Cummins AEB 24.20 Iss. 2015-06, Hoses and Connections (ID 239244)

Application
Engineering
Bulletin
Title: This AEB is for the following applications:
Hose Material and Hose Connection Design
Requirements and Recommendations Automotive Industrial Marine
G-Drive Genset
Filtration Emission Solutions

Date: 09 June 2015 Refer to AEB 9.01 for Safety Practices, AEB Number: 24.20
Guidelines and Procedures
Engine models included: All Industrial, G-Drive and Genset
Owner: Jagdeep Singh Approver: per Procedure GCE-AS-1 Page 1 of 50
This AEB supersedes AEB 24.20 dated 20 August 2013.
The objective of this AEB is to present design guidelines, recommendations and requirements for high
quality hose connections to air, coolant, fuel, and oil systems. This bulletin should be used by OEMs to
assist in machine (vehicle) design but it is not a substitute for validations of machine (vehicle) systems.
Please note, this AEB has been written for all Cummins industrial engines with the exclusion of marine
engines. Marine engine installations are subject to the regulations of various marine certification agencies
and must meet the specific design and installation requirements of those agencies.
Disclaimer: Each hose manufacturer publishes specifications defining the acceptable application of their
products. No attempt has been made to duplicate hose manufacturer product or application specifications
in this document. It is the responsibility to ensure that every hose used in connection to the engine
tallation and intended use.
Recommendations provided in this document are supplemental to those provided by the hose
manufacturer.
the OEM to make the most informed material selection. Testing may be required to ensure the hose
Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.
Revision 09, 09 Jun 2015 Page 1 of 50 © Copyright 2015 Cummins Inc.

Hose Material and Hose Connection Design Requirements and Recommendations AEB 24.20
Table of Contents
1 Installation Requirements ...................................................................................................................... 4

Threaded Hose Barb Fittings for Clamped Hose Connections to Ports ................................................ 4
Clearance around Tube Ends and Hoses.............................................................................................. 4
Routing and Securing Long Hoses (Lines) in Design and Assembly .................................................... 4
Routing Hoses through Sheet Metal ...................................................................................................... 4
Charge Air Cooling System Hoses Hose Material Meta-aramid / Nomex Reinforced Silicone Hump
Hoses ..................................................................................................................................................... 4
Charge Air Cooling System Connections .............................................................................................. 4
Turbocharged Air Compressor Inlet Hoses Special Requirements .................................................... 4
Air Compressor Discharge Hoses Hose Material ............................................................................... 5
Radiator Plumbing Hoses ...................................................................................................................... 5
Oil and Fuel Hoses - Critical Design Criteria ......................................................................................... 5
Oil Hoses (Lines) ................................................................................................................................... 5
Remote Oil Filter Hoses ......................................................................................................................... 5
Crankcase Breather Hoses .................................................................................................................... 5
Fuel Hoses (Lines) ................................................................................................................................. 5
1.1 AQS Installation Requirements ........................................................................................................ 5
Intake Air System - Cleanliness ............................................................................................................. 5
Charge Air Cooling System Hoses - Cleanliness .................................................................................. 5
2 Installation Recommendations ............................................................................................................... 6
3 General Discussion ................................................................................................................................ 8
3.1 Introduction ....................................................................................................................................... 8
3.2 Threaded Fluid Port Connections..................................................................................................... 8
3.2.1 Types of Fluid Ports ................................................................................................................... 8
3.2.2 Thread Sealing........................................................................................................................... 9
3.3 Threaded Hose and Tube End Connections .................................................................................. 10
3.3.1 Fittings for Threaded Hose and Tube End Connections ......................................................... 10
3.3.2 Assembly of Threaded Hose Connections .............................................................................. 12
3.4 Clamped Hose Connections ........................................................................................................... 13
3.4.1 Threaded Hose Barb Fittings for Clamped Hose Connections to Ports .................................. 13
3.4.2 Formed and Cast Tube Ends Sealing Bead ............................................................................ 15
3.4.3 Tube Ends for Clamped Hose Connections ............................................................................ 16
3.4.4 SAE J2044 type connectors: ................................................................................................... 17
3.4.5 Clamped Hose Connection Fit ................................................................................................. 17
3.4.6 Assembly of Clamped Hose Connections ............................................................................... 18
3.4.7 Types of Hose Clamps ............................................................................................................ 20
3.4.8 T-Bolt vs. Worm Gear Style Clamps ........................................................................................ 20
3.4.9 T-Bolt Style Clamps ................................................................................................................. 21
3.4.10 Worm Gear Clamps ............................................................................................................... 21
3.4.11 Spring-Loaded Clamps .......................................................................................................... 22
3.4.12 Non-Adjustable One-Piece Spring Clamps (CTB) ................................................................. 23
3.4.13 Clamps for Small Diameter Push-on Fuel Hose and Coolant Vent Lines ............................. 23
3.4.14 Clamp Features ..................................................................................................................... 24
3.5 Hoses.............................................................................................................................................. 24
3.5.1 Hose Selection ......................................................................................................................... 24
3.5.2 Clearance around Tube Ends and Hoses ............................................................................... 25
3.5.3 Routing and Securing Hoses (Lines) in Design and Assembly ............................................... 25
3.5.4 Bends in Hoses ........................................................................................................................ 28
3.5.5 Hose Lubrication ...................................................................................................................... 29
3.5.6 Brackets ................................................................................................................................... 29
3.6 Air Hoses ........................................................................................................................................ 29
3.6.1 Air Intake Hose Critical Design Criteria ................................................................................... 29
3.6.2 Air Intake Hose Material - Non-silicone Rubber Hoses (EPDM, Nitrile, Neoprene) ............. 29
Revision 09, 09 June 2015 Page 2 of 50 © Copyright 2015 Cummins Inc.

3.6.3 Air Intake Hose Material - Silicone Rubber Air Intake Hoses ............................................... 31
3.6.4 Air Intake System Cleanliness ................................................................................................. 33
3.6.5 Thermal Wraps and Blankets .................................................................................................. 33
3.6.6 Charge Air Cooling Systems Air Hoses and Connections .................................................... 34
3.6.7 Air Compressor Systems Air Hoses and Connections ......................................................... 37
3.7 Cooling System Hoses and Connections ....................................................................................... 39
3.7.1 Cooling System Hoses Critical Design Criteria .................................................................... 39
3.7.2 Cooling System Hoses Hose Shape Hump Hoses............................................................ 39
3.7.3 Cooling System Hose Connections ......................................................................................... 39
3.7.4 Cooling System Hoses ............................................................................................................ 39
3.7.5 Radiator Plumbing Hoses ........................................................................................................ 40
3.7.6 Cab Heater Hoses and Vent Lines .......................................................................................... 40
3.8 Oil and Fuel Hoses ......................................................................................................................... 41
3.8.1 Oil and Fuel Hoses - Critical Design Criteria ........................................................................... 41
3.8.2 Oil and Fuel Hoses - Hoses (lines) for All Fuel and Oil Applications....................................... 41
3.8.3 Oil Hoses (Lines) ..................................................................................................................... 42
3.8.4 Oil and Fuel Hoses - Fire Resistant Hoses and Sleeves......................................................... 43
4 Definitions ............................................................................................................................................ 43
5 Reference Documentation ................................................................................................................... 44
Appendix A Selections of Hoses, Clamps & O-rings ............................................................................... 45
Appendix B Supplier Index ....................................................................................................................... 46
6 Change Log ......................................................................................................................................... 47

1 Installation Requirements
Unless otherwise noted, the requirements listed below apply to all the applications indicated in the
title block of this AEB. In order to obtain Cummins concurrence with Hose Material and Hose
Connection Design, the system must:
Threaded Hose Barb Fittings for Clamped Hose Connections to Ports

1. All hose barb fittings must have a feature for tightening the fitting without damaging the hose sealing
surface.
See Section 3.4.1 Threaded Hose Barb Fittings for Clamped Hose Connections to Ports.
Clearance around Tube Ends and Hoses

2. Sufficient end clearance must be designed to prevent tube end contact through straight hose
connections.
See Section 3.5.2 Clearance around Tube Ends and Hoses.
3. Clearance around all hoses must be designed to prevent contact and wear-through.
See Section 3.5.2 Clearance around Tube Ends and Hoses.
Routing and Securing Long Hoses (Lines) in Design and Assembly

4. Consult AEB 21.46 prior to installing a P-clip underneath any engine bolt.
See Section 3.5.3 Routing and Securing Hoses (Lines) in Design and Assembly.
5. Sufficient hose length (slack) between clipping points subject to relative motion must be provided
in both installation design and assembly.
See Section 3.5.3 Routing and Securing Hoses (Lines) in Design and Assembly.
Routing Hoses through Sheet Metal

6. Rubber grommets must be used when hose is routed through sheet metal without the use of a
bulkhead fitting.
See Section 3.5.3.3 Routing Hoses through Sheet Metal.
Charge Air Cooling System Hoses Hose Material Meta-aramid / Nomex Reinforced Silicone
Hump Hoses
7. Use straight meta-aramid / Nomex reinforced silicone hump hoses with wire restraining rings for
both hot and cold sides of the CAC system. Polyester reinforced silicone hoses may only be used
on the cold side if both of the two conditions listed in this section have been satisfied.
See Section 3.6.6.3 Charge Air Cooling System Hoses Hose Material Meta-aramid / Nomex
Reinforced Silicone Hump Hoses.
Charge Air Cooling System Connections

8. Stainless steel coil spring-loaded T-bolt clamps must be used for all charge air cooling connections,
tightened
Exception: The following clamps been found acceptable on turbocharger pressurized tubing up to
64 mm (2.5 in) diameter.
a: SLHD as per SAE 1508 -Heavy duty (HD) clamp
b: The Ideal WaveSeal360® clamp
See Section 3.6.6.6 Charge Air Cooling System Connections.
Turbocharged Air Compressor Inlet Hoses Special Requirements

9. Turbocharged air compressor applications must be approved by Cummins and the air compressor
manufacturer prior to build.
See Section 3.6.7.3 Turbocharged Air Compressor Inlet Hoses Special Requirements.

Air Compressor Discharge Hoses Hose Material

10. When a solid steel line is not available, extruded PTFE (Teflon ®) hose with a stainless steel wire
braided cover must be used for all air compressor discharge lines and for turbocharged air
compressor inlet lines. Solid steel line is preferred.
See Section 3.6.7.8 Air Compressor Discharge Hoses Hose Material.
Radiator Plumbing Hoses

11. All hoses used in radiator plumbing connections must meet or exceed SAE J20R1 or R2
specifications.
See Section 3.7.5 Radiator Plumbing Hoses.
Oil and Fuel Hoses - Critical Design Criteria

12. Regardless of material or hose style chosen, fuel and oil hoses must be compatible with all of the
critical design criteria.
See Section 3.8.1 Oil and Fuel Hoses - Critical Design Criteria.
Oil Hoses (Lines)

13. Threaded tube (hose) end fittings must be used with oil hoses (lines) listed. Adjustable hose clamps
are not acceptable for oil lines.
See Section 3.8.3 Oil Hoses (Lines).
Remote Oil Filter Hoses

14. Hoses for remote oil filter connections have special requirements above other fuel hoses. Use only
hoses approved for remote flow oil filter head.
See Section 3.8.3.1 Remote Oil Filter Hoses.
Crankcase Breather Hoses

15. Consult AEB 20.17 if a crankcase breather hose extension is required.
See Section 3.8.3.2 Crankcase Breather Hoses.
Fuel Hoses (Lines)

16. Fuel supply hoses must be rated for a minimum of 127 mm (5 in) of mercury in vacuum.
See Section 3.8.3.3 Fuel Hoses (Lines).
17. Except for push-on (clamped) style fuel hose connection on Cummins <10 L engines, all fuel hoses
must have threaded hose ends.
See Section 3.8.3.3 Fuel Hoses (Lines).
1.1 AQS Installation Requirements

Intake Air System - Cleanliness
1. Precautions must be taken to prevent contaminants from entering air intakes and charge air cooler
hoses during shipping and storage prior to assembly in the machine.
See Section 3.6.4 Air Intake System Cleanliness.
Charge Air Cooling System Hoses - Cleanliness

2. Charge Air Cooler (CAC) hoses must meet the cleanliness requirements outlined in this document.
See Section 3.6.6.5 Charge Air Cooling System Hoses Hose Material Meta-aramid / Nomex
Reinforced Silicone Hump Hoses.

