Summary of Evidence Report Hydraulic Brake Hoses(FMVSS 106)

Australian Design Rule 7/00

1. Document
Licences Reference for this
Document(use only 12 characters)
None

Date(dd/mm/yy)
12/08/15

Vechicle Make(optional)
KMC

Vechiele Model(optional)
QL
Export Vehicle Name
SPORTAGE

2. Form Use
Please indicate how this form used. It is being used in support of :
An application for exemption. This vehicle has no hydraulic brake hoses.
(No further responses required)
An application for a vehicle approval submitting brake hose test results.
(complete sections 4)
An application for a vehicle approval, submitting brake hose Component Registration Numbers
(CRN)(complete sections 3)
An application for a brake hose CRN
(complete sections 4)

3. Brake Hoses on Vehicle which have a Component Registration Number

(The vehicle manufacturer need not submit test evidence for these brake hoses)
Manufacturer

Part No.

Function

Component Registration
Number(CRN)

LSMtron

58737-D9000

Brake hose assembly

LSMtron

58737-D9700

Brake hose assembly

LSMtron

58738-D9000

Brake hose assembly

LSMtron

58738-D9700

Brake hose assembly

To list additional brake hoses please use another SE 7/00 form with its own unique reference number

4. Test Results
Test Report No.
LQ(KMC)-5812

Test Report
None

Test Facility Name

The Laboratory of LS Mtron Ltd

Test Facility No.

07-118-001~010

Test Facility Address

238, 3gongdan 2-ro,Gumi-si Gyeongbuk
730-735, Korea

2. Constriction Test(Select only one test method)

1)Drop Ball Test :
In the drop ball test, a steel ball with a diameter equal to the minimum constriction
diameter for a particular hose size is dropped into one end of the hose at its
fitting. Gravity is the only downward force acting on the ball, and friction between
the hose and ball may not be sufficiently overcome in all tests.
Ball Sized at 64% of the hose inside diameter, its weight is 57g.
2)Plug Gauge Test
A cylindrical plug with a small rod handle is inserted into and removed from hose.
The spherical end of the plug gauge must be able to enter the hose or end fitting by
applying a force no greater than gravity. The plug gauge must fall under the force of
gravity within 3 seconds. Gauge end sized at 64% of the hose inside diameter.
3)Extended Plug Gauge Test
Weight and diameter equal to the plug gauge but its length equal to hose.
Hose
No.

PASS

Guage
Size

Hose
No.

PASS

2.03mm

16

2.03mm

2.03mm

17

2.03mm

2.03mm

18

2.03mm

2.03mm

19

2.03mm

2.03mm

20

2.03mm

2.03mm

21

2.03mm

2.03mm

22

2.03mm

2.03mm

23

2.03mm

2.03mm

24

2.03mm

10

2.03mm

25

2.03mm

11

2.03mm

26

2.03mm

12

2.03mm

27

2.03mm

13

2.03mm

28

2.03mm

14

2.03mm

29

2.03mm

15

2.03mm

30

2.03mm

FAIL

FAIL

Guage
size

Remarks : 1-See Lab. Procedure Para 10.2 for proper plug size. 2.03mm. dia . for 1/8 ID Hose

3~4. Expansion and Burst Strength

3. Expansion Test
Four samples of brake hose assembly were individually pressurized at 1000psi(70kgf/,
6.9MPa),1500psi(105kgf/, 10.3MPa), 2900psi(203.9kgf/,20MPa) and the volumetric

expansion was determined for each sample in accordance with the procedure in ASTM
D571-Standard Methods of Testing Automotive Hydraulic Brake Hose.
The maximum expansion and specified maximum allowable limits for each of the hoses
tested are listed below
Sample
No.

