®
Hydraulics 201
Introduction
to Hydraulic
Hose and
Fittings
S-18a
i n t r o d u c t i o n t o H Y DR A U L IC H O S E A ND F ITTIN G S 2 0 1
Introduction to Table of Contents
Hydraulic Hose
and Fittings Fundamentals of Hydraulic Hose and Fittings................................... Page 2
Hose Construction............................................................................ Page 3
Selecting the Right Hose.................................................................. Page 5
Gates SAE Hose Nomenclature....................................................... Page 11
Hydraulic Hose Applications........................................................... Page 13
Hydraulic Fluids ............................................................................. Page 22
Hose Storage.................................................................................. Page 23
Couplings....................................................................................... Page 25
Coupling Identification.................................................................... Page 27
Adapters......................................................................................... Page 44
Proper Hose Assembly.................................................................... Page 45
Assembly Preparation – Hose, Coupling and Crimping.................... Page 48
Installing Hose Assemblies............................................................. Page 54
Troubleshooting: Hose Failure......................................................... Page 58
Crimpers......................................................................................... Page 63
Crimper Troubleshooting................................................................. Page 65
Glossary......................................................................................... Page 69
Level 201 Review Quiz.................................................................... Page 76
i n t r o d u c t i o n t o H Y DR A U L IC H O S E A ND F ITTIN G S 2 0 1
Fundamentals of Hydraulic Hose and Fittings
Why use hydraulic hose assemblies?
Hydraulic hose replaced the ridged pipes and tubes used in early hydraulic
systems because a hose:
n Is less costly
n Weighs less
n Is better able to absorb shock and vibration
n Is easier to route and install
n Needs no brazing or specialized bending
n Allows for movement between components of equipment
n Is less likely to rust
n Absorbs sound better
n Dampens pressure surges
The international
marketplace for
hydraulic
assemblies is
getting larger
every day.
Fundamentals of
Hydraulics
Hydraulic101
Hose and Fittings
ii nn tt rr oo dd uu cc tt ii oo nn tt oo HH YY DR
DR AA UU LL IC
IC HH OO SS EE AA ND
ND FF ITTIN
ITTIN GG SS 22 00 11
Hose Construction
A hose is made up of three components:
Reinforcement
The availability and
routing advantages
of hose make it the
preferred choice
over tubing by
maintenance
personnel.
Cover
Tube
The Tube
The Tube is the conduit. Tube construction varies to accommodate
a) the materials being conveyed, and
b) the temperature of the material.
The Chemical Resistance Table in the Gates Hydraulics Catalog
(Part No. 31-2080, Product No. 35093) lists the recommended
tube stock for conveying a given material.
NOTE: The Inside Diameter (ID) of the tube determines the size
of the hose.
Hose
Hydraulics
Construction
101
i n t r o d u c t i o n t o H Y DR A U L IC H O S E A ND F ITTIN G S 2 0 1
The Reinforcement
The Reinforcement is the muscle of the hose. It provides the strength
to resist internal pressure (or external pressure in the case of suction/
vacuum).
There are three basic configurations of reinforcement:
Braided: R
einforcement can be wire or textile and may have single
or multiple layers.
Spiraled: Spiral-reinforced hose is used in several demanding
applications to provide a longer service life.
Reinforcement is typically wire and has either four
or six layers (plies) for strength.
Helical: Coil reinforcement keeps the hose from collapsing during
suction (vacuum).
The Cover
The Cover protects the reinforcement and tube from such environmental
conditions as:
n Weather n Ozone
n Abrasion n Corrosion
n Temperature n Chemicals
To solve severe hose-to-hose or hose-to-metal abrasion problems, Gates
offers two hose cover options: Hoses with multiple
n MegaTuff™ Hose Cover provides 300-times the abrasion resistance of reinforcements
standard hose covers. have an anti-friction
n XtraTuff™ Hose Cover, for mid-range applications, offers 25-times the layer between them
abrasion resistance of standard hose covers.
to prevent the steel
Abrasion Testing
ISO6945—Metal to Hose Rubbing Cycles to lose 1 gram weight wires from rubbing
600,000 against each other.