2 Installation Recommendations
Applications of NPT (NPTF) port types.

1. When possible, do not use NPT (NPTF) port types for fuel or oil system applications. O-ring type
fittings (ORFS to STOR) are recommended for fuel and oil applications due to the superior sealing
available with compressed O-ring type ports.
See Section 3.2.1.3.1 Applications of NPT (NPTF) port types
Thread Sealing
2. Do not use thread or gasket sealants with O-ring type port connections.
See Section 3.2.2.1 O-ring Type Port Connections.
O-ring Face Seal (ORFS)
3. ORFS to STOR fittings are recommended for fuel supply system connections to prevent air leakage
and subsequent fuel system performance issues.
See Section 0 O-ring Face Seal (ORFS).
O-ring Material
4. Only high temperature fluorocarbon FKM (Viton® or equivalent as defined in ASTM D1418 and
ISO1629) O-rings are recommended on all O-ring style fittings used in connection to engine oil and
fuel ports.
See Section 3.3.1.3 O-ring Material.
Tube End Alignment

5. Hose bend radius limitations set by the manufacturer should be met.
See Section 3.4.6.2 Tube End Alignment.
Worm Gear Clamps
6. If worm gear clamps are to be used, SAE J1508 type HD or SLHD with an internal band liner should
be used exclusively.
See Section 3.4.10 Worm Gear Clamps.
Rounded or Flared Band Edges
7. Regardless of clamp type used, all band edges should be rounded or flared to prevent hose
damage.
See Section 3.4.14.3.1 Rounded or Flared Band Edges.
Flared-Edge Floating Bridge
8. T-bolt clamps with flared-edge floating bridges are recommended for use with silicone hoses.
See Section 3.4.14.3.3 Flared-Edge Floating Bridge.
Hose Selection
9.
See Section 3.5.1 Hose Selection.
Wires or Cable Ties

10. Wires or cable ties should not be used to secure long hoses (lines) to the equipment or the engine.
See Section 3.5.3.2 Wires or Cable Ties.

Air Intake Hose Critical Design Criteria

11. For intake air connections, air hoses should be compatible with all of the critical design criteria
listed in the critical design section of this AEB.
See Section 3.6.1 Air Intake Hose Critical Design Criteria
Charge Air Cooler Hoses - Shape
12. Only straight hump hoses, also known as convoluted hoses, are recommended for CAC
connections. The humps provide flexibility to accommodate some tube end misalignment. Hoses
with more than three convolutes (humps) are not recommended due to increased system
restriction.
See Section 3.6.6.2 Charge Air Cooler Hoses - Shape.
13. The use of elbow shaped hoses is not recommended due to the probability of the hoses blowing
off in CAC systems due to high boost pressures and temperatures and relative movement of the
system.
See Section 3.6.6.2 Charge Air Cooler Hoses - Shape.
Cooling System Hoses

14. When a threaded hose end connection type is used, the hose should be compatible with all of the
critical design criteria listed in this AEB.
See Section 3.3.2, Assembly of Threaded Hose Connections
15. SAE J20 Class A silicone material is recommended for all cooling system hoses if the hose is
expected to last until engine overhaul.
See Section 3.7.4 Cooling System Hoses.
16. When a clamped hose connection type is used for system fill / make-up, coolant heater system,
engine and radiator vents, or cooling system quick-fill / drain, the hose should meet or exceed SAE
J20R3 specifications.
See Section 3.7.4 Cooling System Hoses.
Cab Heater Hoses & Vent Lines
17. All cab heater hoses, vent lines, and coolant accessory hoses should meet or exceed SAE J20R3
specifications if clamped end connections are used.
See Section 3.7.6 Cab Heater Hoses and Vent Lines.
Oil and Fuel Hoses
18. Conductive PTFE (Teflon®) lining steel braided hose per SAE J517 should be used where possible
to avoid static discharge and pinhole burn through.
See Section 3.8.1 Oil and Fuel Hoses - Critical Design Criteria.

3 General Discussion
3.1 Introduction
When designing engines, Cummins carefully selects hoses capable of withstanding the most extreme
operating conditions anticipated. Engine installations include many hose connections to the engine air,
coolant, fuel, and oil systems. Each of these connections are critical to the performance and protection of
the engine and machine (vehicle). If a hose connection fails, symptoms range from slow fluid leaks to rapid
catastrophic engine failures.
In this AEB, an attempt has been made to distinguish between the minimum acceptable hose which
provides reliability up to a scheduled replacement interval and hoses which can be expected to last in most
applications until engine overhaul. When an OEM selects materials to meet the minimum specifications,
they are responsible for supplying inspection criteria and replacement interval recommendations to the end
user.
Materials other than those listed in this AEB should be reviewed carefully with the respective manufacturer
or supplier prior to final selection and installation
3.2 Threaded Fluid Port Connections

A port is an internally threaded hole in the engine oil, fuel, air, or coolant system which is provided
specifically for an OEM hose, tube, or sensor connection. The port includes any special machining or
dimensional features required for proper sealing of a fitting.
3.2.1 Types of Fluid Ports

Three fluid port types are commonly used in Cummins industrial engines for OEM connections: metric
straight thread O-rings, SAE straight thread O-rings, and National Pipe Taper (Fuel) NPT (NPTF). NPT or
NPTF threads work well for sealing air pressure or coolant but STOR fittings are preferred for oil and fuel.
Metric STOR STOR NPT (NPTF)

Figure 1 Three port types used in Cummins engines with matching fitting ends shown above them.
Thread graphics are simplified. Some features will vary by application such as thru-hole dimensions,
optional identification ridge of metric STOR port, etc. (Illustrations are courtesy of Parker Hannifin
Corp.)

3.2.1.1 Metric Straight Thread O-ring (Metric STOR):

The metric straight thread O-ring (Metric STOR) port type is -ring boss (ORB).
It features straight metric internal threads with a specially machined chamfer at the port entry to seal an O-
ring located on the fitting. Metric STOR port dimensional details are provided in SAE J2244 and ISO 6149.
The controlled O-ring compression of this port type provides optimal protection against fluid leakage. This
port is standard design in new engines that use predominantly metric bolts and fittings.
Note: A raised ridge at the port face indicates a metric STOR port. The ridge is an optional feature
described in the SAE / ISO standards and may not be present for all metric STOR ports.
3.2.1.2 SAE Straight Thread O-ring (STOR):
The SAE straight thread O- -ring boss (ORB). It is very similar to
the metric STOR port, except that it features straight UN/UNF internal threads instead of metric threads.
STOR port details are provided in SAE J1926 and ISO 11926. The sealing method and effectiveness is
equivalent to metric STOR ports.
3.2.1.3 National Pipe Tapered (Fuel) - NPT (NPTF):
The National Pipe Taper Fuel (NPTF) port type features Dry seal pipe threads which taper down in diameter
from the port entry. A seal is obtained by thread deformation when the connection is tightened. Applying
liquid thread sealant to the threads or using sealant pre-coated fittings is often necessary to obtain a leak-
free seal with a connection that has been previously tightened. Due to variability of thread manufacture,
sealant may be necessary even on the initial installation.
See Section 3.2.2 for more information on Teflon tape and other thread sealants.
3.2.1.3.1 Applications of NPT (NPTF) port types

NPT or NPTF type fittings are commonly used for coolant and air applications.
When possible, do not use NPT (NPTF) port types for fuel or oil system applications. O-ring type fittings
(ORFS to STOR) are recommended for fuel and oil applications due to the superior sealing available with
compressed O-ring type ports. See Section 0 O-ring Face Seal (ORFS).
3.2.2 Thread Sealing

3.2.2.1 O-ring Type Port Connections
Do not use thread or gasket sealants with O-ring type port connections.
3.2.2.2 PTFE (Teflon®) Tape
The use of PTFE, also known as Teflon®, tape is not recommended due to tape fragment contamination of
the fluid passage and subsequent engine or OEM component damage. If Teflon® tape is wrapped too
closely to the edge of the fitting, or if it is not completely cleaned out of the female end before a re-connection
is made, fragments of tape may contaminate the fluid passage. Application of Teflon® tape is a very
inconsistent process and is subject to error. It should not be used in connections to Cummins engines.
3.2.2.3 Liquid Thread Sealants
Liquid thread sealants are acceptable when applied properly. Greater consistency of liquid sealant
application is possible compared to PTFE (Teflon®) tape. Because the sealant is in liquid form, a minimal
amount of contamination in the fluid passage can usually be dissolved and tolerated. However, this can be
prevented entirely through the correct application of the sealant. Select a type of sealant that is compatible
with the fluid inside the connection and the operational temperatures.

3.2.2.4 Sealant Pre-coated Fittings

Many NPT and NPTF fittings, such as the hose barb fittings shown in 0, are available from the supplier with
a dried sealant coating already applied to the threads. Note that the coating is kept away from the last one
or two threads of the fitting to prevent contamination of the fluid. Pre-coated fittings are preferred to eliminate
the possibility of incorrect liquid thread sealant application during equipment assembly. Often times, a pre-
coated fitting can be removed and reinstalled at least once before reapplication of thread sealant becomes
necessary.
3.3 Threaded Hose and Tube End Connections
3.3.1 Fittings for Threaded Hose and Tube End Connections

The fitting is the physical component allowing the sealed coupling of a port to a hose or tube. In the case
of threaded end connections, the fitting will feature threads and a sealing mechanism on both ends.
A wide variety of threaded fitting types are available for industrial fluid transmission connections. Most
fittings are available in straight and 90° elbow configurations. Two main characteristics which vary between
types are the threads and the sealing mechanism employed on both ends of the fitting. In an effort to
minimize proliferation and to ensure the most leak-free connections with commonly available parts,
Cummins recommends using one of three hose-side sealing mechanism types in industrial engine
installations. The ORFS STOR type is preferred due to its superior elastomer sealing mechanism.
The use of 45° or 90° threaded hose ends is preferred to using 45° or 90° fittings due to reduced weight,
cost, and internal restriction.
A: ORFS STOR B: 37° Flare (JIC) STOR C: 37° Flare (JIC) NPTF
Figure 2 Fittings compatible with Cummins engine ports. Types A and B are available with English or
metric port-side threads. Type A is also available with NPTF port-side threads. Types B and C are
also available with a 45° flare angle (SAE J512). (Illustrations are courtesy of Parker Hannifin
Corporation)
Fittings and O-rings
Engine Port Type Fitting Type O-ring Material
(Quantity Required)
English or Metric STOR STOR to ORFS Preferred FKM (Viton®) (2)

English or Metric STOR STOR to 37° or 45° flare Acceptable FKM (Viton®) (1)
NPTF NPTF to 37° or 45° flare

O-ring Face Seal (ORFS)

The O-ring face seal (ORFS) type of sealing mechanism offers the best prevention against leakage by
precise compression of a face O-ring seal in the hose side of the fitting when the hose end or tube end is
attached. Standard dimensions of this connection type are governed by SAE J1453 and ISO 8434-3.
Fittings of this type are available for use with metric STOR, STOR, or NPTF ports.
The ultimate in sealing performance is achieved when an ORFS fitting is used in combination with a metric
or English STOR port. With the growing intolerance of air in diesel engine fuel systems, the ORFS / STOR
combination fitting is recommended for fuel supply system connections to prevent air leakage and fuel
system performance issues.
Caution: The O-ring in the end face of the fitting can easily be dropped and lost when the hose or tube
end is removed. If an incorrect size or material replacement is used, the sealing performance of the joint
may be compromised.
3.3.1.1 37° Flare Hydraulic (JIC):
The 37° Flare Hydraulic (JIC) type of fitting is extremely popular in fluid power systems and is commonly
available throughout the world. While not as effective as the ORFS at leakage control of air, this connection
type is effective at sealing liquid fluid systems when the sealing surfaces are clean, undamaged, and the
connection is properly tightened. The standard dimensions of this connection type are governed by SAE
J514 and ISO 8434-2.
3.3.1.2 45° Flare (SAE)
The 45° (SAE) flare type of fitting is popular in automotive and truck piping systems. It is similar to the 37°
Flare Hydraulic (JIC). The main differences are the flare angle and the thread specifications, for larger
sizes. The standard dimensions of this connection type are governed by SAE J512.
In the field, 45° flare fittings are often referred to simply as ° flare fittings are often
Select fitting so both male and female ends of the connection have the same flare
angle and thread specification.
Caution: 37° flare fittings are often mistakenly interchanged with 45° flare fittings, which look almost
identical. When the two different male and female ends are connected, the difference in flare angles may
permanently damage the sealing surfaces and the joint may eventually leak.
Figure 3 Example of 37° and 45° flare fittings.

3.3.1.3 O-ring Material
Only high temperature fluorocarbon FKM (Viton® or equivalent as defined in ASTM D1418 and ISO1629)
O-rings are recommended on all O-ring style fittings used in connection to engine oil and fuel ports. It can
also be used on air and coolant port fittings. This material is used for the O-rings of original equipment port
plugs and sensors of most Cummins industrial engines. A FKM fluorocarbon material provides the best
protection against O-ring degradation from heat, and it is compatible with all engine fluids. Other O-ring
materials such as nitrile (Buna-N) may be advertised as compatible with engine fluids and temperatures,
but these other materials have been proven through experience to be less reliable in critical applications
such as remote oil filter head connections.

