DESIGN GUIDE ON

HYDRAULIC
HOSE ASSEMBLY

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HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE

Selecting and installing hose assemblies requires a great deal of thought and care. A hose
assembly is composed of the hose and the end fittings, which are determined by the
application in which the hose assembly is going to be placed.

With hose selection, consider the pressure rating, temperature range, cover material and bend
diameter. You must also know key specifications such as ID, OD and fluid requirements.

Experts say that it pays to differentiate the hose from a completed hose assembly. While
selection of the hose is obviously important, selecting the hose without considering the
fittings can be a costly mistake. Any hose assembly includes fittings that are specific to the
application. An industrial hose assembly must have the hose, fittings, and a way to attach the
fittings to the hose. ▼
Finally, several other items should be considered before assembling and installing your MARY GANNON
assembly. Hose assemblies should be cleaned internally. Using brackets and supports helps Editor
to maintain the best hose position, and to avoid unnecessary flexing. Ensure that the hose is
never forced into a tighter bend than the minimum radius allowed.

TABLE OF CONTENTS
▼

What components make up a full hose assembly?....................................... 3

A primer on hydraulic hose construction...................................................... 4 ▼

How to select the right hydraulic hose for your application......................... 7 PAUL HENEY
VP, Editorial Director
What are hydraulic fittings and flanges?..................................................... 12

How do I specify hydraulic hose fittings?.................................................... 14

What measurements are required for hose assembly sizes?...................... 16

The evolution of hydraulic hose crimping................................................... 17

What is skiving, and when should you use it on your hose assemblies?...... 20

Why should you clean your hose assembly?............................................... 21

How do you clean hydraulic hose assemblies?........................................... 22

Why should you cap your hydraulic hose assembly?.................................. 23 Sponsored by:

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WHAT COMPONENTS
MAKE UP A FULL
HOSE ASSEMBLY?

W
hen looking at a full hose assembly, it is basically a
length of hose with a properly attached fitting on
each end. A hose assembly is composed of the hose
and the end fittings, which are determined by the application in
which the hose assembly is going to be placed.
Hydraulic hoses have three major components, which include
the following:
• Tube: The tube is the inner-most portion of the hose. Its
role is to convey the media from one end of the hose to the
other and protect the outside from the media or fluid being
conveyed.
• Reinforcement: The reinforcement is the strength of the
hose and comes in a variety of types, including braided,
spiral and helical.
• Cover: The cover is designed to protect the reinforcement
and tube from the outside environment.
Fitting components are comprised of the following:
• Socket: The socket is the portion of the fitting that goes over
the outer cover.
• Stem: The stem is the portion of the fitting that goes directly
into the I.D. of the inner tube of the hose. It extends out of
the hose and into the connecting end. The connecting end of
the fitting is the portion of the fitting that allows the hose to
connect to other components.
Like hoses, fittings have to meet various specifications and are
usually designed to fit a specific hose. The hoses and fittings are
typically designed to be a matched set. It is important to refer to
the manufacturers recommended hose and fitting combinations for
proper assembly and application.

Each of these three components plays an important role to Lastly, the hose and fitting need to be assembled using the
allow the hose to work in a variety of environments. Hoses are recommend procedures and proper equipment. When attaching
designed to meet different specifications and requirements a hose fitting permanently to the hose it is important to use the
that arise with the different environments where hoses will be proper method and always check the completed assembly for
installed. proper crimping/swaging, specifications and overall length for the
application.
Fittings are usually
made of metal, Every hose is made up of a tube, reinforcement and cover. Each of
such as carbon these components must be compatible with the media, or product,
steel, stainless steel, flowing through the hose. Every hose lends itself to a specific
brass and so on. application, including the media flowing through it.
Within these fittings
Because hydraulic hoses can support a variety of materials, the tube
there are two major
material needs to be selected based on the type of hydraulic fluid
components.
being used in the equipment. The fittings must also be compatible
with the fluid. Anytime you have an improper combination of
fluid and components, you risk the possibility of hose failure. This
happens when the tube material softens and leads to a leak or the
hose end blows off. Leaks aren’t always visible.

