Laboratory TP-106-10-1 Brake Hoses.pdf

TP-106-10

April 10, 2008

U.S. DEPARTMENT OF TRANSPORTATION

NATIONAL HIGHWAY TRAFFIC SAFETY ADMINISTRATION

LABORATORY TEST PROCEDURE

FOR

FMVSS 106

Brake Hoses

ENFORCEMENT

Office of Vehicle Safety Compliance

Mail Code: NVS-220 1200 New Jersey Avenue, SE

Washington, DC 20590 ii

OVSC LABORATORY TEST PROCEDURE NO. 106

TABLE OF CONTENTS

PAGE

1. PURPOSE AND APPLICATION

2. GENERAL REQUIREMENTS

3. SECURITY

4. GOOD HOUSEKEEPING

5. TEST SCHEDULING AND MONITORING

6. TEST DATA DISPOSITION

7. GOVERNMENT FURNISHED PROPERTY (GFP) AND TEST SAMPLES

8. CALIBRATION OF TEST INSTRUMENTS

9. PHOTOGRAPHIC DOCUMENTATION

10. DEFINITIONS

11. PRETEST REQUIREMENTS

12. COMPLIANCE TEST EXECUTION

12.A. TEST REQUIRMENTS – HYDRAULIC BRAKE HOSES

12.A.1. LABELING INSPECTION

12.A.2. CONSTRICTION TEST

12.A.3. EXPANSION TEST

12.A.4. BURST STRENGTH TEST

12.A.5. WHIP TEST

12.A.6. TENSILE STRENGTH TEST

12.A.7. LOW TEMPERATURE RESISTANCE TEST

12.A.8. END FITTING CORROSION TEST

12.A.9. OZONE RESISTANCE TEST

12.A.10. WATER ABSORPTION TEST)

12.A.11. BRAKE FLUID COMPATIBILITY TEST

12.A.12. HIGH TEMPERATURE IMPULSE TEST

12.A.13. DYNAMIC OZONE TEST)

12.A.14. TRACER CORD IDENTIFICATION

12.B. TEST REQUIREMENTS - AIR BRAKE HOSES

12.B.1. LABELING INSPECTION

12.B.2. CONSTRICTION TEST

12.B.3. HIGH TEMPERATURE TEST

iii

12.B.4. LOW TEMPERATURE RESISTANCE TEST

12.B.5. OIL RESISTANCE TEST

12.B.6. OZONE TEST

12.B.7. LENGTH CHANGE TEST

12.B.8. ADHESION TEST (HOSE NOT REINFORCED BY WIRE)

12.B.9. FLEX STRENGTH AND AIR PRESSURE TEST

12.B.10. CORROSION RESISTANCE AND BURST STRENGTH TEST

12.B.11. TENSILE STRENGTH TEST

12.B.12. WATER ABSORPTION TEST

12.B.13. ZINC CHLORIDE RESISTANCE TEST

12.B.14. SALT SPRAY TEST

12.B.15. ADHESION TEST (HOSE REINFORCED BY WIRE)

12.B.16. TRACER CORD IDENTIFICATION

12.C. TEST REQUIREMENTS - VACUUM BRAKE HOSES

12.C.1. LABELING INSPECTION

12.C.2. CONSTRICTION TEST

12.C.3. HIGH TEMPERATURE RESISTANCE TEST

12.C.4. LOW TEMPERATURE RESISTANCE TEST

12.C.5. OZONE TEST

12.C.6. BURST STRENGTH TEST

12.C.7. VACUUM TEST

12.C.8. BEND TEST

12.C.9. SWELL AND ADHESION TEST

12.C.11. DEFORMATION TEST

12.C.12. SALT SPRAY TEST

12.C.13. TRACER CORD IDENTIFICATION

12.D. TEST REQUIREMENTS – PLASTIC AIR BRAKE TUBING

12.D.1. LABELING INSPECTION

12.D.2. CONSTRICTION TEST

12.D.3. HIGH TEMPERATURE CONDITIONING AND DIMENSIONAL STABILITY

TEST

12.D.4. BOILING WATER CONDITIONING AND DIMENSIONAL STABILITY

TEST

12.D.5. BURST STRENGTH TEST

iv

12.D.6. MOISTURE ABSORPTION AND BURST STRENGTH TEST

12.D.7. UV LIGHT RESISTANCE TEST

12.D.8. LOW TEMPERATURE FLEXIBILITY TEST

12.D.9. HIGH TEMPERATURE FLEXIBILITY TEST

12.D.10. HIGH TEMPERATURE RESISTANCE TEST

12.D.11. HIGH TEMPERATURE CONDITIONING, LOW TEMPERATURE IMPACT

RESISTANCE TEST

12.D.12. BOILING WATER CONDITIONING, LOW TEMPERATURE IMPACT

RESISTANCE TEST

12.D.13. ZINC CHLORIDE RESISTANCE TEST

12.D.14. METHYL ALCOHOL RESISTANCE TEST

12.D.15. HIGH TEMPERATURE CONDITIONING AND COLLAPSE RESISTANCE

TEST

12.D.16. OZONE RESISTANCE TEST

12.D.17. OIL RESISTANCE TEST

12.D.18. TENSILE STRENGTH TEST

12.D.19. BOILING WATER CONDITIONING AND TENSILE STRENGTH TEST...75

12.D.20. THERMAL CONDITIONING AND TENSILE STRENGTH TEST

12.D.21. VIBRATION RESISTANCE TEST

12.D.22. END FITTING RETENTION TEST

12.D.23. THERMAL CONDITIONING AND END FITTING RETENTION TEST

12.D.24. END FITTING RETENTION SERVICEABILITY TEST

12.D.25. END FITTING CORROSION TEST

13. POST TEST REQUIREMENTS

14. REPORTS

14.1. MONTHLY STATUS REPORTS

14.2. APPARENT TEST FAILURE

14.3. FINAL TEST REPORTS

14.3.1 COPIES

14.3.2 REQUIREMENTS

14.3.3 FIRST THREE PAGES

14.3.4 TABLE OF CONTENTS

15. DATA SHEETS

16. FORMS

v

REVISION CONTROL LOG

FOR OVSC LABORATORY

TEST PROCEDURES

TP-106

TEST PROCEDURE FMVSS 106

REV.

