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CS Hose Instruction Training PowerPoint-Manual .pptx

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CS Hose Instruction Training PowerPoint-Manual .pptx

  1. 1. Clean Seal, Inc. AUTOMOTIVE HOSE TRAINING
  2. 2.  Founded in 1978  Manufacturer/Distributor of high quality extruded rubber & plastic seals, automotive hose, molded products, expanded foams, and trim moldings
  3. 3. Located in South Bend, Indiana
  4. 4. Large inventory of stock items in our climate controlled warehouse. We ship product fast!
  5. 5.  Clean Seal has been awarded the prestigious ISO 9001:2015 certification every year since 2002.
  6. 6. We serve hundreds of industries worldwide! Transportation Industrial Marine Energy/Construction Automotive Military Ambulance
  7. 7.  Clean Seal is the innovator and problem solver for our customer’s needs  Our technical expertise sets us apart from the competition  We work directly with engineers to “ensure our customers stays compliant with ever changing CARB, EPA and SAE standards.”  We stock millions of feet to reduce lead time  Clean Seal can ship stock items in 3-4 days
  8. 8. Product Overview • Low-Permeation Fuel Barrier Hose • Black Standard Heater Hose • Nomex World Spec Heater Hose • Gas Tank Fuel Fill Hose • Soft Wall Fuel Fill Hose • Low Perm Tier III Carb Hose • SAE 30R14T2 CARB LEV II Approved Hose • Standard Premium Fuel Line • Gas Tank Vent Hose • Air Conditioning Hose • Molded Hoses • Heavy Duty Air Hose • Push-On Air Hose • Windshield Wiper/Vacuum Tubing • Engine Coolant Hose
  9. 9.  Members of the Society of Automotive Engineers  Work directly with California Air Resources Board (CARB) and the EPA on changing standards for our varied customers  Meet regularly with groups like the RVIA Codes and Standards leadership to help keep clients compliant and up-to-date on all current and future federal regulations  Our location in South Bend, IN provides us the ability to ship quickly and efficiently across the U.S. and Canada
  10. 10. Fuel, A/C, Engine Coolant and Air Hoses
  11. 11. Technical specifications that need to be met from the customer’s perspective:  CARB, EPA, and SAE standards for both low pressure and fuel injection applications  Quality spec reports and testing results on all hoses provided  Provide all current CARB, EPA, and SAE documents verifying products are approved for specified use
  12. 12. SAE J3R14T2 Fuel Injection Hose DM-30R14 Carb EO# Q-19-156 A-LPFL Carb EO# Q-19-002 Used as replacement for all SAE 30R9 Fuel Injection Hoses SAE 30R12 Fuel Injection Hose Meets SAE J2230-1996 Requirements A12-FIL CARB EO# Q-19-024 Used primarily I vehicles operated indoors (Lift Trucks, Floor Sweepers)
  13. 13. SAE is the acronym for Society of Automobile Engineers, currently known as SAE International. They are a U.S.-based, globally active professional association and standards developing organization for engineering professionals in various industries. Their standards are used to identify many products we use individually (example: motor oil, SAE 10W30), as well as the Hose products we sell at Clean Seal.
  14. 14. SAE Callouts for Various Hose Products These SAE callouts help us identify the proper hose that can be used in a particular application. Proper nomenclature of SAE begins these callouts with the letter “J”, however the “J” is not always included in the more standard callouts. The next two numbers of the callout, whether or not they are led by a “J”, identifies the type of hose (or what it can be used to transport). The remaining letters and numbers of the SAE callout indicates the specific use of each type of hose. SAE Types (first two numbers)  J10 - Applies to air accessory reservoirs. Used in auto or off-road vehicles, in conjunction with compressed air or vacuum applications.  J20 - Reinforced and Flexible hoses for use in water and ethylene glycol based engine coolant system applications.  J30 - Various fuels for auto, farm, and small engine machinery (mowers, ATV’s)  J1527 - Marine grade hose and used in Fuel Fill auto applications.
  15. 15. Specific Uses (remaining letters and numbers) See Hose Information Matrix of CS parts  SAE J1037 - Low pressure hose used mainly in windshield washer solution, and auto emissions and power vacuum applications.  SAE 20R3 - Standard Heater Hose used for engine coolant.  SAE J2064 & SAE J3062- Air conditioning hose used for Refrigerants in AC units.  SAE 30R7 - Fuel line, vapor emission, crankcase ventilation. (SAE 30R14 is a similar hose but is used in applications with CARB and EPA constrictions).  SAE 30R9 - Fuel hose used for Fuel Injection Systems. This is a higher pressure and temperature fuel hose.  SAE 30R11 - Low permeation fuel fill and vent hose, commonly used in small engine machinery.
