Hand Tester Operations and Service Manual for Brake
Contents
1. TESTER COMPONENTS IDENTIFICATION Pos Name 6 Dead Test Cone A Ren iva Replace Live Test Cone Red Cap with 2 Black 10 11 Male Air Connector Black Hex Filler Cap 7 BrakeQuip O BQEOS 04 Hand Tester Operations and Service Manual HOSE TESTER OPERATION Safety Precautions Read instructions and identify all component parts before using this tester Do not exceed 3500 PSI test pressure Always wear safety glasses If safety test shield needs to be removed to test a hose safety goggles must be worn Before Operating the Hose Tester Live Test Cones with O ring must be in cone holder with supply tube Always ensure O ring No 010 is in the end of the Live Test Cone To activate timer Remove rear battery cover and remove plastic insulation strip to engage battery If the timer stops working it 1s probably due to a dead battery To replace remove timer from the cabinet by pulling it from the Velcro retaining patch Rotate battery cover slot in an counter clockwise direction and remove the button style battery Replace battery with one of the same specifications reverse these instructions to reinstall Energizer Battery No 357 BrakeQuip 8 Hand Tester Operations and Service Manual BQEOS 04 Operating the Hose Tester 1 Ensure Locking Arms are in the fully released position vertical Slide adjustment rods up allowing clearance for the fitting to moun2. substances or who may otherwise be unable to operate the machine for health reasons Personnel to be trained educated instructed or in an apprenticeship should work only under continuous supervision of an experienced person on the hose crimping machine and tester All personnel need to e wear safety glasses e keep loose clothing hair fingers and all body parts away from moving parts e read and understand the operating manual e be instructed in the mode of operation of the machine e know how the individual work processes need to be conducted e operate the machine while in a positive state of health Training of Personnel A training worksheet has been provided as a checklist of training tasks to be completed by the in house instructor and trainees For quality assurance purposes it is required that the trainee initial every task that he she has been instructed in See Doc No BQI 01 5 BrakeQuip O BQEOS 04 Hand Tester Operations and Service Manual SAFETY Read instruction and identify all component parts before using this tester Do not exceed 3500 PSI test pressure Always wear safety glasses If safety test shield needs to be removed to test a hose safety goggles must be worn MAINTENANCE Maintain this machine per the maintenance section of this manual Use only manufacturer s recommended attachments and replacement parts BrakeQuip 6 Hand Tester Operations and Service Manual BQEOS 04 HOSE
3. ELIVERY AND RESPONSIBILITIES The BrakeQuip brake hose manufacturing system has been designed so that operator adjustments are generally not required The crimp integrity and testing has been achieved by using BrakeQuip fittings and brake hose IF NON APPROVED FITTINGS AND BRAKE HOSE ARE UTILIZED IN THE MANUFACTURING OF BRAKE HOSES BRAKEQUIP CANNOT GUARANTEE THE SAFETY OF THE CRIMP AND COMPLIANCE TO STANDARDS IF FITTINGS OR HOSE OTHER THAN GENUINE BRAKEQUIP PRODUCTS ARE USED YOUR LIABILITY COVERAGE IS VOIDED Ensure the hose stock is stored away from direct sunlight and accidental damage otherwise the quality of the hose can be significantly reduced BrakeQuip has tried to make the fittings as universal as possible to reduce your inventory costs Some fittings may look slightly different from the original but will do exactly the same job For example most male fittings have three sealing surfaces and external thread type fittings have one standard thread A new half nut is supplied if the thread is different from the original Another example a 3 4 Hex fitting is the same as a 5 8 Hex with a shoulder clip Rubber brake hose is for BRAKE FLUID ONLY If you have a mineral oil application you will need to use the stainless steel braided line option Hand Tester Operations and Service Manual BQEOS 04 PERSONNEL REQUIREMENTS Never let personnel operate the hose crimping machine who may be under the influence of reaction limiting
4. Hand Tester dj ai Keep for future use BrakeQuip __ I INNOVATIVE SOLUTIONS FOR AUTOMOTIVE TUBES AND HOSES INNOVATIVE SOLUTIONS FOR AUTOMOTIVE TUBES AND HOSES BQEOS 04 BrakeQuip Hand Tester Operations and Service Manual ABOUT THIS MANUAL Knowledge of and compliance with the operational and service principles outlined in this manual are essential for the efficient operation of this equipment Maximum benefits will be gained from the initial set up and training if all prospective operators have read and are familiar with this manual Please specify all details such as Model number DOT number Serial Number of the equipment in any correspondence referring to your system If any problems relative to the operation or service of this equipment should arise contact your BrakeQuip representative or BrakeQuip direct LIMITED WARRANTY BrakeQuip LLC hereinafter BQ will repair and replace any defective new parts during a period of twelve 12 months from the date of shipment This repair and replacement warranty will not apply if the instructions in this manual are not followed Parts sold for the repair or replacement of existing equipment will only be repaired or replaced for a period of ninety 90 days from the date of installation Expendable items and all accessory tools are sold as If upon inspection by BQ any warranted product shall prove defective in materials or