No.

DATE

AMENDMENT

EFFECTIVE

DATE

DESCRIPTION

00 Original release signed by O.D.

08 3/31/93

09 8/26/05 69FR76298 12/20/2006 Substantive changes to incorporate several SAE Recommended Practices relating to hydraulic brake hoses, air brake hoses, vacuum brake hoses, plastic brake tubing, and end fittings.

10 3/7/2008 72FR57450 12/21/2007 Minor technical amendments and changes to adopt a standardized format for the OVSC test procedures.1

1 The Office of Vehicle Safety Compliance is updating its laboratory test procedures, to the extent practicable, with a standardized format.

1. PURPOSE AND APPLICATION

This document is a laboratory test procedure provided by the National Highway Traffic Safety Administration (NHTSA), Office of Vehicle Safety Compliance (OVSC) for the purpose of presenting guidelines for a uniform testing data and information recording format, and providing suggestions for the use of specific equipment and procedures for contracted testing laboratories. The data correspond to specific requirements of the Federal Motor Vehicle Safety Standard(s) (FMVSS). The OVSC test procedures include requirements that are general in scope to provide flexibility for contracted laboratories to perform compliance testing and are not intended to limit or restrain a contractor from developing or utilizing any testing techniques or equipment which will assist in procuring the required compliance test data.

These test procedures do not constitute an endorsement or recommendation for use of any particular product or testing method.

Prior to conducting compliance testing, contracted laboratories are required to submit a detailed test procedure to the COTR to demonstrate concurrence with the OVSC laboratory test procedure and the applicable FMVSS. If any contractor views any part of an OVSC laboratory test procedure to be in conflict with a FMVSS or observes deficiencies in a laboratory test procedure, the contractor is required to advise the Contracting Officer's Technical Representative (COTR) and resolve the discrepancy prior to the start of compliance testing or as soon as practicable. The contractor’s test procedure must include a step-by-step description of the methodology and detailed check-off sheets. Detailed check-off sheets shall also be provided for the testing instrumentation including a complete listing of the test equipment with make and model numbers. The list of test equipment shall include instrument accuracy and calibration dates. All equipment shall be calibrated in accordance with the manufacturer’s instructions. There shall be no contradictions between the laboratory test procedure and the contractor’s in-house test procedure. Written approval of the in-house test procedures shall be obtained from the COTR before initiating the compliance test program.

NOTE: The OVSC Laboratory Test Procedures, prepared for the limited purpose of use by independent laboratories under contract to conduct compliance tests for the OVSC, are not rules, regulations or NHTSA interpretations regarding the meaning of a FMVSS. The laboratory test procedures are not intended to limit the requirements of the applicable FMVSS(s). In some cases, the OVSC laboratory test procedures do not include all of the various FMVSS minimum performance requirements. Recognizing applicable test tolerances, the laboratory test procedures may specify test conditions that are less severe than the minimum requirements of the standard. In addition, the laboratory test procedures may be modified by the OVSC at any time without notice, and the COTR may direct or authorize contractors to deviate from these procedures, as long as the tests are performed in a manner consistent with the standard itself and within the scope of the contract. Laboratory test procedures may not be relied upon to create any right or benefit in any person. Therefore, compliance of a vehicle or item of motor vehicle equipment is not necessarily guaranteed if the manufacturer limits its certification tests to those described in the OVSC laboratory test procedures.

2. GENERAL REQUIREMENTS

FMVSS 106 specifies labeling and performance requirements for motor vehicle brake hose, brake hose assemblies, and brake hose end fittings.

The purpose of S106 is to reduce deaths and injuries occurring as a result of brake system failure from pressure or vacuum loss due to hose or hose assembly and plastic tubing or plastic tubing assembly rupture. The requirements apply to passenger cars, multipurpose passenger vehicles, trucks, buses, trailers, and motorcycles, and to hydraulic, air, vacuum brake hose, plastic air brake tubing, brake hose and plastic air brake tubing assemblies, and brake hose and plastic air brake tubing end fittings for use in those vehicles.

The test procedures and methods outlined herein are based upon the requirements of S106 effective on December 21, 2007.

METRIC SYSTEM OF MEASUREMENT

Section 5164 of the Omnibus Trade and Competitiveness Act (Pub. L. 100-418) establishes that the metric system of measurement is the preferred system of weights and measures for trade and commerce in the United States. Executive order 12770 directs Federal agencies to comply with the Act by converting regulatory standards to the metric system after September 30, 1992. In a final rule published on March 15, 1990 (60 FR 13639), NHTSA completed the first phase of metrication, converting English measurements in several regulatory standards to the metric system. Since then, metrication has been applied to other regulatory standards (63

FR 28912).

Accordingly, the OVSC laboratory test procedures include revisions to comply with governmental directives in using the metric system. Regulatory standards converted to metric units are required to use metric measurements in the test procedures. For any testing equipment that is not available for direct measurement in metric units, the test laboratory shall calculate the exact metric equivalent by means of a conversion factor carried out to at least five significant digits before rounding consistent with the specified metric requirement.

All final compliance test reports are required to include metric measurements for standards using metrication.

NOTE: The methodology for rounding measurement in the test reports shall be made in accordance with ASTM E29-06b, “Standard Practice for Using Significant Digits in Test Data to Determine Conformance with Specifications.”

3. SECURITY

The contractor shall provide appropriate security measures to protect the OVSC test vehicles and Government Furnished Property (GFP) from unauthorized personnel during the entire compliance testing program. The contractor is financially responsible for any acts of theft and/or vandalism which occur during the storage of test vehicles and GFP. Any security problems which arise shall be reported by telephone to the Industrial Property Manager (IPM), Office of Acquisition Management, within two working days after the incident. A letter containing specific details of the security problem shall be sent to the IPM (with copy to the COTR) within 48 hours.