3.3.1.4 Threaded Hose and Tube Ends

Threaded hose ends and threaded tube ends are the metal components that are attached to the end of an
industrial hose or tube to allow connection to a fitting. Most threaded hose or tube ends feature internally
threaded nuts which are held captive axially but are allowed to rotate freely for joint tightening without hose
or tube rotation.
Threaded hose ends are available in many styles and configurations. The four main characteristics to be
concerned with when selecting threaded hose ends are hose compatibility, method of attachment to the
hose, sealing mechanism type, and orientation of end (such as straight, 45°, 90°). The primary
consideration of threaded hose end selection is that it must be compatible with the hose used. Typically
this requires the purchase of hose ends which are manufactured by the same company that manufactures
the hose.
Common methods of threaded hose end attachment include machine crimping for crimp-on hose ends and
a special threading procedure for reusable hose ends. Both styles are shown in Figure 4. Either method is
acceptable for industrial connections.
Figure 4 Threaded hose ends compatible with fittings shown in Figure 2. Crimp-on 90° ORFS style is
shown on left. Reusable thread-on straight 37° JIC style is shown on right. (Illustrations are courtesy
of Parker Hannifin Corporation.)
The sealing mechanism type (ORFS, 37° JIC, 45° SAE) must be compatible with the fitting type used. This
is a simple procedure of proper threaded hose end selection from catalog listings. Likewise, most threaded
hose ends are available in straight, 45°, and 90° configurations to meet application needs. It is often more
desirable to use a 90° threaded hose end rather than a 90° fitting. The benefits of doing so include lower
total cost, lower total connection weight and lower internal restriction. Contact hose supplier for proper hose
and fitting selection.
Threaded ends are also available for attachment to small diameter metal tubes. Typically, two pieces are
used, a nut and a sealing flange (for ORFS) or flare (37° or 45°). The general process begins with installing
the nut over the cut and prepared end of the tube. Next, the flange or flare is welded on to the end of the
.
Threaded end components for small diameter metal tubes are available from the same hose and fitting
manufacturers.
3.3.2 Assembly of Threaded Hose Connections

A threaded hose connection is the assembly of a flexible hose or metal tube, threaded hose (tube) end, a
fitting, and a port. When tightening a threaded hose connection, care must be taken not to place a torsional
strain on the hose. Torsional strain can lead to a hose or connection failure. To prevent it, use two wrenches
(spanners) when tightening the hose end. One wrench is used to hold the threaded end hex boss, which is
secured to the body of the hose. The other wrench is then used to turn the captive threaded nut, thereby
tightening the connection.
3.3.2.1 Assembly of STOR and ORFS Connections
STOR and ORFS connections must not be over-tightened or thread damage may occur. Unlike NPTF
connections, STOR and ORFS connections seal effectively with a much lower connection torque. Follow

3.3.2.1.1 Sealants in STOR and ORSF Connections

Do not use liquid thread or gasket sealant, or PTFE (Teflon®) tape in the assembly of STOR and ORFS
connections. If the connection will not seal, check all sealing surfaces for damage, and replace the sealing
O-ring with the correct part. See Section 3.2.2 Thread
Sealing for more information about PTFE (Teflon®) tape.
3.4 Clamped Hose Connections

Clamped hose connections are also known in the industry as -
connections.
and adjustable hose clamps on each end.
3.4.1 Threaded Hose Barb Fittings for Clamped Hose Connections to Ports
Requirement 1: All hose barb fittings must have a feature for tightening the fitting without damaging the
hose sealing surface.
Requirement Background: Damaging the hose sealing surface can cause fluid leaks.
The fitting is the physical component connecting the sealed coupling of a port to a hose or tube. For clamped
end connections, one end of the fitting is threaded and the other end features a tube end with a sealing
bead, also known as a hose bead. The hose bead also helps to prevent hose to slipping off the tube. See
0. This type of fitting is also referred to as a hose barb fitting.
Threaded hose barb fittings are used to connect a hose to a threaded port. The threaded hose barb fitting
is connected to the port. The hose is clamped to the hose barb fitting.
DO NOT USE
1 2 3 4
Figure 5 Common hose barb fittings. Styles 1-3 are suitable for industrial use. Style 4 is not to be used
as it has no feature to tighten the connection to the proper torque, In addition, the fitting can be
damaged during tightening creating a potential leak point. Style 2 includes an orifice for flow
restriction, acceptable depending on application.
3.4.1.1 Necessity of a Hexagonal Boss

A variety of threaded hose barb fittings are available for clamped hose connections. Select hose barb fittings
with a feature for tightening the fitting without damaging the hose sealing surface. These fittings usually
include an external or internal hex. Fittings 1-3 in 0 show acceptable fittings, which include hexagonal
bosses.
Fitting 4 in 0 shows a fitting without a hexagonal boss (or hex). Because there is no feature for tightening
the fitting without damaging the hose sealing surface, fitting 4 is unsuitable and not recommended for
industrial hose connections.

As can be seen in 0, the fitting has been damaged during both installation and removal by the use of pliers.
The damage to the shank (see 0) may make future hose sealing difficult or impossible with this fitting. In
addition, the damage to the rim sealing bead may score the inside of the hose as it is installed. Even the
use of a stud installation tool on the shank may damage this fitting because it is hollow and cannot withstand
compression. Fittings without hexagonal bosses should never be used in industrial applications.
Damage from
installation tool
Figure 6 Close-up of damage on the shank on a hose barb fitting without a hexagonal boss. (Style 4 in
0.) Without a hex, the hose sealing contour is often gripped with pliers causing damage on the shank
and the sealing bead.
3.4.1.2 Shank Side of Fitting Selection

The shank side of the fitting should conform or appear similar to the styles listed in SAE J1231, Formed
Tube Ends for Hose Connections and Hose Fittings. Fitting style 3, shown in 0 features several ramped
steps along the shank. Because they are precisely machined, these ramps may help to seal the connection
initially as long as the hose fits snugly, but they may damage the inside of the hose when the clamp is
tightened. Upon removal of a hose from this type of barb fitting, the hose section installed over the barb
would need to be cut off before the hose is re-installed. Shortening the hose may give rise to other
complications such as excessive hose strain. In some installations, sufficient hose slack may eliminate this
concern. However, this is a disadvantage compared to the other fittings which do not require trimming the
hose upon reinstallation.
3.4.1.3 Restrictions in Fittings

When selecting hose barb fittings, the inside diameter should not excessively restrict flow. There are many
fittings commonly available which contain internal orifices. These fittings are made specifically for the
purpose of restricting flow. In certain applications, they may be required. In others, they may result in system
performance issues. Consider the application flow requirements and limitations when selecting all fittings.
For 0.75 in hose ID; This fitting

ID is 0.5625 in.
For 5/8 in. hose ID; this fitting ID is

restricted to 0.25 in. with an
internal rubber orifice
Figure 7 The fitting on the left is not restricted. The fitting on the right is restricted with an internal
rubber orifice.

3.4.2 Formed and Cast Tube Ends Sealing Bead

All formed or cast tube ends to be used with clamped hose connections must have a raised sealing bead
completely around the tube circumference. The bead may prevent the hose from sliding off the tube end
when the clamp is installed correctly.
Recommended sealing bead dimensions are provided in 0. Alternatively, SAE J1231 or AS5131
specifications may be used.
When hump hoses are used, the raised sealing bead on the tube end must not protrude into the humped
portion of the hose. The raised sealing bead hump should be noticeable in the nominal diameter portion of
the hose.
Figure 8 Sealing Bead Profile. Refer to 0.

Recommended Sealing Bead Dimensions for Tube Ends
Bead OD and Bead Radius and Bead to Tube OD Radius and

Nominal Tube OD
Tolerance. Tolerance. Tolerance
A (in)
B (in) R1 (in) R2 (in)
0.750 0.812 +/- 0.03 0.063 +0.000/-0.031 0.031 +0.000/-0.015
0.875 0.937 +/- 0.03 0.063 +0.000/-0.031 0.031 +0.000/-0.015
1.000 1.125 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
1.125 1.250 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
1.250 1.375 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
1.500 1.625 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
1.625 1.750 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
1.750 1.875 +/- 0.03 0.125 +0.000/-0.031 0.063 +0.000/-0.015
2.000 2.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
2.125 2.313 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
2.250 2.438 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
2.375 2.563 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
3.000 3.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
3.500 3.688 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
4.000 4.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
4.500 4.688 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
5.000 5.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
5.500 5.688 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
6.000 6.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
7.000 7.188 +/- 0.03 0.156 +0.000/-0.031 0.094 +0.000/-0.031
8.000 8.188 +/- 0.03 0.156 +0.000/-0.031 0.094 + 0.000/-0.031
10.000 10.188 +/- 0.03 0.156 +0.000/-0.031 0.094 + 0.000/-0.031
12.000 12.188 +/- 0.03 0.156 +0.000/-0.031 0.094 + 0.000/-0.031
3.4.3 Tube Ends for Clamped Hose Connections

Tube ends should be chamfered and be free of sharp edges or burrs. If tube ends are not chamfered and
free of sharp edges or burrs, hose damage may result upon installation or during service.
Tube ends must not make contact inside a clamped hose connection. Sufficient clearance must be
designed, and assemblers must be trained to report this condition if it cannot be prevented during assembly.
The metal filings created by contact may cause an engine failure.

3.4.4 SAE J2044 type connectors

These types of connectors are acceptable for smaller hose connections. Typical applications are coolant,
DEF (Diesel exhaust fluid), and fuel.
Figure 9 Acceptable SAE J2044 type connectors
3.4.5 Clamped Hose Connection Fit

All size hoses should fit snugly over the nominal tube outside diameter when installed by hand. There
should be no air gap between the hose and tube OD past the sealing bead. An air gap requires the clamp
to distort or crease the inside diameter of the hose. This distortion is a predominant cause of clamped hose
joint leaks. The air gap also permits dirt entry and tube corrosion, both of which deteriorate sealing capability
after the joint is serviced for the first time.
A slight interference fit should be designed into all clamped hose connections, large and small diameter.
The largest cause of clamped hose connection leaks is a loose hose fit. Clamping a loose hose results in
an irregular distortion of the hose interior. Over-tightening the clamp may be required to obtain a seal if it is
possible at all. In doing so, the hose becomes permanently damaged, and often, cannot be reused. The
nominal values provided in 0 should be used in hose connection interference fit design. Tolerances should
be discussed with the hose and plumbing manufacturers. For minimal cost, a custom ram die can be made
to enlarge tube ends slightly in order to obtain the correct interference fit. Plumbing manufacturers can
perform this operation quickly and easily during fabrication.
Clamped Hose Connection Nominal Interference Fits
Diametrical Interference
Nominal Hose
Inside Diameter Inches Millimeters
0.625 1.25 in 0.031 0.80
1.5 3 in 0.039 1.0
3.5 5 in 0.059 1.5
5.5 12 in 0.079 2.0
Courtesy of James-Dawson

3.4.6 Assembly of Clamped Hose Connections

Criteria for installing adjustable hose clamps:
Position the clamp squarely across the hose, not at an angle. Viewed from the side, the band should
be parallel to the square-cut end of the hose. If the clamp is not positioned squarely, band pressure
will not be distributed uniformly over the hose and the joint will not seal.
Position the clamp no closer than 6.35 mm (0.25 in) to the cut end of the hose. This margin prevents
the clamp from slipping off the hose.
Position the clamp edge between 3.17 mm (0.125 in) to 6.35 mm (0.25 in) away from the edge of
the sealing bead. If positioned too close to the sealing bead, the clamp edge will rest on the ramped
portion of the hose and band pressure will not be evenly distributed.
Clamp nut tightening torque is to be specified by the clamp manufacturer after review of all relevant
hose connection details. Use hose material, size, and internal joint pressure and any other relevant
information to determine proper nut torque.
service literature.
3.4.6.1 Adjustable Hose Clamp Applications
Adjustable Hose Clamps
Application SAE J1508 Clamp Type
Charge air cooler connections SLTB with flared-edge floating bridge, (WaveSeal360® and SLHD as per
SAE 1508 clamps can be used up to 64 mm (2.5 in) diameter hose)
Intake air connections TB preferred; HD WITH LINER acceptable
Coolant connections SLTB or SLHD preferred; TB or HD acceptable
TB T-bolt, SLTB Spring Loaded T-bolt, HD Heavy Duty, SLHD Spring Loaded Heavy Duty
Figure 10 Proper clamp installation. (Illustration is courtesy of R.G. Ray Corp.)
3.4.6.2 Tube End Alignment

Use hump hoses or wire reinforced straight hoses should be used when alignment of tube ends within 2
degrees cannot be achieved. This is an approximate visual threshold of misalignment. If misalignment
exceeds 5 degrees, the hump hose manufacturer should be contacted for hose life predictions. Hose bend
radius limitations set by the manufacturer should be met.
See Section 3.7.2 for information about hump hoses used in cooling system applications.