(unit:/ft)

1000psi
(70kgf/, 6.9MPa)

1500psi
(105kgf/, 10.3MPa)

2900psi
(203.9kgf/, 20MPa)

Result

Maximum

Result

Maximum

Result

Maximum

0.075

0.33

0.115

0.42

0.265

0.61

0.080

0.33

0.120

0.42

0.270

0.61

0.075

0.33

0.110

0.42

0.260

0.61

0.085

0.33

0.120

0.42

0.265

0.61

4. Burst Strength Test

Hydraulic brake hose assembly withstands water pressure of 4000psi(281.2kgf/) for
two minutes without rupture, it must not rupture at less than 7000psi for for 1/8
inch, 3mm, or smaller diameter hose, or at less than 5000psi for a hose with a
diameter larger than 1/8 inch or 3mm.
Hose
Number

4000psi(27.6MPa)
2min
No leak and No
Pressure down

Actual Pressure
Attained.

Min. Allow.
Burst Strength

PASS

No leak

89.2MPa

49MPa

No leak

90.4MPa

49MPa

No leak

89.3MPa

49MPa

No leak

90.3MPa

49MPa

FAIL

5.Tensile Strength
The hose assembly was mounted in the tensile machine so that the hose and end fittings
had a straight centerline corresponding to the direction of the machine pull.
The hose assembly was pulled at a rate of 1 inch / minute until failing as follows :
(1) Hose pulled out of the end fitting
(2) Hose ruptured

Sample
No.

Actual Total
Load at Time
of Failure (Pound)

PASS

25.4mm/min 50.8mm/min

FAIL

Min. Allow
Tensile
Strength (Pound)
25mm/min

50mm/min

3165N

3250N

1446N

1646N

3190N

3302N

1446N

1646N

3058N

3121N

1446N

1646N

3231N

3276N

1446N

1646N

6.Whip Test
The free length of each specimen was measured in thousandths of an inch between the
end fittings while hanging in a straight position.
Water pressure of 220 to 235 psig was applied, and the hose and passages bled to
eliminate air pockets or bubbles. The machine speed was 795 to 805 rpm.
Sample
No.

Spec

Pass

No Failure

No Failure

No Failure

No Failure

Fail

7.Water Absorption

Burst Strength

Hose assemblies were subjected to the pressure test after being immersed in water for
70 hours at room temperature after 1 1/8inch(28.6mm) piece of outer cover had been
removed.

Hose
Number

4000psi(27.6MPa)
2min
No leak and No
Pressure down

Actual Pressure
Attained,

Min. Allow.
Burst Strength

PASS

No leak

84.0MPa

49MPa

No leak

89.9MPa

49MPa

No leak

86.3MPa

49MPa

No leak

88.4MPa

49MPa

Test results are below;

FAIL

8.Water Absorption Tensile Strength Test

Hose assemblies were subjected to the Tensile Strength test after being immersed in
water for 70 hours at room temperature after 1 1/8inch(28.6mm) piece of outer cover
had been removed.
Test results are below

Sample
No.

Actual Total
Load at Time
of Failure (Pound)
25mm/min

50mm/min

2886N

2775N

2793N

PASS

FAIL

Min. Allow
Tensile
Strength (Pound)
25mm/min

50mm/min

1446N

1646N

2868N

1446N

1646N

2685N

2871N

1446N

1646N

2925N

3028N

1446N

1646N

9.Water Absorption Whip Test

Hose assemblies were subjected to the Whip test after being immersed in
water for 70 hours at room temperature after 1 1/8inch(28.6mm) piece of outer cover
had been removed.
Test results are below
Sample
No.

Spec

Pass

No Failure

No Failure

No Failure

No Failure

Fail

10.Low Temperature Resistance Test

Hose assemblies were conditioned in a straight position at 45~48 degrees C for 70
hours.
After conditioning and without removal from the test chamber, the hose sample was bent
180 degrees around a mandrel three inches(76mm) in diameter.
Visual examination of the hose assembly revealed no evidence of cracking or breaking
of the hose, indicating the hose met the requirement.
Sample
No.

Spec.