If there is leak and a product can’t be contained, it can effuse

through the tube, causing the hose to swell. Because of the
reinforcement, the tube can swell inward, reducing the tube I.D.
and increasing the velocity of the media. This can cause the tube to
start pulling apart, with no exterior visual signs, eventually leading to
system failure or even hose end blow-off.

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A PRIMER ON
HYDRAULIC HOSE
CONSTRUCTION
H
ydraulic hose is one of the least considered components
of a high-pressure fluid power system; however, its habit
of being overlooked does not reduce its importance. Any
machine with actuators attached to moving segments requires
flexible plumbing, and that plumbing is hydraulic hose. Hydraulic
hose has come a long way with regards to pressure limit and
flexibility, especially since the proliferation of synthetic materials,
such as PTFE and buna nitrile. Also, there are many benefits of
hydraulic hose in addition to flexibility, making it an option for
complete system plumbing.
Hydraulic hose has many advantages over fixed plumbing, such
as tube. Advantages to hose are its ability to absorb vibration
and noise, which can be troublesome with pipe or tube,
especially if they are resonating or amplifying a sound created
elsewhere. Hose assemblies are also easier to manufacturer
than hard plumbing, and because hard plumbing can be labor-
intensive, hose is often less expensive. Also, hydraulic hose is
constructed with a rubber outer carcass, so it has no potential to
rust as hard plumbing might, which is often painted to prevent
rust when it is not constructed of stainless steel.
Figure 1. This image from Parker Hannifin shows the typical construction
of a hydraulic hose, with the inner tube, four layers of spiral steel wire
reinforcement and a tough cover to prevent abrasion. Photo courtesy of
Parker Hannifin.
The construction technique and material of hydraulic hose
differs based on its intended application. The various application
parameters required when selecting hose are size, temperature, fluid
type and pressure, to name a few. Depending on these criteria, the
choice of hose construction will change to suit the conditions. The
majority of hydraulic machines are not exotic, however, and typically
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your standard 100R1 or 100R2 (“1-wire” and “2-wire” respectively)
hoses are appropriate. However, when extreme pressures and exotic
fluids come into play, the options for suitable hose are reduced.
TOUGH UNDER PRESSURE
The primary consideration for hydraulic hose — essentially
what separates it from other hoses — is its pressure holding
capacity, which can be anywhere from 1,000 to 6,000 psi or more.
Hydraulic hose uses a three-layer construction: the inner tube, the
reinforcement layer and the outer cover (Figure 1).
The tube construction material is dictated partly by the fluid
being used in the hydraulic system. For example, nitrile or rubber
is fantastic for petroleum-based hydraulic oil, but would not be
compatible with a synthetic fluid such as phosphate ester, which
requires Viton or Teflon. Special attention should also be paid to
chemical compatibility of the outer cover as well. There could be
ambient conditions containing chemicals incompatible with the
cover material, which is commonly nitrile. Tube material varies less
than does cover material, which can be made from neoprene, PVC,
nitrile or even non-rubber woven textile.
Tube and cover composition also play a role in the temperature
range hose is best suited to operate within. Standard hose
construction allows for anything between –40 to 202° F, such as
with the common combination of nitrile tube and neoprene cover,
but special formulations of these polymers are required for colder
conditions. Cold weather polymers need to be highly malleable to
prevent cracking and subsequent hose failure.
At the other extreme, ambient or operating heat can cause
premature hose failure due to a softened tube and cover. Although
most hydraulic systems — and the oil itself — are not happy at
extreme temperatures, sometimes localized heat must be guarded
against, such as in steel mills. For conditions anywhere up to 400° F,
Teflon can be used for the tube, and then wrapped with a stainless
steel cover. The downside of Teflon hose is that it’s not terribly
flexible and has a large bend radius.
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
A PRIMER ON HYDRAULIC HOSE CONSTRUCTION

REINFORCEMENT CHOICES

Steel wire is by and large the most popular choice for the hose
reinforcement layer, and is either cross-braided or spiral wound,
as seen in Figure 2. Cross-braided wire has alternating rows of
perpendicular wire woven in opposite directions around the tube.
Braided steel hose comes in one or two layers, and is usually
separated by another layer of rubber when two layers are used. As
mentioned, the most common types of hydraulic hose are the SAE
100R1 and 100R2 braided hose, affectionately referred to as 1-wire
and 2-wire, respectively.