3.4.6.3 Double Clamping

If a snug interference fit between the hose and tube OD cannot be reliably achieved, design for two clamps
The practice of installing two clamps side by side, known as double clamping, is common in industrial
engine installations. However, it is not necessary when hose connections are designed, manufactured, and
assembled correctly. Most often, one of two quality issues results in the need for double clamping to
maintain a leak-free seal:
Excessive hose strain due to tube end misalignment or movement after assembly
Hose ID fits loosely over tube OD
Although unnecessary, double clamping is acceptable in cooling system, charge air cooling system and air
intake plumbing connections. When two clamps are used, position them close together but not touching.
Follow proper clamp positioning guidelines outlined in Section 3.4.6, Assembly of Clamped Hose
Connections. Double clamping makes it necessary to use a longer hose.
Figure 11 Double clamping shown.
The photo in Figure 11 shows double clamping. In this example double clamping was needed due to poor
connection quality. Note buckling in the center of the hose due to torsional and axial movement after
assembly. The arrow on the left points to an air gap at the cut end of hose, indicative of a loose fit.
If the following conditions are met, a single clamp will be sufficient for a leak-free joint seal:
Hose fits snugly over the tube outside diameter behind the sealing bead when installed by hand
Tube surface behind the sealing bead is smooth, concentric, and of constant diameter
A quality T-bolt clamp is used, tightened to the correct specification, and in the proper position
Tube end sealing beads meet the dimensional specifications provided in this document
Tube ends are well aligned and properly supported with brackets to restrain movement after
assembly

3.4.7 Types of Hose Clamps

The following figure shows types of hose clamps will be discussed in this document.
T-bolt with
flared edge
floating bridge
(Preferred)
T-bolt with
band liner
(Not recommended)
Spring
Loaded
Heavy Duty
with band
liner
Heavy Duty
with band
liner
(Acceptable)
Heavy Duty
clamp without band
(Not recommended)
F, I, M
(Not recommended)
Figure 12 Hose Clamp Types
3.4.8 T-Bolt vs. Worm Gear Style Clamps

T-bolt style hose clamps are generally superior to worm gear style clamps and are preferred in industrial
engine applications for two reasons. First, the T-bolt clamp may be tightened to produce a higher radial
clamping pressure without damaging the clamp. Radial clamping pressure is a major factor affecting hose
joint sealing. In some applications, the required band tension for sealing may not be achieved with a
standard worm gear clamp. Second, the T-bolt clamp does not have band perforations. Worm gear clamp
band perforations may cause hose extrusion during tightening, thereby affecting hose reusability and
resealing.
Figure 13 The photo on the left shows hose extrusion through band perforations. The photo on the right
shows a breeze clamp with internal band liner. (Photos are courtesy of Breeze Industrial Products.)

T-Bolt clamps with a flared edge floating bridge are recommended over a T-Bolt clamp with only a band
liner without flared edges. The flared edge, floating bridge prevents the liner from buckling during tensioning
which can create a leak path. (Figure 14)
Flared Edge
Figure 14 Standard T-bolt clamp (SAE type TB) with an optional floating bridge underneath the latch
assembly. (Photo is courtesy of R.G. Ray Corporation.)
3.4.9 T-Bolt Style Clamps

T-bolt Clamps are a hose clamp equipped with a T-bolt that can be tightened by a hex-nut. T-Bolt Clamps
are used to seal liquid or air connections on hoses.
3.4.9.1 T-Bolt Clamp Sizing
An incorrectly sized clamp may cause sealing issues. R.G. Ray Corporation provides the following general
guidelines for evaluating T-bolt clamp size after the joint is assembled and the correct torque is applied to
the T-bolt nut. See Table 6 Verification of Correct T-bolt Clamp Size. The correct clamp size can be
specified by the manufacturer in advance if the hose size is provided.
Table 6 Verification of Correct T-bolt Clamp Size

If Gap Between Loops Is: Then, Clamp Size Recommended Action:
(Ref. Figure 10) Is:
Between 4.76 mm -19.05 mm Correct None. This is the correct range for
(0.1875 in - 0.75 in) the clamp.
Less than 4.76 mm (0.1875 in) Too Large Select a clamp that is 1.59 mm
(0.0625 in) smaller in diameter.
Greater than 19.05 mm (0.75 in) Too Small Select a clamp that is 1.59 mm
(0.0625 in) larger in diameter.
3.4.10 Worm Gear Clamps

A worm gear clamps is a circular metal band or strip combined with a worm gear fixed to one end. They
are sometimes known as jubilee clips.
Although T-bolt clamps (see Figure 14) are always preferred, certain worm gear style clamps are
acceptable for use in small coolant connections (below 5.08 cm (2 in) diameter) and non-pressurized
turbocharger air intake connections. If worm gear clamps are to be used, SAE J1508 type HD or SLHD with
an internal band liner should be used exclusively. The liner prevents hose extrusion through the outer band
perforations.

When worm gear clamps (see Figure 15) are used in small coolant connections, heavy duty spring-loaded
worm gear clamps (SAE J1508 type SLHD) are recommended. This type of clamp can regulate band
pressure during the hose contraction and expansion that accompany coolant thermal cycles. This capability
ensures reliable joint sealing and virtually eliminates the need for clamp re-tightening. Breeze Industrial
Products offers SAE type SLHD clamps with internal band liners in sizes down to 1.428 cm (0.5625 in)
diameter under their Constant-Torque® product line. They also offer SAE type HD worm gear clamps with
internal band liners in sizes down to 1.11 cm (7/16 in) diameter.
Note: The internal band liner is not a standard clamp feature offered by every manufacturer. It is listed as
an optional feature in SAE J1508.
See Section 3.4.8 for more information about selecting T-bolt clamps vs. worm gear clamps.
Figure 15 Breeze worm gear clamps. SAE type HD is shown on the left. SLHD type is on the right.
Both have internal band liners which cover the outer band perforations. (Photo is courtesy of Breeze
Industrial Products.)
3.4.11 Spring-Loaded Clamps

Spring-loaded clamps have been developed to regulate band pressure in hose connections that expand
and contract during thermal cycling of the joint. Coil springs or stacked Belleville washers may be used with
either T-bolt style clamps to achieve this capability.
Figure 16 Spring-loaded SAE type SLTB clamp shown with a flared-edge floating bridge underneath the
latch assembly. (Photo is courtesy of Voss Industries.)
Spring-loaded clamps regulate band pressure as follows:

After the clamp is tightened to specification, the spring is mostly compressed, but not completely coil bound.
As the temperature increases, the connection will expand slightly and the spring will continue to compress.
This additional spring compression allows the band to expand without exerting a drastic increase in
pressure around the joint or building up excessive internal stresses. Without the spring, or if the spring
became coil bound, the increase in band pressure during an expansion cycle may cause the clamp to break
or to cut into the hose.

As the temperature of the connection decreases and thermal contraction occurs, the spring expands,
thereby keeping sufficient band pressure around the hose. This same action occurs over time as the
connection ages and the hose material flows out from underneath the clamp. A natural material flowing
that clamps need to be re-tightened occasionally. Although clamp nut torque checks are still recommended
due to application variability, spring-loaded clamps virtually eliminate the need for re-tightening.
3.4.12 Non-Adjustable One-Piece Spring Clamps (CTB)

Common in automotive applications, one-piece spring clamps (SAE J1508 type CTB) are a low cost and
effective method of sealing small diameter engine coolant connections in enclosed installations. These
clamps function essentially as a torsional spring. In the relaxed state, the inside diameter is smaller than
the nominal outside hose diameter. By compressing the clamp ends to expand the inside diameter, the
clamp may be installed over the hose and then released to apply pressure around the hose circumference.
This type of clamp offers the joint expansion and contraction tolerance of type SLTB clamps at a fraction of
the cost. However, one piece designs are not suitable where hoses may be subjected to regular or
accidental strain during operation and equipment service. Because there is no mechanism to limit excessive
expansion of this type of clamp, external loads may pull the hose connection apart even with the clamp in
place.
Figure 17 SAE type CTB clamp. (Photo is courtesy of Rotor Clamp, Inc.)
Additionally, the effectiveness of a CTB clamp is extremely sensitive to both hose material durometer
(hardness) and a snug interference hose fit. If a replacement hose uses a higher durometer rubber, or is
slightly larger than the original design, the joint will not seal. This should be considered when considering
the use of CTB clamps.
3.4.13 Clamps for Small Diameter Push-on Fuel Hose and Coolant Vent Lines
For small diameter hoses (<0.75 in or 19 mm) SAE type D clamps should be used so that uniform clamping
pressure is maintained over the hose. The use of small diameter worm gear clamps should be avoided
because the perforated band is susceptible to losing its circular shape in diameters less than 1.90 cm (0.75
in). If the band does not retain its circular shape, clamping pressure may be unevenly distributed around
the circumference of the hose, and the joint may be more likely to leak.
Figure 18 SAE type D hose clamps shown in zinc plated finish (on left) and black oxide finish (on right)

3.4.14 Clamp Features

3.4.14.1 Clamp Metal Selection
A wide range of metals and metal coatings are available for hose clamp construction. Lower cost clamps
will often feature a low quality stainless steel band and a zinc plated tightening screw. The screw may
corrode severely enough to require clamp replacement prior to hose replacement. Higher quality clamps
will feature all stainless steel components. Requirements will vary based upon intended operating
environment (humidity, corrosive cleaners, etc.) and desired reusability of the clamp. An all-stainless
construction is recommended for industrial applications where premium serviceability and durability are
expected.
3.4.14.2 Clamp Band Width
A variety of band widths are available when selecting hose clamps. Clamp band width is not a primary
factor affecting joint sealing capability when the tube end is smooth, concentric, and of constant diameter.
However, non-preventable shape irregularities and defects in the tube end may require a wider band width
to ensure a smooth, continuous portion of the tube is covered by the clamp. Higher clamp load applications
may also necessitate the use of a wider band. Contact the clamp manufacturer to select band width based
on application requirements.
3.4.14.3 Special Clamp Design Features
There are several important clamp design features which are available from many clamp manufacturers
but are not necessarily standard:
3.4.14.3.1 Rounded or Flared Band Edges

Regardless of clamp type used, all band edges should be rounded or flared to prevent hose damage.
Rounded or flared band edges are commonly available. They prevent the edge of the band from cutting
into the hose surface during tightening. Many of the lower cost clamps available have un-chamfered band
edges, not suitable for industrial hose connections.
3.4.14.3.2 Internal Band Liners

Internal band liners are available for higher quality worm gear style clamps. A liner is simply a non-
perforated extension of the band that covers the outer band perforations from inside the clamp. Liners are
not a standard feature of worm gear style clamps. Although commonly available, liners must be specially
requested from the clamp supplier.
3.4.14.3.3 Flared-Edge Floating Bridge

A flared-edge floating bridge is available for T-bolt clamp designs. The purpose of the bridge is to prevent
tightening the clamp. This happens when band friction against the hose surface pulls the hose toward the
latch assembly. Floating bridges are recommended for T-bolt style clamps used with silicone hoses, which
are more susceptible to this problem.
3.5 Hoses
terchangeably throughout this document.
referring to long hoses of small diameter.
3.5.1 Hose Selection
hoses.

3.5.2 Clearance around Tube Ends and Hoses
Requirement 2: Sufficient end clearance must be designed to prevent tube end contact through straight
hose connections.
Requirement 3: Clearance around all hoses must be designed to prevent contact and wear-through.
Requirements Background: If the end clearance are not sufficient, tubes can rub together to generate metal
debris which may damage the engine. It may also cause high hose stresses which may lead to hose failure.
Sufficient end clearance must be designed to prevent tube end contact through straight hose connections.
For 50.8 mm (2 in) diameter and smaller, design a minimum of 12.7 mm (0.5 in) end clearance. For 63.5
mm (2.5 in) diameter and larger, design a minimum of 25.4 mm (1 in).
Clearance around all hoses must be designed to prevent contact and wear-through. Accommodate the
hump in hump hoses to prevent contact. Hose contact may lead to wear through and an engine dust out
failure may result.
When tube end clearance in straight hose connections exceeds the hose diameter, the need for wire
reinforcement (SAE J20R2 type hose) should be considered. For diameters greater than 50.8 mm (2 in),
long lengths of hose are susceptible to collapse for a variety of reasons including vacuum service, missing
or insufficient pipe brackets, and misalignment of tube ends.
3.5.3 Routing and Securing Hoses (Lines) in Design and Assembly
Requirement 4: Consult AEB 21.46 prior to installing a P-clip underneath any engine bolt.
Requirement Background: Adding P clips under engine bolt can reduce integrity of a bolted joint thus
causing failure of the joint.
Requirement 5: Sufficient hose length (slack) between clipping points subject to relative motion must be
provided in both installation design and assembly.
Requirement Background: Insufficient hose length (slack) between clipping may cause excessive hose
strain thus causing hose or connection failures.
3.5.3.1 P-clips and Clamping Blocks
Secure all long hoses (lines) to the equipment with clamping blocks, or insulated P-clips, in such a way to
prevent chafing against sharp edges and rubbing against flat surfaces. Figure 19 gives an example of a
hose in direct contact with a sharp edge of a sheet metal.