The contractor shall protect and segregate the data that evolves from compliance testing before and after each vehicle test. No information concerning the vehicle safety compliance testing program shall be released to anyone except the COTR, unless specifically authorized by the COTR or the COTR's Division Chief.

NOTE: No individuals, other than contractor personnel directly involved in the compliance testing program or OVSC personnel, shall be allowed to witness any vehicle or equipment item compliance test or test dummy calibration unless specifically authorized by the COTR.

4. GOOD HOUSEKEEPING

Contractors shall maintain the entire vehicle compliance testing area, fixtures and instrumentation in a neat, clean and painted condition with test instruments arranged in an orderly manner consistent with good test laboratory housekeeping practices.

5. TEST SCHEDULING AND MONITORING

The contractor shall submit a test schedule to the COTR prior to conducting the first compliance test. Tests shall be completed at intervals as required in the contract. If not specified, the first test shall be conducted within 6 weeks after receiving the first delivered unit.

Subsequent tests shall be completed in no longer that 1 week intervals unless otherwise specified by the COTR.

Scheduling of tests shall be adjusted to permit vehicles (or equipment, whichever applies) to be tested to other FMVSSs as may be required by the OVSC. All compliance testing shall be coordinated with the COTR in order to allow monitoring by the COTR and/or other OVSC personnel if desired. The contractor shall submit a monthly test status report and a vehicle status report (if applicable) to the COTR. The vehicle status report shall be submitted until all vehicles are disposed of. The status report forms are provided in the forms section.

6. TEST DATA DISPOSITION

The Contractor shall make all preliminary compliance test data available to the COTR on location within four hours after the test. Final test data, including digital printouts and computer generated plots (if applicable), shall be available to the COTR in accordance with the contract schedule or if not specified within two working days. Additionally, the Contractor shall analyze the preliminary test results as directed by the COTR.

All backup data sheets, strip charts, recordings, plots, technicians’ notes, etc., shall be retained by the contractor for a minimum of 3 years after conclusion of each delivery order, purchase order, etc. The COTR shall direct final disposition at that time.

The contractor shall protect and segregate the data that evolves from compliance testing before and after each test.

TEST DATA LOSS

A. INVALID TEST DESCRIPTION

An invalid compliance test is one, which does not conform precisely to all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test.

B. INVALID TEST NOTIFICATION

The Contractor shall notify NHTSA of any test not meeting all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test, by telephone, within 24 hours of the test and send written notice to the COTR within 48 hours or the test completion.

C. RETEST NOTIFICATION

The Contracting Officer of NHTSA is the only NHTSA official authorized to notify the Contractor that a retest is required. The retest shall be completed within 2 weeks after receipt of notification by the Contracting Officer that a retest is required.

D. WAIVER OF RETEST

NHTSA, in its sole discretion, reserves the right to waive the retest requirement. This provision shall not constitute a basis for dispute over the NHTSA's waiving or not waiving any requirement.

6. TEST DATA DISPOSITION….Continued

E. TEST REPORT

No test report is required for any test that is determined to be invalid unless NHTSA specifically decides, in writing, to require the Contractor to submit such report. The test data from the invalid test must be safeguarded until the data from the retest has been accepted by the COTR. The report and other required deliverables for the retest vehicle are required to be submitted to the COTR within 3 weeks after completion of the retest.

F. DEFAULT

The Contractor is subject to the default and subsequent reprocurement costs for nondelivery of valid or conforming test (pursuant to the Termination For Default clause in the contract).

G. NHTSA'S RIGHTS

None of the requirements herein stated shall diminish or modify the rights of NHTSA to determine that any test submitted by the Contractor does not conform precisely to all requirements/specifications of the OVSC Laboratory Test Procedure and Statement of Work applicable to the test.

7. GOVERNMENT FURNISHED PROPERTY (GFP) AND TEST SAMPLES

TEST SAMPLE IDENTIFICATION AND STORAGE

A test set of brake hoses shall consist of a quantity of test hoses plus a specific quantity which may be required for retest if necessary. The quantities shown below shall be used for tests unless amended by the contract.

HOSE TYPE NO. OF TEST HOSES

Hydraulic 21

Air 15

Vacuum 10

Plastic tubing 23

Each test specimen shall be banded on one end or tagged at one end, and marked with a laboratory group number and individual sample number such as "001-2" for group 1, specimen number 2. The marking shall be suitable to withstand all tests and handling environments.

Test flow and usage of the test specimens shall be as shown in Figures 1, 2, 3 and 4.

7. GFP AND TEST SAMPLES....Continued

An inventory shall be made of the number, name and condition of samples received, and then the samples shall be stored in a dry, clean, dark, and dust free area to prevent damage to them in any manner which may affect test results.

R e c e iv in g /In s p e c tio n o f S a m p le s

F L O W S E Q U E N C E F O R B R A K E H O S E C O M P L IA N C E T E S T S

O N E T E S T S E T

T a g & S ta m p E n d s A & B

T e s t E q u ip m e n t C a lib ra tio n

S A M P L E T E S T S (s e e D e ta il D ia g ra m s -

F ig u re s 2 , 3 & 4 )

In te r im F a ilu re R e p o rt If N e c e s sa ry

F IN A L R E P O R T

D u e 3 w e e k s a fte r la s t te s t c o m p le te d

S P A R E H O S E S

T a g a n d S ta m p

A s R e q u ire d

FIGURE 1

Hydraulic Brake Hoses – Test Sequence

(All brake hose sizes @ 5000psi)

FIGURE 2

HYDRAULIC BRAKE HOSES – TEST REQUIREMENTS (FMVSS No. 106) Par. Par.

S5.3.1 Constriction S5.3.8 Low Temperature Resistance S5.3.2 Expansion and Burst S5.3.9 Brake Fluid Compatibility, Constriction and Burst Strength S5.3.3 Whip Resistance S5.3.10 Ozone Resistance S5.3.4 Tensile Strength S5.3.11 Dynamic Ozone Test S5.3.5 Water Absorption and Burst Strength S5.3.12 High Temperature Impulse S5.3.6 Water Absorption and Tensile Strength S5.3.13 End Fitting Corrosion Resistance S5.3.7 Water Absorption and Whip Resistance

Water Absorption

[16-18]

Expansion [1-4]

Fluid Compatibility

[19]

Tensile Strength [9-12, 18]

Whip Resistance

[5-8, 17] Burst Strength

[1-4,16,19]

Constriction [19]

Ozone Resistance

[15]

Dynamic Ozone

[20]

Low Temp.

