Application
Charge air bellows are used on diesel truck engines to deliver pressurized intake air through the charge air intercooler into the intake manifold. Meta-Aramid reinforcement is required since the temperature of the turbocharger outlet is approximately 260C+ (500F+). Fluorocarbon lining is used inside the bellows since crankcase fumes are also recycled through the bellows.

Design Features
Charge air bellows are used on diesel truck engines to deliver pressurized intake air through the charge air intercooler into the intake manifold. Meta-Aramid reinforcement is required since the temperature of the turbocharger outlet is approximately 260C+ (500F+). Fluorocarbon lining is used inside the bellows since crankcase fumes are also recycled through the bellows.

• Pilot flare on the end of the bellows aids in bellows installation to the mating stem.
• Bellows is designed for connection to SAE AS J5131 pipe bead with internal pockets on the ID of the cuffs to mate and positively locate the bellows on the mating stem. Hoses can be used with a one or two bead configuration.
• Designed clamp groove for positive location of clamp.
• Fluorocarbon liner for closed crankcase vapors
• Premium silicone bonding layer and jacket layer with low compression set to reduce clamp torque falloff.
• Bellows tested at 1 million hot air pulses, 500F internal, 250F external, 5 to 70 psig with no delamination of the fluorocarbon liner.
• Low convolute design reduces length growth to .30 inches max. at 60 psig and 500F.
• Blow-off equal to or greater than 150 psig with clamp torque tolerance range of 60 to 120 inch-pounds using production "T" bolt clamps. 210 psi blow-off minimum with clamp torque of 120 inch-pound.

Pressure Capability with External Rings

ID Sizes:
76mm (3.00 inch), 89mm (3.50 inch), 102mm (4.00 inch), 115mm (4.50 inch).

Length:
152mm (6.00 inch) available in all ID’s.

Construction:
High-temperature fluorocarbon elastomer liner, reinforced with a minimum of 4 plies of temperature resistant Meta-Aramid fabric. The bellows has four external convolutions and three stainless steel external pressure retention rings.

Endurance Capability:
1 million pulse cycles at 260 degrees C (500 degrees F), of bellows/pipe/bellows assembly pressurized to 4.8 bar ( 70 psig ) at approximately 20 cycles per minute. Exterior air temperature is at 250F. Hose is flexible and air tight after this dynamic heat aging test when pressurized to 4.8 bar (70 psi) with a constant torque hose clamp.

Life expectancy:
Flexible and air tight for life of vehicle or 1,609,270 kilometers (1 million miles).

Environmental capability:
Resistant to salt spray, engine oil vapors and splash; and fuel splash, ultraviolet light, ozone & flexibility at minus 40 degrees C ( minus 40 degrees F ).

Mating Stem Specifications:
The stem the hose is clamped to must be round, clean, and smooth without flat spots caused by the grinding of casting flash or burrs. The stem must have a bead height and profile equivalent to SAE J 1231 Type 1, Type 2 or Type 3, with 32.5mm centerline to centerline distance between tube beads. The bead must be continuous for 360 degrees around the OD of the stem for proper sealing of the hose.

Clamp Specifications:
The clamp type and installation must be per the clamp manufacturer, the OEM specifications or TMC RP 332.

	Flexfab® 1699 West M-43 Highway Hastings, MI (USA) 49058 Tel: 269-945-2433 Fax: 269-945-4802