Figure 19 Hose in direct contact with a sharp edge of a sheet metal belt guard. In this case, the fittings
and hose routing used are critical to engine fan drive performance. A relief cut should be made in the
belt guard to prevent hose contact during operation and vibratory movement.
The P-clips or clamping blocks should be spaced close enough to prevent the hose from flexing to contact
other components in between them. The proper locations and spacing for P-clips or clamping blocks must
be shown on the machine assembly prints to eliminate variation between workers.
Figure 20 Clamping blocks properly used to separate and secure long hoses (lines) along the
equipment frame.
Figure 21 Hump hose contact with steel turbocharger frame. If left uncorrected, the hose will eventually
wear through, and an engine dust-out failure will result.
Long hoses (lines) must be held snug inside the clamping block or P-clip when it is tightened. The line must
not be allowed to twist or vibrate against it. If moderate hand force causes the line to move within the
clamping block or P-clip after it is tightened, a smaller size must be used.
Clamping blocks and P-clips must be secured directly to the equipment frame or to studs or threaded holes
provided for this purpose on the engine block. Consult AEB 21.46 prior to installing a P-clip underneath any
engine bolt. Sufficient bolt thread engagement must be maintained to prevent an engine failure.

Sufficient hose length (slack) between clipping points subject to relative motion must be provided in both
installation design and assembly. This requires adding specifications to installation diagrams and prints,
and providing training to equipment assembly workers.
Figure 22 Air conditioner and fuel lines laid over an I-Beam frame, unclipped. If left alone, the lines may
wear through on the sharp edge of the I-Beam. In this case, the lines should be re-routed and
securely clipped underneath the I-Beam.
Figure 23 A coolant vent line is shown improperly attached with a P-clip to a hose clamp T-bolt screw.
Note the line is also routed close to turbocharger housings. In this case, the line must be routed
above the engine to vent correctly; therefore, it should not be clipped to a hose clamp.
3.5.3.2 Wires or Cable Ties

Normally, long hoses need to be secured. However, wires or cable ties should not be used to secure hoses
(lines) to the equipment or the engine. The use of wire cable ties on hose (lines) may cause rubbing and
premature hose failure. Also wire or cable ties often do not have sufficient durability for industrial
applications.
Wire ties may be used only to secure bundles of hoses that are commonly routed, when used to prevent
the individual hoses from chafing against each other.

3.5.3.3 Routing Hoses through Sheet Metal
Requirement 6: Rubber grommets must be used when hose is routed through sheet metal without the use
of a bulkhead fitting.
Requirement Background: If rubber grommets are not used, the hose may chafe on the sheet metal and
may eventually wear through.
When hoses are routed through sheet metal or solid structures, either bulkhead fitting or rubber grommets
should be used. Rubber grommets must be used when hose is routed through sheet metal without the use
of a bulkhead fitting. Otherwise, the hose will chafe on the sheet metal and will eventually wear through.
See Figure 24.
Rubber Grommets
Figure 24 Properly sized grommets used in floor plate for passage of cab heater coolant hoses.
3.5.4 Bends in Hoses

Meet the minimum hose bend radius specification published by the hose manufacturer during both design
and assembly. Too tight of a bend radius may kink the hose, increasing internal restriction. In worse cases,
a hose failure may result. Angled hose ends and fittings may be used to keep the hose bend radius within
specification.
Hoses and hose routing should be designed to avoid kinking of the hose. If an immediate bend is required,
an angled fitting should be considered. See Figure 25.
Figure 25 A kinked hose due to a bend immediately after connection.

3.5.5 Hose Lubrication

Use a lubricant that is approved by the hose supplier. A diluted solution of glycerin is often the
recommended agent to ease hose installation with clamped hose connections. The use of mild dish soap
and water solution can cause joint rewetting and reduce joint sealing capability. The use of oil, petroleum
jelly, grease, sealants, or other chemicals may degrade the hose, reduce joint sealing capability, or make
hose removal more difficult. Often, measures taken to remove stubborn hoses lead to tube surface damage
and future joint leakage problems.
3.5.6 Brackets
Vibratory resonance can destroy hoses which visually appear to adequately support the plumbing. When
designing brackets for cooling system plumbing, consider the weight of coolant in addition to the plumbing
itself.
Select support brackets which are sufficiently stiff in both vertical and lateral directions. Simple lateral
braces restraining horizontal motion are commonly used but often provide insufficient vertical support of
the pipe.
The effectiveness of support brackets and braces used to secure hard plumbing should be checked after
assembly by applying hand pressure. The hard plumbing should not move side-to-side more than 12.7 mm
(0.5 in) when applying moderate to heavy hand pressure immediately beside the hose connection. No
plumbing motion should result from light pressure.
3.6 Air Hoses
3.6.1 Air Intake Hose Critical Design Criteria

For intake air connections, air hoses should be capable of handling the following operating conditions:
Ambient (internal) temperature range of -40 °C (-40 °F) to 52 °C (125 °F), for non-arctic applications
Ambient (internal) temperature range of -48 °C (-55 °F) to 52 °C 125 °F) for arctic applications
Hoses used under-hood or within engine compartment require higher temperature capability
Convection and radiation heat transfer from engine and exhaust
Conduction heat transfer through turbocharger compressor inlet flange
Internal low pressure (vacuum) air flow up to 12.5 kPa (50 in H2O) at operating temperatures. The
hose must not collapse.
Periodic external contact with engine cleaning fluids and solvents
Accidental contact with engine fluids such as fuel, oil, and coolant
Vibratory stresses, and some amount of installed strain from plumbing misalignment
3.6.2 Air Intake Hose Material - Non-silicone Rubber Hoses (EPDM, Nitrile, Neoprene)
The most commonly available hoses for intake air connections are made from one or more of the synthetic
rubber compounds ethylene~propylene (EPDM), acrylonitrile (Nitrile), and polychloroprene (Neoprene).
They are relatively low cost compared to silicone due to high volume injection-molded production, but they
cannot withstand surrounding temperatures greater than 121 °C (250 °F) over extended periods of time.
These compounds are injection-molded without embedded reinforcement fabric. Consequently, tear
resistance is low. External stiffening ribs are available from some manufacturers to help prevent the hose
from collapsing with the low pressure (vacuum) airflow carried inside. The ribs also help to prevent the hose
from buckling under the weight of poorly supported or misaligned steel plumbing.

Figure 26 Injection-molded EPDM intake air hoses. (Photos are courtesy of Air Flow Systems, Inc.)
EPDM, Nitrile, Neoprene Comparison

EPDM, Nitrile, Neoprene
Advantages Disadvantages
Many shapes and sizes readily available Limited to 121 °C (250 °F) operating environment
Low cost compared to silicone Low tear resistance: No reinforcement fabric
Age and heat hardening occur even below 121 °C
(250 °F)
Poor flame resistance
3.6.2.1 Disadvantages of Non-Silicone Rubber Hoses

Many costly engine dust-out failures have occurred due to the failure of intake air hoses. The failure most
often occurs when a non-silicone rubber hose is subjected to excessive heat from the engine or vehicle
exhaust system. This is especially a concern for the connection into the turbocharger compressor as this
hose is typically near to the engine exhaust manifold. Heat and age hardening will cause brittleness and
subsequent cracking of non-silicone hose compounds. The crack initiation is often aided by the depression
of the clamp edge in the hose. An over-tightened clamp aggravates this issue. With the weight and vibration
of the plumbing, and lack of reinforcement fabric, the tear may quickly propagate to create a substantial
opening for dirt ingress.
Figure 27 EPDM compressor inlet hose cracked due to excessive heat and low temperature capability.
Note missing piece. An engine dust-out failure resulted.
3.6.2.2 Guidelines for Regulating Non-Silicone Rubber Hoses for Intake Air Connections
The recommendations in this section are intended to prevent costly failures due to failures in non-silicone
rubber hoses for intake air connections.
Only use non-silicone rubber hoses if the surrounding air temperature does not regularly exceed 121 °C
(250 °F).
The OEM is to provide inspection criteria and a recommended service replacement interval to the customer
for all non-silicone air intake hoses.

Exhaust pipe
Exhaust manifold
Figure 28 QSK60 Single-Stage installation which suffered a dust-out failure. Two 90° EPDM elbows
were used to make the 180° bend required from the intake pipe to the compressor inlet flange. Note
close proximity to engine exhaust manifold and exhaust pipe.
Figure 29 90° elbow hose from failed engine in Figure 28. Note crack initiation at edge of clamp
depression in hose material. Excessive plumbing strain and heat both contributed to this failure.
3.6.3 Air Intake Hose Material - Silicone Rubber Air Intake Hoses
Select silicone material for the air intake hose when surrounding air temperatures will regularly exceed 121
°C (250 °F). Superior resistance to age hardening, weathering effects, and high temperatures also makes
SAE J20 Class A silicone the preferred choice when hose life equal to engine overhaul is required.
Silicone hoses may be manufactured by injection-molding or mandrel-wrap fabrication. A very small
selection of non-reinforced injection-molded silicone hoses exists in the aftermarket. This is due to the high
tooling costs involved with injection-molding equipment and the predominant need for reinforcement fabric
in silicone hoses, which cannot be added through injection-molding. When built on a mandrel, a silicone
hose may be fabricated with or without reinforcement fabric. The use of reinforcement fabric not only
considerably improves the strength of the hose but also the ease of manufacture and the dimensional
quality of the finished product.
Due to the vastly improved tear resistance over non-reinforced rubber hoses, fabric-reinforced silicone is
recommended for all applications which require the high temperature capability of silicone. If non-reinforced
silicone material is used, plumbing should be securely braced and supported to alleviate all loading of the
hose.

3.6.3.1 Turbocharged Air Compressor Air Intake Hoses

Several Cummins engines offer options for high mount turbochargers that have the turbo compressor inlet
directly above the exhaust manifold resulting in higher compressor inlet hose temperatures. Also, vee
configuration engines with the turbocharger located inside the vee may experience higher compressor inlet
hose temperatures. Because of the high heat, silicon hose should be used when routed near hot surfaces
such as exhaust manifolds, turbochargers, and / or exhaust system components.
3.6.3.2 Reinforcement for Silicone Rubber Air Intake Hoses

A variety of reinforcement fabrics are available including polyester, fiberglass, and meta-aramid (Nomex ).
Fiberglass reinforcement is not recommended for compressor inlet hoses due to the minor relative
movement expected across the connection. The strength of fiberglass may deteriorate as a result of any
relative movement. Fiberglass reinforcement is commonly used in on-engine hoses where no relative
movement exists across the connection and alignment is well controlled.
Polyester reinforced silicone can withstand relative motion across the connection and surrounding
temperatures up to approximately 177 °C (350 °F). Most common engine applications are expected to fall
within this limit. Meta-aramid (Nomex ) reinforced silicone can withstand up to approximately 260 °C (500
°F). Although no compressor inlet hose applications have required Nomex® to date, confined and enclosed
engine compartments may necessitate its use.
Note: Nomex® reinforced silicone charge air cooling hoses are generally not suitable for intake air hoses
because of the 12.5 kPa (50 in H2O) vacuum collapse resistance requirement.
Vacuum collapse resistance of a mandrel-built silicone hose is proportional to its wall thickness. The
number of fabric reinforcement plies contained in the silicone also affects collapse resistance; however, it
is not an indicator alone. A thinner wall thickness with six plies of reinforcement may have less collapse
resistance than a thicker wall with five plies of reinforcement. Wall thickness and the number of
reinforcement plies must be considered together for each application. In some cases, the desire to re-use
existing clamps may limit the wall thickness of new designs. The hose manufacturer must be aware of the
design constraints for the application being considered.
3.6.3.3 Diameter Reducing Inserts for Compressor Inlet and Air Intake Hoses
Diameter reducing inserts are available in the aftermarket to help adapt existing hoses to smaller pipe and
compressor inlet flange sizes. Inserts not only provide an additional leakage path in theory, but they do not
seal well in practice and should never be used in industrial applications for turbocharger compressor inlet
or air intake system connections. Only the hose size which directly matches the pipe size should be
specified and used. Do not use diameter reducing inserts because they may increase the risk of leakage
and an engine dust-out failure.
Figure 30 Diameter reducing hose insert, which is not appropriate to this application. (Photo is courtesy
of Air Flow Systems, Inc.)