Resistance

[13]

Constriction [All samples]

Labeling [All samples]

End Fitting Corrosion

[14]

High Temp.

Impulse

[21]

Length Change

Test Hose 7

W ater Absorption

Test Hose 12

High Temp.

Test Hose 1

Corrosion Resistance & Burst Test Hose 10

Corrosion Resistance

Test Hose 14

Adhesion Test

Hose 8

Zinc Cloride

Resistance Test

Hose 13

Tensile Test

Hose 11 & 12

Flex Strength & Air Pressure

Hose 9

Low Temp Test

Hose 2

Oil Resist.

Test Hose 3 - 5

Ozone Test

Hose 6

Labeling Inspection

Hoses 1 - 14

Constriction Test

Hoses 1 - 14

Tracer Cord Color

Identification To Reports

FLOW SEQUENCE FOR AIR BRAKE HOSES

[A-15]

[A-1]

[A-2]

[A-7] [A-12] [A-3] [A-10] [A-14] [A-8,15]

[A-13] [A-11] [A-9] [A-4] [A-5] [A-6]

[A-16]

NOTE: Numbers shown in [ ] are the

TEST NUMBERS

FIGURE 3

FLOW SEQUENCE FOR VACUUM BRAKE HOSES

FIGURE 4

Water Absorption All Hoses

Deformation Hose 9

Swell Hose 7

High Temp

Hose 1

Low Temp Reistance

Hose 2

Adhesion Hose 8

Labeling Inspection

All Hoses

Ozone Hose 3

Bend Hose 6

Vacuum Hose 5&7

Burst Hose 4

Salt Spray Hose 10

Tracer Cord

All Hoses

8. CALIBRATION OF TEST INSTRUMENTS

Before the Contractor initiates the vehicle safety compliance test program, a test instrumentation calibration system must be implemented and maintained in accordance with established calibration practices. The calibration system shall include the following as a minimum:

A. Standards for calibrating the measuring and test equipment shall be stored and used under appropriate environmental conditions to assure their accuracy and stability.

B. All measuring instruments and standards shall be calibrated by the

Contractor, or a commercial facility, against a higher order standard at periodic intervals not exceeding 12 months for instruments and 12 months for the calibration standards except for static types of measuring devices such as rulers, weights, etc., which shall be calibrated at periodic intervals not to exceed two years. Records, showing the calibration traceability to the National Institute of Standards and Technology (NIST), shall be maintained for all measuring and test equipment.

C. All measuring and test equipment and measuring standards shall be labeled with the following information:

1. Date of calibration

2. Date of next scheduled calibration

3. Name of the technician who calibrated the equipment

D. A written calibration procedure shall be provided by the Contractor, which includes as a minimum the following information for all measurement and test equipment unless the calibration is performed by a licensed commercial facilty:

1. Type of equipment, manufacturer, model number, etc.

2. Measurement range

3. Accuracy

4. Calibration interval

5. Type of standard used to calibrate the equipment (calibration traceability of the standard must be evident).

6. The actual procedures and forms used to perform the calibrations.

E. Records of calibration for all test instrumentation shall be kept by the

Contractor in a manner that assures the maintenance of established calibration schedules.

8. CALIBRATION OF TEST INSTRUMENTS….Continued

F. All such records shall be readily available for inspection when requested by the COTR. The calibration system shall need the acceptance of the COTR before vehicle safety compliance testing commences.

G. Test equipment shall receive a system functional check out using a known test input immediately before and after the test. This check shall be recorded by the test technician(s) and submitted with the final report.

H. The Contractor may be directed by NHTSA to evaluate its data acquisition system.

Further guidance is provided in the International Standard ISO 10012-1, “Quality Assurance Requirements for Measuring Equipment” and American National Standard ANSI/NCSL Z540-1, “Calibration Laboratories and Measuring and Test Equipment General Requirements.”

NOTE: In the event of a failure to meet the standard's minimum performance requirements additional calibration checks of some critically sensitive test equipment and instrumentation may be required for verification of accuracy. The necessity for the calibration will be at the COTR's discretion and shall be performed without additional cost.

9. PHOTOGRAPHIC DOCUMENTATION

Digital Photographs

The contractor shall take digital photographs of the test execution procedures.

Photographs shall be taken in color and contain clear images. A tag, label or placard identifying the test item, NHTSA number (if applicable) and date shall appear in each photograph and must be legible. Each photograph shall be labeled as to the subject matter. The required resolution for digital photographs is a minimum of 1,600 x 1,200 pixels. Digital photographs are required to be created in color and in a JPG format. Glare or light from any illuminated or reflective surface should be minimized while taking photographs.

The test reports should include enough photographs to describe the testing in detailed and should be organized in a logical succession of consecutive pictures.

The digital photographs should be included in the test report as 125 mm x 175 mm (5 x 7 inch) pictures. All photographs are required to be included in the test report in the event of a test failure. Any failure must be photographed at various angles to assure complete coverage.

9. PHOTOGRAPHIC DOCUMENTATION….Continued

Upon request, the photographs should be sent to the COTR on a CD or DVD and saved in a “read only” format to ensure that the digital photographs are the exact pictures taken during testing and have not been altered from the original condition.

10. DEFINITIONS

ARMOR

Protective material installed on a brake hose/plastic tubing to increase the resistance to abrasion or impact damage.

BRAKE HOSE

A flexible conduit, other than a vacuum tubing connector, manufactured for use in a brake system to transmit or contain the fluid pressure or vacuum used to apply force to a vehicle's brakes.

BRAKE HOSE ASSEMBLY

A brake hose, with or without armor, equipped with end fittings for use in a brake system, but does not include an air or vacuum assembly prepared by the owner or operator of a used vehicle, by his employee, or by a repair facility, for installation in that used vehicle.