  16. 16.  SAE 30R12 - Low permeation fuel feed and return hose, used for higher emissions control in interior type vehicles, like forklifts.  SAE 30R14T2 – Fuel Hose used in Fuel Injection Systems where CARB & EPA requirements are mandatory. This product works in most SAE 30R9 applications.  SAE J1527 - This SAE callout contains an additional Rating System for Marine applications.  A1 - Fuel feed hose; has fire resistant cover, designed to have fuel in hose at all times. Least permeable with highest fire resistance.  A2 - Fuel vent hose; has fire resistant cover, is not designed to have fuel in it at all times.  B1 - Fuel feed hose; without fire resistant cover, designed to have fuel in it at all times, intended for non-enclosed spaces. Diesel engines or above deck outboard gasoline application.  B2 - Fuel vent hose; without fire resistant cover, is not designed to have fuel in it at all times. Diesel vent line.
  17. 17. Terminology Permeation – Penetration of a liquid, gas, or vapor through a solid. Reinforced – Typically denotes a structure reinforcement, using wire or nylon. Vent Hose – Fuel and fuel fumes are always meant to pass through and not sit in the hose. Feed Hose – Hose that can always have fuel in it. CARB – California Air Resources Board which is a “Clean Air Agency” that regulates specifications. Normally, others follow their directives. EPA – Environmental Protection Agency which regulates what can and cannot be done to the environment. DEF – Diesel Exhaust Fluid which is a mixture of synthetic, high-purity, automotive- grade urea and deionized water. Biodiesel – A biofuel intended as a substitute for diesel, which is a vegetable oil- or animal fat-based diesel fuel consisting of long-chain alkyl (methyl, ethyl, or propyl) esters.
  18. 18. A timeline of events concerning current CARB / EPA requirements 1) Original CARB / EPA Standards from 2005 (when fuel was initially added to the CARB line up) consisted of an SAE 30R9 Fuel Hose being tested under SAE Standards. This compromise was necessary initially as an effort to work with the Automotive Industry and to bypass any and all lawsuits said industry was preparing. This testing included the hose in question of being “pre-soaked” in Fuel Type C (Regular Gasoline) at a temp of 23 degrees C (73 degrees F). This hose was to soak for 48 hours BEFORE any permeation testing per SAE testing regulations. 2) The original “layers” that make up most SAE 30R9 Fuel Hoses at that time (before the MY2020 CARB upgrades) were as follows: A) Inner Layer – NBR (Synthetic Nitrile Rubber) Barrier Layer – FKM (Fluorocarbon Rubber – Viton) Reinforcement Layer – (Aramid Spiral) Cover – CSM (Black Hypalon made by DuPont Chemical)
  19. 19. 3) Once CARB had given their EO# for a particular product, then the hose was to be submitted to EPA for approval. The EPA has mandated that all hoses be submitted annually for updated approvals. CARB made their initial EO#’s good for the life of the program. 4) All hose Mfg.’s were to then submit their testing to CARB in order to receive approval, followed by CARB issuing an Executive Orders number. This number was to be printed on the hose in question and this original EO# was then approved “for life” as long as no changes were made to the formulation of the raw materials used to build this product. 5) Over the years the various automotive fuel hose Mfg.’s had to make changes to the raw materials for a variety of reasons. When making these changes, they were supposed to re-submit their products to CARB for updated approvals. For the most part this didn’t happen. Hose Mfg.’s kept on using old CARB EO#s on hose that technically wasn’t approved. Once CARB found out about this, they decided to take action.
  20. 20. 6) In 2016 CARB started making changes to their approval process that was to take effect no later than Model Year 2020 (MY2020). In 2017 these updates (along with higher testing standards) were posted on the CARB website and the changes required by CARB were as follows: A) The pre-soak fuel went from Fuel Type C to Fuel Type CE10 (Regular Gasoline with 10% Ethanol). B) The temp of the Fuel Type CE10 during the pre-soak phase went up from 23 degrees C (73 Degrees F) to 40 Degrees C (104 Degrees F). This pre-soak period remained at 48 hours. C) CARB made new rules that requires ALL fuel hose Mfg.’s to re-submit their products for approval to CARB every 5 years. This way (in CARB’s opinion) they can police this process much better. D) The EPA then decided to NOT approve any fuel hoses that have not been first approved by CARB for these reasons.