Cycles
500,000
400,000
300,000
200,000
100,000
0
Rubber XtraTuff MegaTuff Nylon Urethane Textile Hose
Hydraulics
Construction
101
Sleeve Cover A Cover
ii nn tt rr oo dd uu cc tt ii oo nn tt oo HH YY DR
DR AA UU LL IC
IC HH OO SS EE AA ND
ND FF ITTIN
ITTIN GG SS 22 00 11
Selecting the Right Hose
Remember the acronym, “STAMPED”. Use it as a checklist to select the
right hose assembly for an application.
S = Size
T = Temperature
A = Application
M = Material
P = Pressure
E = Ends of couplings
D = Delivery (Quantity and Volume)
Do not use hose
S = Hose Size (Dash Numbers)
OD to identify the
Dash Numbers, the industry standard, describe hose and coupling size.
ID of the hose. This number precedes the hose or coupling description (see table on
Different hose page 6).
constructions will Dash numbers denote hose ID in sixteenths of an inch. A hose of ¼” ID
vary with the wall is classified as -4 (4/16). A hose with ½” ID is a -8 (8/16).
thickness and OD. The exception to this is the SAE100R5 hoses C5C, C5D, C5E and C5M,
as well as C14 PTFE hose and AC134a Refrigerant hose, where dash
sizes denote hose ID equal to equivalent tube OD.
Replacing a Hose
Determining the Right Size
The easiest way: Read the layline on the original hose.
If the original hose layline is unreadable, cut the original hose and
measure the inside diameter.
NOTE: You also need to identify and count the number of
reinforcement layers.
Selecting
Hydraulics
the Right
101 Hose
i n t r o d u c t i o n t o H Y DR A U L IC H O S E A ND F ITTIN G S 2 0 1
Dash Numbers Table
Hose I.D. (Inches)
All Except C5 Series, C5 Series, C14 and
C14 and AC134a AC134a
Dash No. Inches Millimeters Inches Millimeters
-2 1/8 3.2 -- --
-3 3/16 4.8 -- --
-4 1/4 6.4 3/16 4.8
-5 5/16 7.9 1/4 6.4
-6 3/8 9.5 5/16 7.9
-8 1/2 12.7 13/32 10.3
-10 5/8 15.9 1/2 12.7
-12
-14
3/4
7/8
19.0
22.2
5/8
--
15.9
--
Avoid equipment
-16 1 25.4 7/8 22.2 breakdown and
-20 1-1/4 31.8 1-1/8 28.6
-24 1-1/2 38.1 1-3/8 34.9 possible injury by
-32
-36
2
2-1/4
50.8
57.6
1-13/16
--
46.0
--
not exceeding the
-40 2-1/2 63.5 2-3/8 60.3 manufacturer's
-48 3 76.2 -- --
-56 3-1/2 88.9 -- -- recommended
-64
-72
4
4-1/2
101.6
115.2
--
--
--
--
maximum operating
temperature.
T = Temperature
When selecting a replacement hose, you have to consider
a) the temperature of the fluid being conveyed,
b) the ambient temperature of the environment it passes through, and
c) the minimum and maximum temperature created by the system itself.
Fluid Temperature - Consult the Hose Selection Guide and the Additional
Temperature Limits Chart in the Gates Hydraulics Catalog. When choosing
a hose for a given application, you MUST NOT exceed the maximum
operating temperature.
NOTE 1: Intermittent temperature surges of the fluid (up to 10 percent
of operating time) are acceptable.
NOTE 2: DO NOT expose the hose to maximum temperature and maximum
working pressure at the same time. That reduces the service life of the
hose.
Ambient Temperature - When routing near hot manifolds, you may need
to protect the hose with a heat shield.
System Temperature - The temperature generated by the hydraulic system
itself is created by several factors, among them:
a) the length of the hose assembly,
b) the friction inside the hose and the size of the hose.
See “Pressure Drop” on page 9. Selecting
Hydraulics
the Right
101 Hose