BRAKE HOSE END FITTING

A coupler other than a clamp, designed for attachment to the end of a brake hose.

DIMENSIONAL DESCRIPTIONS

For hose, a dimensional description such as "1/4-inch hose" refers to the Nominal Inside Diameter (I.D.).

For tubing, a dimensional description such as "1/4-inch tubing" refers to the Nominal Outside Diameter (O.D.).

FREE LENGTH

The linear measurement of hose exposed between the end fittings of a hose assembly in a straight position.

10. DEFINITIONS….Continued

PERMANENTLY ATTACHED END FITTING

An end fitting that is attached by deformation of the fitting about the hose by crimping or swaging, or an end fitting that is attached by use of a sacrificial sleeve or ferrule that requires replacement each time a hose assembly is rebuilt.

PREFORMED

A brake hose that is manufactured with permanent bends and is shaped to fit a specific vehicle without further bending.

RUPTURE

Any failure that results in separation of a brake hose from its end fitting or in leakage.

VACUUM TUBING CONNECTOR

A flexible conduit of vacuum that –

• Connects metal tubing to metal tubing in a brake system

• Is attached without end fittings

• When installed, has an unsupported length less than the total length of those portions that cover the metal tubing

11. PRETEST REQUIREMENTS

IN-HOUSE TEST PROCEDURE

Prior to conducting any compliance test, contractors are required to submit a detailed in-house compliance test procedure to the COTR which includes a step-by-step description of the methodology to be used. Written approval must be obtained from the COTR before initiating the compliance test program so that all parties are in agreement.

The test methods and procedures shall be based on the requirements of the following non-NHTSA documents wherein S106 shall take precedence followed by this Laboratory Test Procedure in case of conflict.

Society of Automotive Engineers (SAE) - -

SAE RM–66–04, Compatibility Fluid

11. PRETEST REQUIREMENTS….Continued

SAE Standard J1703, Motor Vehicle Brake Fluid

American Society for Testing of Materials (ASTM) - -

ASTM E4–03, Standard Practices for Force Verification of Testing Machines

ASTM B117–03, Standard Practice for Operating Salt Spray (Fog) Apparatus

ASTM D471–98, Standard Test Method for Rubber Property—Effect of Liquids

ASTM G154–00 Standard Practice for Operating Fluorescent Light Apparatus for UV Exposure of Nonmetallic Materials

ASTM G151–97, Standard Practice for Exposing Nonmetallic Materials in Accelerated Test Devices that Use Laboratory Light Sources

ASTM D4329–99, Standard Practice for Fluorescent UV Exposure of Plastics

Military Specifications (MIL) - -

C-45662A, Calibration System Requirements

The procedure shall contain instructions for the following:

A. Sample tagging or marking B. Sample stowage C. Testing setup

D. Testing procedure (step-by-step) E. Data recording F. Setup photographs G. Photographs of sample failure(s) illustrating point(s) of failure (include photographs of samples before testing) H. Description of failure(s)

11. PRETEST REQUIREMENTS....Continued

TEST DATA LOSS

A compliance test is not to be conducted unless all of the various test conditions specified in the applicable OVSC Laboratory Test Procedure have been met.

Failure of a contractor to obtain the required test data and to maintain acceptable limits on test parameters in the manner outlined in the applicable OVSC Laboratory Test Procedure may require a retest at the expense of the contractor.

The retest costs will include the cost of the replacement item of motor vehicle equipment and all costs associated with conducting the retest. The original test specimen used for the invalid test shall remain the property of OVSC, and the retest specimen shall remain the property of the contractor. If there is a test failure, the contractor shall retain the retest specimen for a period not exceeding 2 years. If there is no test failure, the Contractor may dispose of the test specimen upon notification from the COTR that the final test report has been accepted.

The Contracting Officer of NHTSA is the only NHTSA official authorized to notify the contractor that a retest is required. The retest shall be completed within two

(2) weeks after receipt of notification by the Contracting Officer that a retest is required. If a retest is conducted, no test report is required for the original test.

TEST CONDITIONS

Unless otherwise specified, all tests and measurements shall be conducted under the following environmental conditions:

A. Temperature 75ºF ± 5ºF B. Relative Humidity 50% ± 10%

C. Atmospheric Pressure

Continuous recording of environmental temperature and relative humidity of the testing area shall be available during all tests. Test samples, unless otherwise specified, shall be stabilized at test room conditions for a period of at least 24 hours immediately prior to testing.

TEST PERSONNEL PERFORMANCE

Personnel supervising and/or performing the compliance test program shall be thoroughly familiar with the requirements, test conditions, equipment for the test to be conducted, and safety requirements.

RECORDING OF TEST DATA

Environmental data and test data shall be recorded on permanent strip charts, circular recording charts, or other acceptable media. Where permanent trace recording is not required, data will be recorded on standard report forms.

Changes or corrections shall be made by drawing a line through the original entry, which must still remain legible, and adding the change alongside.

Test data will be submitted on the standard form Test Data Sheets specified for use in the final test report and shown in Section 15. Data will be typed before the sheets are submitted.

All test areas will require permanent trace recordings, where applicable, and before/after photographs where feasible. This is required to document that test conditions have been maintained as specified and that test criteria have been applied properly and uniformly throughout the test program. The test laboratory will submit for the approval of the contracting officer technical representative the type of permanent data history the laboratory proposes to use, based on test equipment and conditions applicable to each test.

When a sample failure does occur (sample WILL NOT be subjected to further testing), all of the charts and/or recordings for the failed sample or copies thereof shall be retained by the contractor along with the failed specimen unless otherwise directed by the COTR. This shall include a copy of the original operators hand written data as recorded during the test failure.

