtime and repair costs in the long run. It’s worth remembering that a well-maintained hydraulic system will have a longer lifespan.

One efficient way to build a maintenance routine is through an asset tagging and ID system. These systems can help a business cut repair downtime by increasing the ease of access to hydraulic assembly information. The basis of this system is a unique ID code assigned to each hose or part. This identification system allows for streamlined repairs. Asset tagging and ID systems also include reporting tools that can enhance maintenance efforts.

QUICK TIP: Always review federal, state, and local regulations before cleaning an oil spill.

2) Don’t ignore signs of leakage

Make no mistake; external hose leakage is always a sign of a problem. These leaks also represent a higher expense than just repair and downtime. If the leak of hydraulic oil is large enough, you can expect fines from OSHA and the EPA on top of the other costs. That doesn’t take into account the potential for lawsuits. Oil spilled on the floor can lead to employees slipping and falling in the oil spill. Furthermore, it’s possible pressurized hoses, valve seals, and threaded pipe connectors can rupture and cause an injury. The oil itself is its own risk given how flammable the substance is. This risk is even higher in environments with ignition sources constantly present.

3) Replace hoses when they wear down

It’s possible to identify potentially dangerous hoses before disaster strikes. The best practice is to inspect hoses for cracks, tears, twisting, bends, or abrasions. The cover of the hose is designed to protect the sturdier wire reinforcements from environmental hazards including the weather or sharp objects. Once the cover wears down and is breached the risk of rapid deterioration in the integrity of the hose increases. Unlike the cover, the wire reinforcements are much more susceptible irritants like rocks and sharp objects. What’s more, wire reinforcements can rust and crumble when exposed to water. Reviewing each hose for twists is the first step in preventing this type of damage. It is also critical to inspect the connection at each coupling. If there is seeping leaking out of the coupling, it’s possible there is damage that is causing that redistribution of pressure. Finally, some environments are naturally abrasive. The best answer to these circumstances are hoses with covers designed to withstand severe abrasions.

4) Prevent contamination through proper cleaning

Contamination within a hydraulic hose is as critical of an issue as damage to its exterior. It’s necessary to properly clean all hydraulic equipment after each use. Hoses that aren’t properly cleaned can experience a buildup of debris. During future use the hydraulic fluid can carry the debris through the hose, damaging the interior tube and leading to a breached hose assembly. Thankfully, a hydraulic hose can be cleaned using a hose cleaning kit. These kits flush pellets through the hose to force out any contaminant. Once cleaned it is recommended to seal the caps of the hose before transporting them. External dirt and debris can be harmful not only to the inner tube but also the cylinder that powers the hydraulic system. Dirt entering cylinders or valves can be catastrophic and require replacement of the entire system.

5) Maintain the appropriate fluid temperature

The fluid within a hose needs to be kept at the temperature specified by the hose manufacturer. Every hose has a temperature rating displayed on the layline. Fluid that overheats above the recommended temperature range can lead to cracks in the inner tube. These cracks can lead to leaks and a loss of flexibility.

QUICK TIP: A hose that is too hot to touch is likely overheated beyond the safe temperature range as prescribed by the manufacturer.

6) Adhere to pressure limits

Much like with the temperature ratings, each hose also has a maximum hydraulic pressure rating. It is critical that the internal hydraulic pressure not exceed the pressure ratings as prescribed by the manufacturer. Exceeding the pressure rating can lead to a shortened hose life.

7) Perform a hose failure analysis

If, after a maintenance schedule is enacted, a hose still fails it is worth determining the exact cause. There’s no way to go back in time and prevent the failure, but it may be possible to eliminate future failures. Correcting the root problem that led to the hose failure can mitigate future losses and save both time and money.