  21. 21. 7) We also understand that CARB did a very poor job of rolling these new updated regulations out to everyone. They (CARB) posted these new requirements on their website, but failed to (for example) take adds out in the various trade publications, send bulletins to companies that have been issued CARB EO#’s in the past, etc. They merely expected everyone to go to their website periodically and find this info out for themselves. This didn’t happen. 8) In late 2019, one of the lead engineers from a prominent hose Mfg. discovered this “update” within CARB by accident and brought this up at a CARB meeting in Sacramento, CA in early January 2020. At that point all hose Mfg.’s found themselves in “scramble mode” trying to come up with an SAE 30R9 Fuel Hose that would meet these new standards.
  22. 22. 9) It was determined that nobody could build an SAE 30R9 Fuel Hose using the current line up of raw materials due to the higher fuel temp causing severe wall separation during the pre-soak phase of the testing. Companies like DuPont, Dow Chemical, and others have been working on possible solutions for this problem, but the main issue is that the SAE 30R9 raw materials do not work well on a consistent basis with the previous adhesives used to bond each layer. 10) The alternative product that does meet the SAE / CARB / EPA certifications is the SAE 30R14T2 Fuel Hose. The raw materials used to build this hose are as follows: o Inner Layer – NBR (Synthetic Nitrile Rubber) o Barrier Layer – THV 500 (A 3M Fluorothermalplastic made by Dyneon (a 3M Div) o Tie Layer – NBR (Synthetic Nitrile Rubber o Reinforcement – Polyester (Fabric) o Cover – CM (Chloropolyethylene)
  23. 23. 11) To make sure the fuel hose your company is using in these applications is CARB compliant, simply look for the CARB EO# on the fuel hose itself. Using Akwel Automotive’s EO# as an example, you’ll notice the number “Q-19-002” printed in the hose. The number “19” within the CARB EO# indicates that this product was approved by CARB in 2019. All CARB hoses showing a year older than 2017 are no longer considered to be “currently approved” products by CARB. We are seeing old CARB Approved fuel hoses being used, with EO#’s similar to C-U-12-017. In this EO#, the “12” indicates this hose was first approved by CARB in 2012. Since this was approved before 2017, CARB no longer recognizes this product as it doesn’t meet their updated standards for approval. 12) The SAE 30R14T2 product has become a suitable replacement for all “small engine” applications using fuel injection or low-pressure engines. Products like golf carts, scooters, ATV’s, on board generators, lawnmowers, garden equipment, and any and all secondary devices used on larger vehicles that require fuel being ran to them from the main fuel tank are all “approved for use” by both CARB and the EPA.
  24. 24. 13)We are looking at least another year before the SAE 30R9 Fuel Hose can be redeveloped properly and will then meet CARB / EPA requirements. The reality is that as long as the current demands are in place with the various fuel hose Mfg.’s this issue will continue to be pushed onto the “back burner” as resources and personnel are stretched too thin to properly test and evaluate these new products for both the industrial and aftermarket programs currently in place today. 14)In the meantime, we suggest that our customers continue to periodically visit the CARB / SORE website for updates as to what products have been approved for use by CARB. Their website is as follows: https://ww2.arb.ca.gov/our-work/programs/small- road-engines-sore/sore-evaporative-component- executive-orders
  25. 25. CARB EVAPORATIVE EMISSIONS (Handheld)  Applies to small engines < 80 cc  Typical equipment includes string trimmers, leaf blowers, and chainsaws CARB Evaporative Emissions Regulations Section 2754
  26. 26. Performance Requirements Section 2754(a) Design Requirements Section 2754(b) Effective Date Model Year Diurnal Standard Grams HC/day Fuel Hose Permeation Grams ROG/m 2 /day Fuel Tank Permeation Grams ROG/m 2 /day Carbon Canister or Equivalent Butane Working Capacity Grams HC 2006 None 15 None None 2007 through 2011 1.20 + 0.056*tank vol. (liters) 15 2.5 Specified in TP-902 2012 0.95 + 0.056*tank vol. (liters) 15 1.5 Specified in TP-902  Applies to equipment other than walk-behind mowers with engines > 80 cc to < 225 cc CARB EVAPORATIVE EMISSIONS (Small Non-Handheld) CARB Evaporative Emissions Regulations Section 2754