REPORTING FORMS

The attached forms will be used for submission of data to the COTR. These forms will be reproduced on the Test Laboratory's stationary. One set of the data sheets will be used for each test set of brake hose assemblies. The final report data sheet information shall be typed. One set of data sheets shall consist of the following:

Data Sheets H-1 through H-12 for HYDRAULIC BRAKE HOSES

Data Sheets A-1 through A-15 for AIR BRAKE HOSES

Data Sheets V-1 through V-13 for VACUUM BRAKE HOSES

Data Sheets P-1 through P-13 for AIR BRAKE TUBING

TEST DATA REPORTING SHEETS

In addition to the instrument recording data (which may be in analog form), all test data shall be recorded, in standard engineering units, on forms specifically prepared for this purpose such as those shown as the data sheet for each test.

Changes or corrections of data sheets shall be made by drawing a line through the original entry, which must still remain legible, and adding the change alongside. The initials of the changer shall appear alongside the change.

Data sheets presented in a final form must be typewritten, signed, and include the date of test and date of sign-off. The Report Number must appear at the top of each Data Sheet.

SAMPLE INFORMATION AND SUMMARY OF RESULTS

Preceding the test data sheets in the Final Report, there will be test specimen information and a summary of test results. These sheets will describe the articles tested, list the various tests performed, and indicate the result as either Pass (P) or Fail (F) as supported by the information tabulated on the test data sheets.

PARTS DATA AND SUMMARY OF TEST RESULTS

A. On parts data section of the reporting forms, each space shall be filled out.

Where data is not present, write "NONE."

B. Where a trademark is present, provide a recognizable sketch.

C. Where the hose assemblies are not in a container, but certification statement is provided, write the statement. Where no certification is provided, write "NONE."

D. Sketch the data-bearing portion of the band on the bottom of the report form if a band is present.

E. A hose, which fails one test phase, shall be subjected to NO FURTHER

TESTING unless so directed by the COTR.

12. COMPLIANCE TEST EXECUTION

12.A. TEST REQUIREMENTS - HYDRAULIC BRAKE HOSES

12.A.1. - LABELING INSPECTION - (See Data Sheets H-1A, B & C)

All hydraulic test specimens shall be subjected to labeling inspection and any markings, if present, are to be recorded.

All hydraulic test specimens, which are represented by a vehicle manufacturer to be used on a specific motor vehicle, need NOT have any marking and therefore are NOT subjected to any labeling PASS/FAIL criteria.

The data sheets contain a selection matrix allowing designation of the test specimens as being the following:

• Vehicle Specific Assemblies

• Aftermarket Assemblies (NON-OEM)

• Special Test Assemblies

Vehicle Specific Assemblies are those designated by a vehicle manufacturer as being assemblies used on specific vehicle models and generally will be sold and shipped directly to the test contractor by the vehicle manufacturer or those sold by an authorized vehicle dealer and shipped to the test contractor by the dealer or OVSC.

Aftermarket Assemblies are NON-OEM hose assemblies, and, whereas the assembly manufacturer may sell the assemblies as replacement assemblies for specific vehicles, the vehicle manufacturer accepts NO responsibility for their performance.

Special Test Assemblies are those that a vehicle manufacturer may provide as surrogate assemblies for particular tests such as may be necessary to fit a particular test machine (generally these will be shorter assemblies that will fit a tensile test machine or a whip test machine). Markings are NOT required on the Special Test Assemblies.

HOSE MATERIAL MARKING

The following hydraulic hose information may be present on the hose material of the assemblies to be tested and shall be recorded although the specimens are NOT subject to the PASS/FAIL criteria in all applications. The stripes described in (A) below are NOT required on Vehicle Specific Assemblies. Markings (B) through (F) are NOT required on the brake hose material in any assembly.

12. COMPLIANCE TEST EXECUTION....Continued

(A) Two torque stripes parallel to the longitudinal axes of the hose and placed on opposite sides of the hose. One of the stripes may be interrupted by the information listed in (B) through (F), and the second by any other information that the manufacturer may provide. The two torque stripes are NOT required if the end fittings are such as to prevent the assembly from being installed in a twisted orientation in the vehicle.

(B) The letters "DOT"

(C) Hose Manufacturer's Identification

(D) Date of Manufacturer (Month, Day and Year OR Month and Year expressed in numerals).

(E) Nominal Inside Hose Diameter (I.D. in inches or mm)

(F) Expansion Characteristics (HR or HL)

END FITTINGS

End fittings are NOT required to be marked EXCEPT if the assembly does not contain a band. In that case, except for Vehicle Specific Assemblies, at least one of the fittings shall be etched, stamped or embossed with the assembly manufacturer's identification.

HOSE ASSEMBLIES

Except for Vehicle Specific Assemblies, each hydraulic brake hose assembly shall be labeled with a band (unless the option for end fitting marking has been selected) which shall be etched, stamped or embossed with the following.

(A) The letters "DOT"

(B) Manufacturer's Identification

12.A.2. – CONSTRICTION TEST – (See Data Sheet H-2)

All test specimens shall be subjected to this test. This is basically a "go" or "no go" test in which a plug gage, an extended plug gage, or a drop ball is inserted in the upper end of a hose assembly, which is held vertically, and allowed to drop by gravity through the hose. The hose is acceptable if the gage passes through the hose and can be seen at the lower fitting. Failure to appear at the lower fitting shall be considered a test failure.

The constriction gage shall have a minimum diameter as follows (same diameter ball or rod is permissible):

0.079" for 1/8" I.D. hose (2.048 mm for 3.2 mm I.D.)

0.119" for 3/16" I.D. hose (3.072 mm for 4.8 mm I.D.)

0.159" for 1/4" I.D. hose (4.032 mm for 6.3 mm I.D.)

The gage plug diameter used by the test laboratory shall be shown under "REMARKS" on the Data Sheet.

If a constriction does exist, establish the approximate location of the constriction.

Insert drill rods into the end coupling to determine the maximum size that can be inserted without force. Note size and location on the Data Sheet. Drill rod sizes can be found in the Machinist's Handbook.

The brake hose constriction test requirements shall be met using at least one of the methods specified below.

PLUG GAUGE

(A) Utilize a plug gauge as shown in Figure 5. Diameter ‘A’ is equal to 64 percent of the nominal inside diameter of the hydraulic brake hose being tested.

