The standard "VW 96283 Reinforced coolant hoses - Requirements and tests" developed by the Volkswagen automobile company applies to reinforced pressure coolant hoses consisting of coolant hoses and associated quick-connect systems for the distribution of liquid coolant. This standard describes the material and functional requirements for hoses, hose branches and fittings.
In terms of design and quality, the implementation according to the drawing, subscription requirements take precedence over this standard. The inner surface of the hoses must be free of defects and irregularities. Defects in the general structure such as bubbles, residues in rubber and fabric defects are not allowed. The hoses must be free of stains, shine, crystalline residue, gray haze, as well as separating and washing agents. The individual layers must have a perfect bond even after contact with the media. The reinforcement must be smooth and wrinkle-free. The material must not have an unpleasant odor.
The inner wall thickness of the hose, hose branches and fittings shall be 50% to 70% of the total wall thickness. The type of fibre, type of yarn, yarn count, yarn density, type and structure of the knit or knitted fabric shall be specified during sampling, if necessary with the help of a sketch and on delivery. The approved template shall be followed. There are no additional requirements for the outer layer.
Inner layer materials and outer layer materials should be EPDM (synthetic rubber), peroxide cross-linked (in accordance with “ISO 1629 Rubber and tyres - Nomenclature”). Reinforcement materials should be aramid (in accordance with “ISO 2076 Textiles - Artificial fibres - General names”).
The color of the hoses and fittings must be black. Other colors are determined according to the arrangement. The dimensions of the hoses and the structure of the hose elbows are determined according to the drawing.
When testing hoses, hose branches and fittings for specifications and requirements, a test consisting of at least 5 separate tests must be performed. The individual values must be stated in the test report. The requirements are considered to be met if 80 percent of the individual values comply with the requirements. The materials and contents used must meet the requirements of the PN 1004 standard.
When performing properties and requirements testing, the samples should be conditioned for at least 23529 hours in normal climate before testing according to the standard “ISO 24 Rubber - General procedures for preparation and conditioning of test pieces for physical test methods”.
In this standard, the features and requirements are explained under the following headings:
In this standard, functional requirements are described under the following headings:
When performing working load simulation testing, test specimens should be exposed to temperature changes, pressure cycles, and mechanical vibrations.
The static long-term test is performed for cables with PP (polypropylene) or PA (polyamide) components.
In the failure stress test, the sample is connected to a pressure source and placed as stress-free as possible. A suitable liquid such as water or water-oil emulsion should be used as the pressure medium. The sample and the connection line should be de-aerated before starting the test.
The tensile strength test is only valid for branch hoses.
The leak test is only valid for branch hoses or shaped hoses with a bending radius of up to 25 mm.
In the storage test, samples of 10 g each are used, taken from the inner layer measuring 10 mm x 20 mm. The test should preferably be carried out on three samples. Before starting the test, the filters required for the test should be conditioned to constant mass at 188 degrees in a naturally ventilated heating cabinet according to ISO 105 standard method A and then stored in a desiccator until used, but for at least 24 hours.
The electrochemical resistance test is performed in accordance with the “SAE J 1684-2005 Test method for evaluating the electrochemical resistance of cooling system hoses and materials” standard.
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