  27. 27. CARB EVAPORATIVE EMISSIONS (Small Non-Handheld) Performance Requirements Section 2754(a) Design Requirements Section 2754(b) Effective Date Model Year Diurnal Standard Grams HC/day Fuel Hose Permeation Grams ROG/m 2 /day 2006 None 15 2007 and 2008 1.3 N/A 2009 1.0 N/A  Applies to walk-behind mowers with engines > 80 cc to < 225 cc CARB Evaporative Emissions Regulations Section 2754
  28. 28. The Solution:
  29. 29. • Cost Effective • High performance to meet CARB and EPA emission requirements • Hoses are available either formed or in bulk quantities • Available in either reinforced or non-reinforced constructions Multi-Layer Technology Optimizes Emissions Performance
  30. 30. Nitrile Core THV Barrier Tie Layer Optional Reinforcement CSM Cover Hypalon is a registered trademark of Dupont Corporation CARB Executive Order Q-19-082  Suitable Low-permeation replacement for most SAE J30R7 applications  Nitrile Rubber Interior – Designed for improved sealing  Hose Cover – CSM (Hypalon®) for excellent durability, weathering and ozone resistance – Flammability - Self extinguishing – Temperature resistance to 100ºC continuous
  31. 31.  Suitable Low-permeation replacement for most SAE J30R9 applications  FKM Rubber Interior – Very Good Sour Fuel Resistance – Designed for improved sealing – Minimized “wicking” – FKM rubber for excellent durability and Maximum fuel resistance  Hose Cover – CSM (Hypalon®) for excellent durability, weathering and ozone resistance – Flammability - Self extinguishing – Temperature resistance to 100ºC continuous EPA Certified by Design (per 40CFR §1051.110 (b) FKM Core THV Barrier Tie Layer Optional Reinforcement CSM Cover Meets requirements of SAE J30R12
  32. 32.  Variety of hose printing options to aid in assembly applications  Superior quality, durability & sealing  High performance barrier materials  Optional expanded hose ends provide economic solutions by reducing material requirements and easing assembly installation effort FORMED HOSES… Our molded hoses come in a wide range of shapes and size requirements. These hoses can be made for use in fuel systems meeting the various SAE30R7, SAE J1527, and the CARB LEV II fuel ratings required. Many of the more traditional SAE20R3 D2 and the 20R3D1. Class B engine coolant molded hoses are also available.
  33. 33. Product Advantages  Extensive knowledge in the fuel hose industry, with a history of working with CARB and EPA  We are the leaders in small diameter barrier hose products for the automotive industry  Flexibility to provide a variety of hose reinforcement options  Bulk supplied product or cut-to- length fuel hose available  Mandrel formed barrier hose options to meet installation needs
  34. 34. Packaging Options…  Flexibility to provide a variety of packaging options for: • Bulk Hose • Cut to Length hose • Formed hoses • Assemblies  Packaging options include: • Reels • Expendable Packaging • Returnable Packaging
  35. 35. Black Standard Heater Hose A replacement for hose on most cars and light trucks. This standard grade hose meets SAE20R3 Class D2 spec for normal duty service. Withstands the abuse of corrosive solutions and additives. Resists weathering to provide a long, trouble-free service life. Application: Heater Style: Black Grade: Black Standard Specifications: SAE20R3 Class D2 Cover Color: Black Construction- Tube: EPDM Reinforcement: Two Spiral Polyester Cover: EPDM Temperature Resistance: -40 Degrees F to +212 Degrees F
  36. 36. Application: Heater Style: Black Grade: Black Standard Specifications: WSEM96D34-A4 Cover Color: Black Construction- Tube: EPDM Reinforcement: Two Spiral Polyester Cover: EPDM Temperature Resistance: -40 Degrees F to +212 Degrees F Nomex World Spec Heater Hose A replacement for OE hose on all FORD cars, as well as heavy and light trucks chassis. This high quality hose is made from flame retardant Nomex materials and meets or exceeds WSEM96D34-A4 for higher under hood temperatures. Withstands the abuse of corrosive solutions and additives. Resists weathering to provide a long, trouble-free service life.