Pass

No Crack

No Crack

No Crack

No Crack

Fail

11~12.Brake Fluid Compatibility

Fill the hose assembly with brake fluid RM 66-04, seal the lower end, and place the
test assembly in a vertical position in an oven.
Condition the hose assembly at 120+5, -0(248+9-0) for 70h.
After completion of the heat aging period, remove the hose assembly and cool at room
temperature for 30 min5 min.
Drain the brake hose assembly, and within 10 min, do constriction test.
The brake hose assembly shall be burst within 3h.
Hose
Number

4000psi(27.6MPa)
2min
No leak and No
Pressure down

Actual Pressure
Attained,

Min. Allow.
Burst Strength

PASS

No leak

94.3MPa

34.5MPa

No leak

97.1MPa

34.5MPa

No leak

95.6MPa

34.5MPa

No leak

96.2MPa

34.5MPa

FAIL

14.Ozone Resistance Test

Bend a brake hose around a cylinder, the diameter of which shall be eight times the
nominal outside diameter of the brake hose, and bind the ends. The cylinder and
binding shall be made of metal or materials that prevent the consumption ozone. If
the hose collapses when bent around the cylinder, provide for internal support of
the hose. Condition the hose on cylinder for 24 h0.5 h at room temperature, and
then place it in an exposure chamber containing air mixed with ozone at ozone
partial pressure of 100ppm5ppm for 70 to 72 h. Ambient air temperature in chamber
during test shall be 403.
Examine the cover of the hose for crack under 7X magnification, ignoring the areas
immediately adjacent to or within the area covered by the binding.
Sample
No.

Spec.

Pass

No Crack

Fail

15.Dynamic Ozone Test

Brake Hose cut lengths of 218mm3mm, SAE J1401 Dynamic ozone test apparatus that
will flex the brake hose as shown in Figure 6 and the ozone test chamber.
Precondition all the brake hose samples in a nonstressed condition at 276 for
at least 24 h prior to the start of the test.
Install the brake hose over the fixture pins until the hose has bottomed out. Use
band clamps to securely retain the brake hose on the pin. Install the test apparatus
and assembled hoses in a stabilized ozone chamber. The chamber shall contain air
mixed with ozone at the ozone partial pressure 100ppm5ppm. The air temperature in
the chamber shall be 403.
Start cycling when the chamber reaches the specified ozone concentration but no
later than 1 h after putting the test apparatus in the ozone chamber. The flex rate
shall be 0.3Hz0.05Hz. The stroke shall be 76.2mm2.5mm.
Examine the hoses for ozone cracks every 24 h 1 h. Reinstall the fixture in the
cbinet within 15 min of its removal.
The hose shall not crack after testing a minimum of 48 h.
Sample
No.

Spec

Pass

No Crack

No Crack

No Crack

No Crack

Fail

16. Hot Impulse Test

Fill the pressure cycling apparatus and hose assemblies with Brake fluid RM 66-04,
and bleed free of air. Place the assemblies in the circulating air oven, and within
30 min attain an oven temperature of 1463. Subject the assemblies to a cycling
internal pressure of 11 MPa(1595psi) for 1 min and 0 pressure for 1 min.
(Pressure to be attained within 2 s.)
Pressure cycle assemblies for 150 cycles minimum.
Remove the assemblies from the oven. Cool the assemblies in air at room temperature
for 45 min minimum. Subject the assemblies to the burst test.
The Hose assemblies shall withstand impulsing for 150 cycles without leakage.
There shall be no leakage during a 2 min, 27.6 MPa(4000psi) pressure hold.
The assembly shall not burst at less 34.5 MPa(5000psi)
Sample
No.

Impulse for
150 Cycles

2 min at 27.6MPa

Burst

Pass

No Leakage

No Leakage

68.4MPa

No Leakage

No Leakage

69.7MPa

No Leakage

No Leakage

68.7MPa

No Leakage

No Leakage

69.3MPa

Inspector :

Reviewed by :

Fail

Date : 12/08/2015