3.6.4 Air Intake System Cleanliness
AQS Requirement 1: Precautions must be taken to prevent contaminants from entering air intakes and
charge air cooler hoses during shipping and storage prior to assembly in the machine.
Requirement Background: Cleanliness of the air intake and CAC system is critical to engine and
turbocharger durability.
The variable geometry turbocharger (VGT) used on newer engine design is more complex than older
turbocharger designs and is much more sensitive to damage due to foreign objects that may pass through
the turbine side of the turbocharger. Therefore, the cleanliness of the intake air system is critical to engine
/ turbocharger durability. Any contamination in the system may be ingested directly into the engine cylinders
and passed through the turbo machinery, and may result in serious engine damage. The internal portions
of all intake air hoses should be visually clean when assembled on the machine.
3.6.5 Thermal Wraps and Blankets

Do not use shielding blankets or covers over air intake hoses.
Thermal wraps and blankets that cover the compressor inlet hose are not acceptable and should not be
used. Covers hinder access for hose and clamp inspection. Damage resulting from plumbing strain may
not be visible with covers in place. A crack formation underneath a cover will still allow enough dirt into the
engine to cause a dust-out failure. Some covers employ a wire mesh inner wrap to retain the insulating
material. In several instances, these wire meshes have vibrated during operation, worn through the
compressor inlet hose, and caused an engine dust-out failure.
Figure 31 QSK45 installation shown with EPDM rubber 45° hoses. Note the extremely close proximity
to exhaust manifolds. This engine suffered a dust-out failure when exhaust manifold heat caused
brittleness and cracking of the compressor inlet hoses.
Figure 32 Failure of compressor inlet hose in QSK45 installation. Large chunk shown missing. The
hose became brittle from exhaust manifold heat and it cracked. The engine quickly suffered a dust-
out failure. Note proximity of exhaust manifold.

3.6.6 Charge Air Cooling Systems Air Hoses and Connections

3.6.6.1 Charge Air Cooling System Hoses Critical Design Criteria
For charge air cooling systems, choose air hoses capable of handling the following operating conditions:
Ambient temperature range of -40 °C (-40 °F) to 52 °C 125 °F) for all non-arctic applications
Ambient temperature range of -48°C (-55 °F) to 52 °C 125 °F) for arctic applications
CAC hoses used under-hood or within engine compartment require higher temperature capability
Internal air temperatures of up to 232 °C (450 °F) for intermittent or sustained periods of time
Internal air pressures up to 275 kPa (40 psig) for intermittent or sustained periods of time. The hose
must not burst.
Cyclical pressure pulsation in some applications. The hose reinforcement must not fatigue or
degrade.
Accidental contact with engine fluids such as fuel, oil, and coolant
Vibratory stresses and some amount of installed strain from plumbing misalignment
3.6.6.2 Charge Air Cooler Hoses - Shape
Only straight hump hoses, also known as convoluted hoses, are recommended for CAC connections. The
humps provide flexibility to accommodate some tube end misalignment. Hoses with more than three
convolutes (humps) are not recommended due to increased system restriction. The use of elbow shaped
hoses is not recommended due to the internal pressure loading. Elbow shaped hoses are extremely prone
to blow-off in CAC systems due to high boost pressures and temperatures and relative movement of the
system, even with rigorous efforts to brace and support the plumbing.
All CAC hump hoses should have external steel restraining rings in between the humps to keep the hose
from swelling excessively during pressure cycles. Additionally, the number of plies of reinforcement fabric
should be appropriate for the hose size and pressures expected. The hose manufacturer should be supplied
with the turbocharger compressor outlet pressure listed on the Engine Data Sheet. Typically, four plies of
reinforcement are used in a 101.6 mm (4 in) hose. A minimum of five plies is required for larger sizes.
3.6.6.3 Charge Air Cooling System Hoses Hose Material Meta-aramid / Nomex Reinforced
Silicone Hump Hoses
Requirement 7: Use straight meta-aramid / Nomex reinforced silicone hump hoses with wire restraining
rings for both hot and cold sides of the CAC system. Polyester reinforced silicone hoses may only be used
on the cold side if both of the two conditions listed in this section have been satisfied.
Requirement Background: Failure to use straight meta-aramid / Nomex reinforced silicone hump hoses with
wire restraining rings can cause turbocharger, air intake connection, and CAC failures.
Hoses used in the charge air system operate in a high temperature, high pressure environment and provide
the charge air system the flexibility to absorb the relative motion between engine and chassis. Select hoses
that will retain their flexibility when operating under high boost temperature and pressure conditions. The
Engine Data Sheet lists typical operating boost temperatures and pressures.
Normally, two flexible hoses are used in the piping to the charge air cooler, and two in the piping returning
air from the charge air cooler to handle the relative motion between engine and chassis. Select hoses that
will maintain their seal throughout the life of the engine to prevent air leakage and the resulting loss of
engine power and possible damage.
Nomex reinforced bellows-type silicone hoses with external reinforcing rings must be used with charge air
cooled engines. In general, four-ply Nomex reinforcement (or equivalent) with external reinforcing rings
have provided adequate service life for charge air hoses.
Bellows-type hoses with external rings control hose ballooning to prevent hose blow-off, and remain flexible
even under high boost pressures.

Hoses used on the cold side of the charge air cooling system will operate at the same boost pressures as
the hot side, but at much lower temperatures. This may allow different types of rubber and reinforcement
to be used.
Fiberglass reinforced hoses have proven unacceptable. Molded elbows are not recommended because
they are prone to blow-off
Figure 33 Nomex reinforced silicone charge air cooling hose, with stainless steel restraining rings.
(Photo is courtesy of Flexfab.)
Silicone hose reinforced with meta-aramid (Nomex ) fabric is the industry standard for engine charge air
cooling system connections. The special meta-aramid fabric is used because of its greater temperature
resistance compared to other commonly used materials such as polyester. Meta-aramid reinforced CAC
hoses are typically advertised as supporting temperatures up to 260 °C (500 °F). Some suppliers offer
polyester reinforced hoses for the cold side of automotive CAC systems. Polyester reinforced hoses are
not recommended for industrial applications due to the consequences of accidental installation on the hot
side and service part confusion in the field. Additionally, many industrial applications run the engine at rated
power for extended periods of time. Under these conditions, even the cold side of the CAC system may
require the temperature resistance of meta-aramid reinforcement fabric.
3.6.6.4 Charge Air Cooling System Hoses Hose Material Polyester-Reinforced Silicone Hoses
The use of polyester-reinforced silicone hoses for the cold side of a CAC system is only acceptable if the
following conditions are both satisfied:
Temperature testing has been performed under worst-case ambient and duty-cycle conditions, with
the maximum engine ratin
specifications
-
formed to fit only the cold side plumbing.
3.6.6.5 Charge Air Cooling System Hoses - Cleanliness
AQS Requirement 2: Charge Air Cooler (CAC) hoses must meet the cleanliness requirements outlined in
this document.
Requirement Background: Contamination of the air intake can cause engine damage.
The variable geometry turbocharger (VGT) used on newer engine design is more complex than older
turbocharger designs and is much more sensitive to damage due to foreign objects that may pass through
the turbine side of the turbocharger. Therefore, the cleanliness of the intake air system is critical to engine
/ turbocharger durability. Any contamination in the system may be ingested directly into the engine cylinders
and passed through the turbo machinery, and may result in serious engine damage. The internal portions
of all CAC hoses should be visually clean when assembled on the machine.

3.6.6.6 Charge Air Cooling System Connections
Requirement 8: Stainless steel coil spring-loaded T-bolt clamps must be used for all charge air cooling
connections, tightened
Exception: The following clamps been found acceptable on turbocharger pressurized tubing up to 64 mm
(2.5 in) diameter.
a: SLHD as per SAE 1508 -Heavy duty (HD) clamp
b: The Ideal WaveSeal360® clamp
Requirement Background: CAC hose blow off is likely due to the extreme thermal cycling of these joints.
Spring-loaded T-bolt clamps (SAE J1508 type SLTB) are required for all charge air cooling system
connections due to the extreme thermal cycling of these joints. For industrial applications, type SLTB
clamps are required for both the hot and cold sides of the charge air cooling system. This requirement
simplifies system design and helps to prevent accidental replacement of a critical hot-side clamp with an
inferior part.
Exception: The following clamps have been found to be acceptable on turbocharger pressurized tubing up
to 64 mm (2.5 in) diameter.
a. SLHD as per SAE 1508 (Heavy duty (HD) clamp modified to incorporate a stack of conical spring
washers for energy storage),
Figure 34 SLHD type hose clamp
b. The Ideal WaveSeal360® clamp, has two parts, the outer clamp assembly and the inner wave
profile liner. The clamp rides on the liner so the pressure is evenly distributed around the hose.

Figure 35 Ideal WaveSeal360® clamp

3.6.6.7 Charge Air Cooler Hoses V-band Clamp Adaptations to Hard Plumbing
Some manufacturers offer high quality CAC hoses with special ends designed for V-band clamp
adaptations to hard plumbing. Although more expensive, they are perfectly acceptable and will likely
improve the robustness of the system over a band-style clamp connection.
3.6.7 Air Compressor Systems Air Hoses and Connections

3.6.7.1 Naturally Aspirated Air Compressor Inlet Hoses Critical Design Criteria
For naturally aspirated air compressors, choose inlet hoses capable of handling the following operating
conditions:
Internal and external air temperatures from -40 °C (-40 °F) to 60 °C (140 °F)
Internal air vacuum up to 17 kPa (5 in Hg). A reinforced hose is recommended.
Periodic contact with engine cleaning fluids and solvents
Select inlet hoses for naturally aspirated air compressors that meet SAE J20R3 vacuum requirement
specifications. An SAE J20R3 heater hose is acceptable.
3.6.7.2 Naturally Aspirated Air Inlet Hose Connections
system. Most naturally aspirated air compressors have a formed or cast inlet hose barb connection for the
air inlet, instead of a threaded port. This necessitates adding a hose barb fitting to the air intake pipe for the
other end of the hose.
If the air compressor is equipped with a threaded inlet port, two options are available. A threaded hose barb
(nipple) may be installed to allow the adaptation of the hose type mentioned in section Naturally Aspirated
Air Inlet Hoses, 3.6.7.2 or, fittings may be installed to allow the adaptation of a more robust industrial hose
with threaded hose ends. As the hose must meet the vacuum requirement of 17 kPa (5 in Hg), the option
of threaded hose end connections may provide a more durable seal.
Caution: It is important to remember that any leakage in the air compressor inlet hose connections may
result in engine air intake system contamination. Therefore, this hose connection is as critical to the
prevention of engine dust-out failures as the connection to the intake air.
3.6.7.3 Turbocharged Air Compressor Inlet Hoses Special Requirements
Requirement 9: Turbocharged air compressor applications must be approved by Cummins and the air
compressor manufacturer prior to build.
Requirement Background: Air compressor failure may occur on some engines if air is supplied from the
engine turbocharger.

3.6.7.4 Turbocharged Air Compressor Inlet Hoses - Critical Design Criteria

For turbocharged air compressors, choose inlet hoses capable of handling the following operating
conditions:
Internal air temperatures up to 121 °C (250 °F) for intermittent or sustained periods of time
Internal air pressures up to 275 kPa (40 psig) for intermittent or sustained periods of time
3.6.7.5 Turbocharged Air Compressors as Original Equipment
For turbocharged air compressors available as original equipment on Cummins engines, a steel inlet tube
that connects the engine intake manifold to the air compressor inlet port will have been designed. When a
turbocharged air compressor option is up-fit to an engine which was originally offered with the option, use
all of the original equipment parts, including the steel inlet tube.
3.6.7.6 Turbocharged Air Compressors on Engines Not Originally Offered with Turbocharged Air
Compressors
If a customer wishes to turbocharge an air compressor with an engine that was not originally offered with a
turbocharged compressor option of the exact model under consideration, obtain approval from both
Cummins and the air compressor manufacturer. If approval is given by both Cummins and the air
compressor manufacturer, a port in the OEM supplied cold side CAC plumbing or on the engine will be
indicated for turbocharged air supply use.
While it is still desirable to use a steel line for the turbocharged inlet, it may be impractical for the customer
to custom manufacture such a line in low volumes. In such cases, the inlet hose should be of the same
material and size as that used for the discharge. FKM (Viton®), or equivalent as defined in ASTM D1418
and ISO1629, O-rings should be used in all connections. See Section 3.3.1.3 O-ring Material for more
information about O-rings.
3.6.7.7 Air Compressor Discharge Hoses Critical Design Criteria
Select air compressor discharge hoses capable of handing the following operating conditions:
Internal air temperatures up to 205 °C (400 °F) for intermittent or sustained periods of time
Internal air pressures up to 1000 kPa (145 psig) for intermittent or sustained periods of time
Internal pressure pulsation
3.6.7.8 Air Compressor Discharge Hoses Hose Material
Requirement 10: When a solid steel line is not available, extruded PTFE (Teflon ®) hose with a stainless
steel wire braided cover must be used for all air compressor discharge lines and for turbocharged air
compressor inlet lines. Solid steel line is preferred.
Requirement Background: Extruded PTFE (Teflon®) hose is required to achieve acceptable hose durability
and to prevent premature hose failures.
A solid steel line is preferred for air compressor discharge tube. The only suitable flexible hose material for
an air compressor discharge line is extruded PTFE (Teflon®) hose with a stainless steel wire braided cover.
No other hose material can withstand the air temperature at the compressor discharge port. This type of
hose may be purchased from Aeroquip and Parker.