(B) Brake hose assemblies that are to be used for additional testing have constriction testing only at each end fitting. Other brake hose assemblies may be cut into three inch lengths to permit constriction testing of the entire assembly. Hose assemblies with end fittings that do not permit entry of the gauge (e.g., restrictive orifice or banjo fitting) are cut three inches from the point at which the hose terminates in the end fitting and then tested from the cut end.

(C) Hold the brake hose in a straight position and vertical orientation.

(D) Place the spherical end of the plug gauge just inside the hose or end fitting. If the spherical end will not enter the hose or end fitting using no more force than gravity acting on the plug gauge, this constitutes failure of the constriction test.

(E) Release the plug gauge. Within three seconds, the plug gauge shall fall under the force of gravity alone up to the handle of the gauge. If the plug gauge does not fully enter the hose up to the handle of the gauge within three seconds, this constitutes failure of the constriction test.

FIGURE 5. CONSTRICTION TEST PLUG GAUGE

EXTENDED PLUG GAUGE

(A) The test in S6.12.1 may be conducted with an extended plug gauge to enable testing of the entire brake hose from one end fitting, without cutting the brake hose. The extended plug gauge weight and spherical diameter specifications are as shown in Figure 5, but the handle portion of the gauge may be deleted and the gauge length may be greater than 3 inches.

(C) The required performance of the extended plug gauge in paragraph

S6.12.1(e) is that after the plug gauge is released, the extended plug gauge shall fall under the force of gravity alone at an average rate of 1 inch per second until the spherical diameter of the extended gauge passes through all portions of the brake hose assembly containing hose. If the extended plug gauge does not pass through all portions of the brake hose assembly containing hose at an average rate of 1 inch per second, this constitutes failure of the constriction test.

DROP BALL TEST

(A) Utilize a rigid spherical ball with a diameter equal to 64 percent of the nominal inside diameter of the hydraulic brake hose being tested. The weight of the spherical ball shall not exceed 2 ounces (57 grams).

(B) Hold the brake hose in a straight position and vertical orientation.

(C) Hold the ball just above the end fitting.

(D) Release the ball. The ball shall fall under the force of gravity alone completely through all portions of the brake hose assembly containing hose, at an average rate of 1 inch per second. Failure of the ball to pass completely through all portions of the brake hose assembly containing hose, at an average rate of 1 inch per second, constitutes failure of the constriction test.

12.A.3. - EXPANSION TEST - (See Data Sheet H-3)

GENERAL -

Hoses numbered 1 thru 4 shall be subjected to this test. All portions of the test setup exposed to high pressure shall be made of stainless steel tubing to eliminate any measurable expansion except for that due to the hose being

The test fluid shall consist of distilled water and be free of air or gases. If at any time during the test an air bubble flows out of the hose, repeat the test allowing at least 5 minutes without pressure for the hose to contract to its original size when NOT pressurized.

Compression rings may be used for unconventional ends which have long metal tubes attached to the final end fitting. In these cases, the laboratory shall take adequate precaution to remove all trapped air.

REQUIREMENTS –

The maximum expansion of a hydraulic brake hose assembly shall not exceed the values specified in the table below.

PREPARATION

Measure the free length of the hose assembly and mount the brake hose assembly so that it is in a vertical straight position without tension while under pressure (See Figure 1 of FMVSS No. 106). Allow the test fluid to flow through the brake hose and the burette to bleed all gases from the system.

Close the valve to the burette and apply 15,000 psig for 10 seconds. Check the system for leaks. Release the pressure.

PROCEDURE

Adjust the fluid level in the burette to zero. Close the valve to the burette. Apply a hydrostatic pressure of 1,000 psig at the rate of 1,500 psig/minute and hold this pressure for three seconds.

Close the lower valve and open the upper valve for 10 seconds to allow the fluid level in the burette to rise. This should be accomplished 3 times yielding 3 hose expansions. Do not remove the hose between expansions. The burette reading divided by 3 will give the actual hose expansion.

Repeat the Preparation and Procedure above for 1,500 psig and 2,900 psig.

This actual hose expansion must then be compared to the Maximum Allowable cc/ft. from the table below by dividing the Actual by the hose free length in ft. to determine the "PASS" or "FAIL" for each hose.

Pressure vs. Time shall be permanently recorded.

TABLE

MAXIMUM EXPANSION OF FREE LENGTH BRAKE HOSE (cc/ft)

Test Pressure

1,000 psi 1,500 psi 2,900 psi

I.D.

Regular expansion hose

Low expansion hose

Regular expansion hose

Low expansion hose

Regular expansion hose

Low expansion hose 1/8 in (or 3mm) or less 0.66 0.33 0.79 0.42 1.21 0.61

>1/8in (or 3mm) to 3/16in (or 5mm) 0.86 0.55 1.02 0.72 1.67 0.91

>3/16in(or 5mm) 1.04 0.82 1.30 1.17 Not applicable

Not applicable

12.A.4. - BURST STRENGTH TEST - (See Data Sheet H-4)

Hoses listed below shall be subjected to this test after completion of the

Burst Strength test:

HOSE NO(S). PRIOR TEST

1 - 4 Volumetric Expansion Test (H-3)

16 Water Absorption Test (H-10)

19 Brake Fluid Compatibility and Constriction Test (H-11)

Hoses subjected to the burst test need not be burst.

Connect the brake hose to a pressure system and fill it completely with water, allowing all gases to escape.

(a) Brake hose larger than 1/8 inch or 3 mm diameter:

Apply water pressure of 4,000 psi at a rate of 15,000 psi per minute, hold for 2 minutes at 4000 psi, and increase the pressure at the rate of 15,000 psi per minute until the pressure exceeds 5,000 psi.

(b) Brake hose of 1/8 inch, 3 mm, or smaller diameter:

Apply water pressure of 4,000 psi at a rate of 15,000 psi per minute, hold for 2 minutes at 4000 psi, and increase the pressure at the rate of 15,000 psi per minute until the pressure exceeds 7,000 psi.

Hydrostatic Pressure vs. Time shall be permanently recorded.