5. nsure O ring No 010 is in the end of the live test cone PULLS TAT HO For festing small banjo fittings and larmake Tow fittings For testing mala fittings igid and swivel and any iting where the sealing diameter i small Far testing iomal sane fittings amp female fittings wih a OPS BQ206S BQ20KHS i For testing lemale swivel AA KY Mbhngs amp fermake FAs J LA Wilh an inverted seal ga EA Bij 207 EQ207H BrakeQuip 12 Hand Tester Operations and Service Manual BQEOS 04 CONSTRICTION TEST Blow air through the hose to ensure there are no blockages Place the Constriction Gauge BQ2001W into each fitting and check for clearance The gauge should easily pass through the fitting port For fittings that have no access port to conduct this test Banjo fittings Ensure that the fluid ports are clear before crimping 13 BrakeQuip
6. t in the test jig 2 Push adjusting rod down and aligning ey Af test cone onto fitting Push a adjusting rod down 3 Jiggle fitting slightly to centralize cone into fitting 9 BrakeQuip BQEOS 04 Hand Tester Operations and Service Manual 4 With Knurled Nut at a slight angle slide it up the adjusting rod to the base of the clamping mechanism 5 Align Knurled Nut to be horizontal on Clamping Mechanism allowing the internal threads of the Knurled Nut to grab the threads Snug the Knurled Nut against the base of the Clamping Mechanism finger tight 6 Pull the locking arms forward horizontal this will apply adequate sealing pressure on the fitting face if done properly 7 Make sure safety shield is in place and you are wearing safety glasses to avoid injury You are ready to test your hose assembly 8 Connect air hose to male connector on Test Fluid Pump 9 Depress control pedal toward AIR stamp to pressurize hose assembly 10 Release control pedal when pressure gauge reaches adequate pressure 3000 Ibs 8 9 minimum or if a problem arises 11 Press digital timer start button check for abnormalities or leaks on hose assembly while digital timer counts down from 15 seconds 12 To remove the hose from the test jig release pressure from hose by pressing control pedal toward RELEASE stamp 13 After observing there is no pressure at the press
7. ure gauge push locking arms upward vertical to release pressure on fitting BrakeQuip 10 Hand Tester Operations and Service Manual BQEOS 04 MAINTENANCE Hose Tester Maintenance 1 Unscrew the knurled nuts and slide down the adjusting rods 2 Slide the readjusting rods up giving adequate clearance to remove fittings from test jig Test Fluid Replenishment To replenish test fluid remove Black Hex filler cap on top of Test Fluid Reservoir Fill reservoir approximately 1 2 from the top Note Test fluid must be 100 anti freeze Do no dilute or used a pre mix anti freeze as this will void all warranty WARNING NO SOLUBLE OIL OR ANY MINERAL BASED FLUIDS 11 BrakeQuip O BQEOS 04 Hand Tester Operations and Service Manual Timer Maintenance If the timer stops working it 1s probably due to a dead battery To replace remove timer from the cabinet by pulling it from the Velcro retaining patch Rotate battery cover slot in a counter clockwise direction and remove the button style battery Replace battery with one of the same specifications reverse these instructions to reinstall Energizer Battery No 357 Test Cones Test Cones need to be replaced from time to time The Test Cones are retained in the Cone Holder by the drag of an O ring To remove cone simply pull cone out from holder by hand The O ring may need to be lubricated from time to time to make this an easier task Always e
8. workmanship during the warranty period that product shall be repaired or replaced at BQ s option if the buyer at its sole expense returns the products to BQ s factory or such other place as BQ designates Such repair or replacement shall be BQ s sole obligation and the buyer s exclusive remedy under this warranty This warranty supersedes all prior oral or written agreements statements promises advertising or representations THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER REPRESENTATIONS AND WARRANTIES EXPRESS OR IMPLIED AND BQ EXPRESSLY DISCLAIMS AND EXCLUDES ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE Hand Tester Operations and Service Manual Table of Conents ABOUT TAS MANUAL Lapeer 2 LIMITED WARRANTY sage preses eee 2 SCOPE OF DELIVERY AND RESPONSIBILITIES 4 PERSONNEL REQUIREMENTS suisse erwin 5 SE he 6 MAINTENANGE vaere 6 HOSE TESTER COMPONENTS IDENTIFICATION T HOSE TESTER OPERA ION usa 8 Safety Precautions Before Operating the Hose Tester Operating the Hose Tester rrrrrrnrrnnrrnnornnnrnnnrnnnrnnnrnnnennner 9 MAINTENANGE nese 11 Hose Tester Maintenance Test Fluid Replenishment Timer Maintenance ccccccccececcecccccceccececeuceceaceneaeeneaees 12 TETTE NE SA 12 GONSTRIG HON TEST uussaeskeee sne couse stotiste 13 3 BQEOS 04 BrakeQuip O BQEOS 04 BrakeQuip Hand Tester Operations and Service Manual SCOPE OF D
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