3.6.7.8.1 Air Compressor Discharge Hoses Fittings

Special threaded end fittings are required for exclusive use with this type of hose.
Figure 36 Stainless steel wire braided cover with extruded PTFE inner tube, manufactured by Aeroquip.
Required for all air compressor discharge lines, and turbocharged supply lines when a solid line
cannot be obtained. (Photo is courtesy of Eaton Hydraulics.)
3.7 Cooling System Hoses and Connections

3.7.1 Cooling System Hoses Critical Design Criteria
Select coolant hoses that can handle the following operating conditions. This applies to both clamped and
threaded end connections.
Ambient temperature range of -40 °C (-40 °F) to 52 °C (125 °F) for non-arctic applications
Ambient temperature range of -48 °C (-55 °F) to 52 °C (125 °F) for arctic applications
Internal coolant temperatures of up to 105 °C (221 °F) for intermittent or sustained periods of time
Internal pressures up to approximately 210 kPa (30 psig) for intermittent or sustained periods of
time
Continuous transmission of ethylene-glycol or propylene-glycol coolant mixtures and additives
Accidental contact with engine fluids such as fuel and oil
Vibratory stresses and some amount of installed strain from plumbing misalignment
3.7.2 Cooling System Hoses Hose Shape Hump Hoses

Hump hoses are useful in radiator plumbing connections when plumbing angular misalignment exceeds 2
degrees or when optimal vibration isolation between the engine and equipment is desired. Cooling system
hump hoses should still meet or exceed SAE J20R1 specifications.
Hoses which conform to SAE J20R2 included an embedded wire wrap which allows the hose to withstand
additional forced curvature while maintaining burst and collapse strength. These hoses may provide a lower
cost alternative to hump hoses when angular misalignment of tube ends is of concern.
See Appendix B for a list of manufacturers specializing in the manufacture of hump hoses.
3.7.3 Cooling System Hose Connections

Spring-loaded clamps are recommended, though not required, for all cooling system hose connections.
See Section 3.4.11 Spring-Loaded Clamps for information on spring-loaded clamps.
3.7.4 Cooling System Hoses

Design all hard plumbing for coolant to be extremely well supported and braced in both vertical and
horizontal planes.
There are many other cooling system connections where hoses are used. These include the following:
system fill / make-up, coolant heater system, engine and radiator vents, cooling system quick-fill / drain.
SAE J20 Class A silicone material is recommended for all cooling system hoses if the hose is expected to
last until engine overhaul.

When a clamped hose connection type is used for system fill / make-up, coolant heater system, engine and
radiator vents, cooling system quick-fill / drain, the hose should meet or exceed SAE J20R3 specifications.
When a threaded hose end connection type is used, the hose should be compatible with all of the critical
design criteria listed in 3.3.2 Assembly of Threaded Hose Connections.
A sample listing of brands and hose types which meet the criteria is provided in Appendix A.
3.7.5 Radiator Plumbing Hoses
Requirement 11: All hoses used in radiator plumbing connections must meet or exceed SAE J20R1 or R2
specifications.
For optimal cooling system hose durability, reinforced silicone hose material which meets SAE J20R1 Class
A specifications should be used. The exclusive use of silicone hoses in cooling system connections is
strongly recommended due to superior durability over non-silicone materials. Silicone cooling system hose
is commonly available from U.S. suppliers. Some suppliers specialize in custom silicone hose
manufacturing. They also offer many off-the-shelf products to meet common needs of coolant and charge
air applications. See Appendix B for a list of suppliers.
Figure 37 Four-ply polyester reinforced silicone coolant hose; meets SAE J20R1 Class A specifications.
(Drawing is courtesy of Federal Hose.)
Regardless of material type, all radiator plumbing hoses must meet or exceed SAE J20R1 or R2
specifications. SAE J20R1 provides manufacturing and performance standards for heavy duty coolant
hose. SAE J20R2 provides standards for wire-reinforced heavy duty coolant hose; to be used in
applications requiring greater hose flexibility and collapse resistance. Adherence to these standards will
ensure that the coolant hose meets the minimum requirements of most heavy duty applications. If abnormal
chemical contact, vibration, temperature extremes, or strain are expected, consult the hose manufacturer
to review the application. Testing of a prototype installation may be required to ensure an adequate coolant
hose material has been chosen.
All cooling system hoses must be able to withstand operating pressures up to 210 kPa (30 psi). The rated
operating pressure of a hose is usually given by the manufacturer as 1/4 of the minimum burst pressure.
Although greater heat resistance and durability make silicone far superior to EPDM for coolant hose
material, silicone typically requires more plies of reinforcement fabric to achieve the same pressure rating
due to its lower modulus of elasticity. Four plies of reinforcement fabric are typically required.
Premium non-silicone synthetic rubber hose materials have been developed recently by various
manufacturers for radiator plumbing connections. These are products that have been promoted as offering
extended life beyond standard EPDM cooling system hoses. When silicone hoses are not used, the use of
these premium materials is highly recommended. Examples include the Goodyear Hi-Miler and Dayco
Gold Label hoses, both of which meet or exceed SAE J20R1 specifications.
The OEM should provide inspection criteria and a recommended service replacement interval to the
customer for all non-silicone coolant hoses.
3.7.6 Cab Heater Hoses and Vent Lines

All cab heater hoses and vent lines with clamped connections should meet or exceed SAE J20R3
specifications. Use a Class A silicone material if the hose is expected to last until engine overhaul.

3.8 Oil and Fuel Hoses
3.8.1 Oil and Fuel Hoses - Critical Design Criteria
Requirement 12: Regardless of material or hose style chosen, fuel and oil hoses must be compatible with
all of the critical design criteria.
Select fuel and oil hoses capable of handling the following operating conditions:
Ambient temperature range of -40 °C (-40 °F) to 52 °C (125 °F) for non-arctic applications
Ambient temperature range of -48 °C (-55 °F) to 52 °C (125 °F) for arctic applications
Internal fluid temperatures up to 121 °C (250 °F) for intermittent or sustained periods of time
Internal pressures up to 2100 kPa (300 psi) intermittent, and up to 855 kPa (125 psi) continuous
Fuel supply hose vacuum up to 127 mm Hg (5 in Hg). The hose must not collapse
Continuous transmission of diesel fuels or used diesel engine oil
Periodic strain and foot compression during equipment servicing
Conductive PTFE (Teflon®) lining steel braided hose per SAE J517 should be used where possible
to avoid static discharge and pinhole burn through, except when validation testing has found it to
be unnecessary
Select the same type of hose for all engine fuel and oil system connections to minimize the chance of
accidental installation of an unsuitable hose type.
3.8.2 Oil and Fuel Hoses - Hoses (lines) for All Fuel and Oil Applications
Design engine fuel and oil systems to use a single type of hose whenever possible. Using a single type of
hose for all engine fuel and oil system connections can reduce cost and complexity, and can help prevent
accidental replacement with an inadequate hose type.
Fuel and oil hose connection needs may include:
Lube Oil
Remote Oil Filtration hoses
Centinel make-up tank
Oil sump level maintenance systems
Quick sump drain / fill systems
Oil pressure manifold block for pressure senders
Prelubrication devices
Fuel
Fuel supply (suction) hose
Fuel return (drain) hose
Recirculating heater systems
Hose types that meet the requirements of fuel and oil applications are listed in Appendix A. If an unlisted
hose is to be considered, it must be compatible with all of the critical design criteria listed at the beginning
of this section.

3.8.3 Oil Hoses (Lines)
Requirement 13: Threaded tube (hose) end fittings must be used with oil hoses (lines) listed. Adjustable
hose clamps are not acceptable for oil lines.
See Section 3.8.3 Oil Hoses (Lines).
Requirement Background: If oil line connections fail, severe engine damage may occur or spray on hot
surfaces.
All oil lines must have threaded hose ends. Both crimped and reusable styles are acceptable. Clamped
hose connections are not acceptable for oil lines.
3.8.3.1 Remote Oil Filter Hoses
Requirement 14: Hoses for remote oil filter connections have special requirements above other fuel hoses.
Use only hoses approved for remote flow oil filter head.
Hoses used to connect a remote oil filter to the engine block must be rated to handle a 121 °C (250 °F) oil
temperature at a working pressure of 2100 kPa (300 psig). In a -40 size, required for Cummins QSKV
engines, there are only three commonly available hoses which meet these criteria. They are all listed in
Appendix A. All three of these hoses are advertised as being capable of handling temperatures up to
148.88 °C (300 °F) at pressures below 2100 kPa (300 psig). Although oil temperature should never exceed
121 °C (250 °F), this extra temperature capability at lower pressures has been determined through
experience to be necessary as a durability margin in oil filter head connections. The materials listed in
Appendix A should be used exclusively for full-flow oil filter head connections with all Cummins engines.
Consult AEB 20.17 for additional information regarding remote oil filters.
When ORFS to STOR fittings are used, both O-rings on each fitting must be made of FKM (Viton®). See
Section 3.2.2.1 O-ring Type Port Connections.
3.8.3.2 Crankcase Breather Hoses
Requirement 15: Consult AEB 20.17 if a crankcase breather hose extension is required
Cummins engines with open crankcase breather systems are equipped with factory supplied crankcase
breather vent hoses. Vent hose size, length, and material are critical to the proper function of Cummins
crankcase breather systems and blow-by measurement devices. If the hose is missing or requires
replacement, use the original equipment Cummins part. If an extension to the hose is necessary, consider
the effects on the entire breather system, and on any blow-by measurement device prior to selecting a hose
size and material. Potential for freezing in cold weather also needs to be considered. Consult AEB 20.17 if
a crankcase breather hose extension is required. In cold climates crankcase breather hose extensions may
block due to freezing.
3.8.3.3 Fuel Hoses (Lines)
Requirement 16: Fuel supply hoses must be rated for a minimum of 127 mm (5 in) of mercury in vacuum.
Requirement 17: Except for push-on (clamped) style fuel hose connection on Cummins <10 L engines, all
fuel hoses must have threaded hose ends.
-
have threaded hose ends. Both crimped and reusable styles are acceptable. See Section 3.3.1.4, Threaded
Hose and Tube Ends for information about threaded hose ends.

For bio-diesel use, consult the hose supplier to confirm hose compatibility.
3.8.4 Oil and Fuel Hoses - Fire Resistant Hoses and Sleeves
Fire resistant hoses are made primarily for marine applications, but are also used in some industrial
applications. The only suitable fire resistant hose for both fuel and oil connections (excluding remote oil
filters) to Cummins engines is Aeroquip FC234. This hose meets the critical design criteria listed at the
beginning of this section.
For remote oil filter connections, a fire sleeve should be used over one of the hoses recommended for oil
filter connections in Appendix A. Fire sleeves are available from several manufacturers. When used, they
should be cut to a sufficient length such that they cover the entire length of hose and the threaded end.
Only steel ties should be used to secure fire sleeves over hoses. They should be fastened around the
portion of the sleeve that covers the threaded metal end.
the use of fire resistant hoses.
4 Definitions
Term Definition
Must This is used to indicate a mandatory practice or requirement.
Shall This is used to indicate a mandatory practice or requirement.
Should This is used to indicate a strongly recommended practice.
May Indicates guidance only. A practice that can be deviated from.
CAC Charge Air Cooler
EPDM Ethylene propylene diene monomer (M-class) rubber
A fluoroelastomers containing vinylidene fluoride as a monomer. Example:
FKM
Viton
NPTF National Pipe Tapered Female
OD Outer diameter
ORB O-ring boss
ORFS O-ring face seal
PTFE Generic version of Teflon
SLHD heavy duty spring-loaded worm gear clamps
STOR Straight Thread O-ring
VGT Variable Geometry Turbocharger
Hose throughout this document.
Line
the end to accommodate a clamped hose connection.