  37. 37. Gas Tank Fuel Fill Hose Designed for connection between gas tank and filler neck on automotive vehicles. This special hose handles leaded, unleaded, alcohol-added, diesel, and ethanol based fuels. Resists heat, weather, abrasion and ozone. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Fuel Line Gas Tank Filler N/A SAEJ1527 Type A2 Black with Red Stripe Nitrile Spiral Polyester Cord Poloychloropene 257 Degrees F
  38. 38. Soft Wall Fuel Fill Hose This hose meets the same standards as our gas tank fill hose, but is not wire re- enforced. It is an excellent product when used in a "straight run" from the fuel tank to the filler neck. This provides a production friendly connection application. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Fuel Line Gas Tank Filler N/A SAEJ1527 Type A2 Black with Red Stripe Nitrile N/A Poloychloropene 257 Degrees F
  39. 39. Standard Premium Fuel Line Designed for conveying most modern fuels in cars, trucks, buses, etc. Handles temperature ranges of -40 to +257 Degrees F. Withstands oil, grease, abrasion and ozone. An excellent product for all diesel based fuels. Meets or exceeds the burst requirements of the SAE30R7 specification. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Fuel Line SAE30R7 N/A SAE30R7 Black Nitrile Two Spiral Polyester Nitrile/PVC -40 Degrees F +257 Degrees F (+302 Degrees F Intermittent)
  40. 40. Low Perm Tier III Carb Hose Our low permeable fuel line is more cost-efficient alternative for those companies wanting to meet the California Air Resources Board (CARB) requirements. While some applications are mandatory to meet the more stringent requirements listed under Executive Orders Q-19-082. CARB LEV II Low Perm Hose is a suitable low- permeation replacement for most standard SAE30R7 applications. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Fuel Line CARB Low Perm Hose N/A SAE30R11 CARB Tier III Black Nitrile Rubber THV Barrier CSM (Hypalon) -40 Degrees F +257 Degrees F Continuous
  41. 41. Air Conditioning Hose Air Conditioning Hose 4826 *Two Polyester Spiral Barrier Hose *J51 All Outside Diameters *Temperature Range -40 to +257 Degrees F *Compatible with: *R-12/R134A Refrigerants *Mineral Oil, PAG's *Meets J2064 "TYPE C Class II" Hose Performance *Low Volumetric Expansion *Dimensionally Stable *Flexible - Easy to Route
  42. 42. Heavy Duty Air Hose A multi-purpose hose designed for tough general service air and water applications. It features an EPDM tube and cover with a four spiral polyester reinforcement that keeps the hose kink resistant and flexible in extreme temperatures. The cover is resistant to abrasion, weathering and ozone. Rated at 200 to 300 PSI working pressure. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Air Heavy Duty Bulk Air N/A N/A Red EPDM Four Spiral Polyester EPDM -40 Degrees F to +212 Degrees F (not for steam use)
  43. 43. Windshield Wiper/Vacuum Tubing Low pressure EPDM tubing for windshield washers, vacuum and emissions systems for power accessories. Meets SAE J1037 specifications. Will not deteriorate from heat, weathering or ozone. Maintains its flexibility even at low temperatures. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Windshield Wiper/Vacuum N/A N/A SAE J1037 Black EPDM None N/A -40 Degrees F to +257 Degrees F (not for steam use)
  44. 44. Push - On Air Hose This high quality hose can be used by all industries. It has a Class A high oil resistant tube and cover that offers excellent resistance to oil and petroleum based products. It has excellent coupling retention. It holds the special fitting tightly and safely. With an easy push, the spiral hose design grips the fitting securely and maintains a constant internal holding action. The fitting will not give, even under full working pressure. Not recommended for unleaded gasoline. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Air Push-On Hose N/A N/A Black, Blue, Gray, Red, or Yellow Nitrile Two Spiral Aramid Fiber Nitrile/PVC Blend -30 Degrees F to +160 Degrees F (180 Degrees F Intermittent)
  45. 45. Engine Coolant Hose A general purpose, low pressure coolant and heater connector built for long lasting performance at temperature ranges of 0 to +212 Degrees F. Resists aging, ozone, chemicals and lubricants. Application: Style: Grade: Specifications: Cover Color: Construction Tube: Reinforcement: Cover: Temperature Resistance: Engine Coolant Black General Purpose Coolant SAEJ2006 Black Nitrile/SBR Blend 3 PLY Nylon Screen Nitrile/SBR Blend 0 Degrees F to +212 Degrees F
  46. 46.  For Engine Exhaust & Coolant Air Intake EPDM RUBBER
  47. 47.  Variety of Material, Construction, Forming and Packaging Options  Customer Focus  In-House Testing Capabilities  Capability to Meet the Needs of New Fuel Technologies  History of Working with SAE, EPA and CARB  Low-Cost, High-Performance Option Summary
  48. 48. AUTOMOTIVE HOSE Clean Seal®, Inc. offers an extensive line of Automotive Fuel Fill Hose, Gas Tank Vent Hose, Air Conditioning Hose and Molded Hose products. Let our hose expert assist you in meeting your spec requirements
  49. 49. Please contact: Steve Peach Automotive Hose Division Manager Clean Seal, Inc. 20900 W. Ireland Road South Bend, In. 46680 1-800-366-3682 1-574-299-1888 Visit our website @: www.cleanseal.com Thank you for completing the Clean Seal Automotive Hose training!

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