12.A.5. - WHIP TEST - (See Data Sheet H-5)

GENERAL -

Hoses numbered 5 thru 8 shall be subjected to this test and Hose #17 shall also be subjected after completion of the Water Absorption Test (H- 10).

The whip machine shall be similar to that indicated in SAE J1401 and shall be dynamically balanced without hoses, and suitably mounted to avoid sympathetic vibrations. Hose couplings shall be mounted perpendicularly to the hose-mounting surfaces of the whip machine (movable and stationary headers with no twist in the hose). If at any time during the test, a hose fails due to a machine malfunction, ALL of the hoses in the test set shall be replaced by extra hoses from the group under test and the test will be repeated. The extra hoses must undergo the Constriction Test (H-

2) prior to the Whip Test.

PREPARATION FOR TEST -

The free length of the hoses to be whip tested shall be measured to within a tolerance of 0.015" with the hose assembly in a straight position using a vernier caliper scale or equivalent. When measuring the free length, the lengths of the end fittings are not included; only the length of the exposed rubber outer cover is measured. Hoses with a free length of less than 8" or more than 24" are not required to be tested.

All external appendages such as chafing collars, removable mounting brackets, date bands and spring guards shall be removed from the brake hose assembly prior to testing on the whip machine. The removed pieces shall be retained for regrouping with each sample until disposal.

The hoses shall be installed on the whip test machine with the slack settings in the table below.

If a whip test failure occurs, prior to removal of the hose from the whip test machine, two photographs, one from above, and one from the side, shall be taken to show that the hose is not twisted. The torque stripe on the hose will be used as an indicator. The photographs shall be kept on file with the chart recordings. Remove failed hose, replace all hose assemblies with new untested hoses, and repeat the test.

TEST -

Apply the 220 to 235 psig water pressure and bleed all hoses and passages to eliminate air pockets and bubbles.

TABLE - HOSE LENGTHS

Free Length Between End Fittings, inches

SLACK

1/8" hose (3 mm) or less

More than 1/8" hose (3 mm)

8 to 15½, inclusive 1.750" No Test Over 15½ to 19, inclusive 1.250" No Test

Over 19 to 24, inclusive 0.750" No Test

10 to 15½, inclusive 1.000"

The time duration for the whip test shall be 35 hours at a machine speed of 780 to 800 rpm.

Pressure and RPM vs. Time shall be permanently recorded for this test.

12.A.6. - TENSILE STRENGTH TEST - (See Data Sheet H-6)

Hoses numbered 9 thru 12 shall be subjected to this test and Hose #18 shall also be subjected after completion of the Water Absorption Test (H- 10).

The tension test consists of subjecting the hose assembly to increasing tensile load in a suitable testing machine until failure occurs, either by -

(A) Separation of the specimen from the end fittings, OR

(B) Failure of the hose structure

A tensile testing machine, which conforms to the requirements of ASTM

Methods, E4-03, "Standard Practice for Force Verification of Testing Machines," and provided with a recording device to measure the force applied throughout the slow and fast pull tests. A machine of 1,000 lbs.

capacity is sufficient. After removal of any hose armor or date bands, etc., the hose assembly fittings shall be attached to the machine by suitable fixtures so that the hose and fittings shall have a straight center line parallel to the direction of the machine pull.

(A) Conduct the slow pull test by applying tension at a rate of 1" per minute. The assemblies shall withstand a minimum pull of 325 lbs.

(B) Conduct the fast pull test by applying tension at a rate of 2" per minute. The assemblies shall withstand a minimum pull of 370 lbs.

Load vs. displacement will be permanently recorded.

12.A.7. – LOW TEMPERATURE RESISTANCE TEST - (See Data Sheet H-7)

Hose #13 shall be subjected to this test. After removal of any hose armor, date bands, etc., the hose shall be placed in the cold box on a low conductivity material such as wood. A wood mandrel of the size noted below shall be conditioned with the test hose:

HOSE I.D.

MANDREL DIAMETER

(+ 0.03", -0")

Less than 1/8" 2.50"

1/8" 3.00"

3/16" and 1/4" 3.50"

Greater than 1/4" 4.00"

The 70 hour test period shall begin when the box recorded temperature stabilizes between -49ºF and -54ºF. The hoses are to be conditioned in the cold box in a straight position and after 70 hours are to be bent around the mandrel favoring any natural curvature already in the hose. The bending operation shall occur in the cold box.

The hose assembly shall be wrapped around the mandrel 180º by hand at a steady rate in 3 to 5 seconds, using suitable gloves, and holding the hose rather than grasping the end couplings.

After bending and removal from the cold box, inspect the outer rubber cover for cracks. Cut the hose lengthwise to expose the inner liner for its inspection for cracks. An external fabric braid may have to be removed to expose the outer rubber cover for inspection.

The Cold Box Temperature vs. Time shall be permanently recorded.

12.A.8. – END FITTING CORROSION TEST - (See Data Sheet H-8)

Hose #14 shall be subjected to this test. Utilize the apparatus described in ASTM B117-03, "Standard Practice for Operating Salt Spray (Fog) Apparatus."

CONSTRUCTION -

Construct the salt spray chamber so that:

(A) The construction material does not affect the corrosiveness of the fog.

(B) The hose assembly is supported or suspended 30º from the vertical and parallel to the principal direction of the horizontal flow of fog through the chamber.

(C) The hose assembly does not contact any metallic material or any material capable of acting as a wick.

(D) Condensation which falls from the assembly does not return to the solution reservoir for respraying.

(E) Condensation from any source does not fall on the brake hose assemblies or the solution collectors.

(F) Spray from the nozzles is NOT directed directly onto the hose assembly.

PREPARATION -

(A) Plug each end of the hose assembly.

(B) Mix a salt solution five parts by weight of sodium chloride to 95 parts of distilled water, using sodium chloride substantially free of nickel and copper, and containing on a dry basis not more than 0.1 percent of sodium iodide and not more than 0.3 percent total impurities.

Insure that the solution is free of suspended solids before the solution is atomized.

(C) After atomization at 95ºF (-2º F, +0º F) ensure that the collected solution is in the PH range of 6.5 to 7.2.