Tube refers to metal plumbing smaller than 1 inch in diameter designed
to accommodate weld-on threaded ends for port fitting connections these
tube ends do not have raised sealing beads.

g larger
Pipe
than 2 inches in diameter. See Figure 1.
Refers to an internally threaded hole in the engine oil, fuel, air, or coolant
system which is provided specifically for an OEM hose, tube, or sensor
Port
connection. The port includes any special machining or dimensional features
required for proper sealing of a fitting. See Figure 9.
Refers to the physical component which allows the sealed coupling of a hose
or tube to a port. In the case of threaded end connections, the fitting will feature
threads and a sealing mechanism on both ends. See Figure 10. In the case of
Fitting
clamped end connections, one end of the fitting will be threaded and the other
end will feature a miniature tube end with a sealing bead. See Figure 12. This
type of fitting is also referred to as a hose barb fitting.
Refers to the metal components which are attached to the end of an industrial
Threaded
hose or tube to allow connection to a fitting. Most threaded tube/hose ends
Tube/Hose
feature internally threaded nuts which are held captive axially but are allowed
End
to rotate freely for joint tightening without tube / hose rotation. See Figure 11.
Threaded
Hose Refers to the assembly of a metal tube or flexible hose, threaded tube / hose
Connection end, fitting, and port.
-
Clamped Hose
refers to the assembly of a hose, two tube ends with raised sealing beads, and
Connection
adjustable hose clamp(s) on both ends.
5 Reference Documentation
AEB / Document Title

Number
SAE AS5131 Tube End Beaded, Design Standard; [Note: SAE AS5131 superseded
MS 33660]
SAE J1231 Formed Tube Ends for Hose Connections and Hose Fittings
SAE J1273 Selection, Installation and Maintenance of Hose and Assemblies
SAE J1508 Hose Clamp Specifications
SAE J20 Coolant System Hoses
SAE J30 Fuel and Oil Hoses
TMC RP 332 Guidelines for Hoses, Clamps, and Fittings for Cooling and Charge Air
Cooler Systems

Appendix A
Intake Air
Application Material
Surrounding air temperature exceeds 250 °F regularly Polyester Reinforced Silicone
(includes all HHP Vee engines)
Surrounding air temperature less than 250 °F Synthetic Rubber Ethylene Propylene (EPDM)
Charge Air Cooler
All connections Multi-ply
Meta-aramid
Nomex Reinforced Silicone Hump Hoses with
Wire Retaining Rings
Air Compressor Inlet and Discharge
Naturally aspirated inlet SAE J20R3 compliant
Turbocharged inlet Aeroquip: FC186, 2807
Original Cummins part must be used if turbocharged
compressor is available as original equipment.
Discharge Aeroquip: FC186, 2807
Coolant
Radiator connections SAE J20R1 or R2 compliant, Class A silicone preferred.
Class A silicone required if target replacement is at
engine rebuild.
AQP FC352; Federal Hose 4-ply silicone; Flexfab
FLX5581/5501
Cab Heater & Vent (push-on) SAE J20R3 compliant Class A silicone preferred.
Class A silicone required if target replacement is at
engine rebuild.
Federal Hose 5526 Series; Flexfab FLX5521 / FLX
5526
Fuel Supply and Drain*, Oil Rifle, Remote Filter, Sump, Centinel, etc.
Note: For bio-diesel, consult hose supplier on compatibility.
Remote oil filter head connections Aeroquip: FC300
Parker: 201/261, 206 PKR
Push-on Fuel Hose SAE J30R7 or R8 compliant
SAE J517 recommended
All Other Connections Aeroquip: FC234, FC300, FC350, FC355, FC650,
FC699, FC186, 2807
Parker: 201/261, 206 PKR , 213 PKR , 266 PKR ,
293

Appendix B
Major Suppliers of Hose for Coolant, Fuel, and Oil
Aeroquip http://www.aeroquip.com/ or
http://www.eaton.com/Eaton/ProductsServices/Hydraulics/HowtoBuy/AeroquipExpress/index.htm
Dayco http://www.daycoproducts.com/
Federal Hose http://www.federalhose.com/
Goodyear http://www.goodyear.com/
Parker http://www.parker.com/
Specialists in CAC Hoses and Custom Silicone Hose for Air and Coolant
Flexfab http://www.flexfab.com/
James Dawson http://www.james-dawson.com/
Thermopol http://www.gfk71.dial.pipex.com/
Suppliers of T-bolt and High Quality Worm Gear Clamps
Breeze Clamps http://www.breezeclamps.com/

R.G. Ray Corporation http://www.rgrayclamps.com/
Voss Industries http://www.vossind.com/
Ideal Tridon http://idealtridon.com/aftermarket/

6 Change Log
Revision Date Author Description Page(s)

09 09Jun15 Jagdeep Singh Industrial (A Series 1
-Drive and
1
design guidelines, recommendations and
requirements for high quality hose connections
to air, coolant, fuel, and oil systems. This
bulletin should be used by OEMs to assist in
machine (vehicle) design but it is not a
substitute for validations of machine (vehicle)
1
Added 4
requirements listed below apply to all the
applications indicated in the title block of this
AEB. In order to obtain Cummins concurrence
with Hose Material and Hose Connection
All hose barb fittings must 4

have an external hexagon boss for installation
hose barb fittings must have a feature for

tightening the fitting without damaging the
ins Application 4
Exception: The following clamps been 4

found acceptable on turbocharger pressurized
tubing up to 64 mm (2.5 in) diameter. a: SLHD
as per SAE 1508 -Heavy duty (HD) clamp. b:
The
Solid steel line is 5
- 5
5
Application Engineer for material type and
5
6
preferred over all others due to the O-ring seal
on both sides. This provides the best
When possible,
do not use NPT (NPTF) port types for fuel or
oil system applications. O-ring type fittings
(ORFS to STOR) are recommended for fuel
and oil applications due to the superior sealing
available with compressed O-
Liquid thread or gasket 6
sealant, or Teflon® tape, is NOT to be used in
the assembly of STOR and ORFS
connections.
sealants with O-
6, 16

7, 31
8
8
8, 9
8, 9
9
9
9
9
C
9
10
11
supply system connections to prevent air
Changed text - 11
Added Figure 3. 11
11
on
all O-ring style fittings used in connection to
engine oil and fuel ports. It can also be used
12
assembly of a flexible hose or metal tube,
threaded hose (tube) end, a fitti
12
13
connecting the sealed coupling of a port to a
hose or tube. For clamped end connections,
one end of the fitting is threaded and the other
end features a tube end with a sealing bead,
also known as a hose bead. The hose bead
also helps to prevent hose to slipping off the
tube. See 0. This type of fitting is also referred
to as a hose barb fitting. Threaded hose barb
fittings are used to connect a hose to a
threaded port. The threaded hose barb fitting
is connected to the port. The hose is clamped
to the hose barb fitting.
Updated Figure 8. 15
Changed text f If tube ends are 16
not chamfered and free of sharp edges or
.
17
17
18
18
SLHD as per 18, 36
SAE 1508 clamps can be used up to 64 mm
18
18
-on fuel hoses for Cummins 18
A, B, & C series engines, and push-on coolant
T-bolt, SLTB Spring Loaded T- 18

bolt, HD Heavy Duty, SLHD Spring Loaded
.

20
Added Figure 12. 20
Added - 21
A worm gear clamps is a circular 21
metal band or strip combined with a worm gear
fixed to one end. They are sometimes known
23
23
seri -
connections, and for push-on coolant vent line

connections (e.g. QST30), SAE type D hose
clamps are recommended. The use of small
diameter worm gear clamps is not
recommended because the perforated band is
susceptible to loosing its circular shape in
diameter hoses (<0.75 in or 19 mm) SAE type

D clamps should be used so that uniform
clamping pressure is maintained over the
hose. The use of small diameter worm gear
clamps should be avoided because the
perforated band is susceptible to losing its
circular shape in diameters less than 1.90 cm
Consult AEB 21.46 prior to installing 26

a P-
28
metal or solid structures, either bulkhead fitting
Hoses used under-hood or within 29

engine compartment require higher
Changed text from 29

kPa (50 inH2
30
32
H2
CAC hoses used under-hood or within 34
engine compartment require higher
Added Figure 34. 36

Added Figure 35. 37
37
37
38
38
Ad 39
40
3.3.2 Assembly of Threaded
Hose Connections
40
Flexfab, and Dayco.
nd 40
Appendix B 40
- 40

40
41
-flow oil filter head. 41
08 20Aug13 P. Lannan Added note about Bio-Diesel use to Table 1. 7

® ®
to 8, 16, 18, 31, 35
maintain consistency with AEB 24.10).
®
to 16, 31
fluorocarbon material (Viton® or equivalent as
defined in ASTM D1418 and ISO1629
maintain consistency with AEB 24.10).
Changed engines that require silicone 26
compressor inlet hoses to all high mount and
vee engine configurations.
-diesel use, consult the 34
07 14Aug12 P. Hepner Updated AEB to most recent format. All

Added recommended changes for Radiator 10, 31
Plumbing Hose Connections and Hose
Assembly.
06 21Sep10 R. Bergstedt Revised cleanliness requirements to require 25 & 28
visually clean only.
05 18May09 R. Bergstedt Various
document.
Added cleanliness requirements for intake air and 25 & 27
charge air hoses.
04 14Jan09 P Hartstirn Changed AEB author to Paul Hartstirn 1
Added SAE J517 fuel hose recommendation 6, 32, 34
03 Mar, 2006 P Hartstirn Added fluorocarbon material recommendation for 1, 34
fuel plumbing.
02 Feb, 2004 P Hartstirn Small Diameter CAC Hoses; ownership of this 27
AEB moved to Paul Hartstirn.
01 Oct, 2003 S Orlin Hose Materials Table 6
Non Silicone Hose 22, 23, 24,
Summary of Recommendations and 25
Requirements
00 S Orlin Original Release All

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Application

Filtration Emission Solutions

Engine models included: All Industrial, G-Drive and Genset

Owner: Jagdeep Singh Approver: per Procedure GCE-AS-1 Page 1 of 50

This AEB supersedes AEB 24.20 dated 20 August 2013.

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 Jun 2015 Page 1 of 50 © Copyright 2015 Cummins Inc.

1 Installation Requirements ...................................................................................................................... 4

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 2 of 50 © Copyright 2015 Cummins Inc.

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 3 of 50 © Copyright 2015 Cummins Inc.

Threaded Hose Barb Fittings for Clamped Hose Connections to Ports

Clearance around Tube Ends and Hoses

Routing and Securing Long Hoses (Lines) in Design and Assembly

Routing Hoses through Sheet Metal

Charge Air Cooling System Connections

Turbocharged Air Compressor Inlet Hoses Special Requirements

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 4 of 50 © Copyright 2015 Cummins Inc.

Air Compressor Discharge Hoses Hose Material

Radiator Plumbing Hoses

Oil and Fuel Hoses - Critical Design Criteria

Oil Hoses (Lines)

Remote Oil Filter Hoses

Crankcase Breather Hoses

Fuel Hoses (Lines)

1.1 AQS Installation Requirements

Charge Air Cooling System Hoses - Cleanliness

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 5 of 50 © Copyright 2015 Cummins Inc.

Applications of NPT (NPTF) port types.

Tube End Alignment

See Section 3.5.1 Hose Selection.

Wires or Cable Ties

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 6 of 50 © Copyright 2015 Cummins Inc.

Air Intake Hose Critical Design Criteria

Cooling System Hoses

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 7 of 50 © Copyright 2015 Cummins Inc.

3.2 Threaded Fluid Port Connections

3.2.1 Types of Fluid Ports

Metric STOR STOR NPT (NPTF)

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 8 of 50 © Copyright 2015 Cummins Inc.

3.2.1.1 Metric Straight Thread O-ring (Metric STOR):

3.2.1.3.1 Applications of NPT (NPTF) port types

3.2.2 Thread Sealing

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 9 of 50 © Copyright 2015 Cummins Inc.

3.2.2.4 Sealant Pre-coated Fittings

3.3 Threaded Hose and Tube End Connections

3.3.1 Fittings for Threaded Hose and Tube End Connections

English or Metric STOR STOR to ORFS Preferred FKM (Viton®) (2)

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 10 of 50 © Copyright 2015 Cummins Inc.

O-ring Face Seal (ORFS)

Figure 3 Example of 37° and 45° flare fittings.

Cummins Internal Use Only: This information is labeled per CORP-00-24-00-00.

Revision 09, 09 June 2015 Page 11 of 50 © Copyright 2015 Cummins Inc.

3.3.1.4 Threaded Hose and Tube Ends

3.3.2 Assembly of Threaded Hose Connections

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