Braided hose is the most popular type of hydraulic hose, and is

available in a vast array of sizes and pressure ratings. It should be
noted that hose pressure rating is reduced as tube ID increases
due to higher internal forces. Also, hose working pressure is rated
a quarter of burst pressure, giving the hose a safety factor of four
to one, but I digress. Braided hose has excellent flexibility for its
strength, and most manufacturers make high-flex braided hose with
half the bend radius as its standard cousin.

Figure 2. Comparison between spiral and wire braid reinforcement.

KEEP IT COVERED FOR SAFETY’S SAKE

The cover’s primary job is to protect the tube and reinforcement

from environmental conditions, above and beyond the temperature
and chemical resistance already discussed. Not all hose is created
equally, and because a common failure of hydraulic hose is the result
of cover abrasion, special attention should be paid to the cover
construction material.
Illustration of a hose assembly cutaway shows
Although abrasion can easily be avoided through proper installation the inner workings between Parker’s Parkrimp
and use of hose clamps, sometimes friction is unavoidable, like with hose fittings and its hoses. No matter what
a portable concrete saw tool, which has a remote power unit feeding style hose you choose, making a correct
the saw through 50 ft or more of hose strewn across the job site. In assembly is critical to safe design and use.
a case like this, special hose construction with an abrasion resistant Photo courtesy of Parker Hannifin.
cover is a solid choice (as is the use of protective hose wrap). I
should point out that an old-school textile hose cover — although
dubious looking — is actually superior to most neoprene rubbers in
regards to abrasion resistance.

The central defining criteria most people associate with hydraulic

hose is its pressure holding capacity, and it owes that capacity to the
reinforcement layer. To say the reinforcement is sandwiched between
the tube and cover would do it injustice and imply the reinforcement
is loosely wrapped. More accurately, the reinforcement layer(s)
is tightly wound upon the tube with a spiral winding or braiding
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
A PRIMER ON HYDRAULIC HOSE CONSTRUCTION

A hose braiding machine

creates the reinforcement
layer for hydraulic hose,
with the braided wire laying
helically around the tube
in opposite directions. This
allows the wires to slide over
and under each other to add
flexibility.

There are two types of spiral-wound hydraulic hose. The helically-
coiled hose is a mild reinforcement used to increase pressure
capacity, but is limited to suction lines where little or no pressure
exists, or sometimes used on return lines where pressure spikes
are of no concern. However, the tightly wound spiral layers used
for hydraulic hose are used on ultra-high pressure systems. Four
layers of high-tensile steel wire is laid directly on top of each other
perpendicular to each subsequent layer.
All hydraulic hose is manufactured to North American or
international standards to ensure construction techniques and quality
guidelines are met or exceeded, and because of the potential safety
hazards in and around hydraulic machinery, this is a good thing.
There has never been a wider selection of hydraulic hose available,
particularly for specialized applications. Because of the increased
demands for high-pressure performance, I imagine the choice of
hydraulic hose will only continue to grow.

The four-layer spiral wound hydraulic hose is extremely strong and

is common in high-pressure, large-diameter hose assemblies. This
4-wire hose is available up to a 5,000 psi rating at a 2-in. diameter,
although sometimes 6-wire hose is used for extreme requirements.
The downside to 4- and 6-wire hose is its flexibility, or lack thereof.
Because of rigid, multi-layer construction, 4-wire 100R12 hose is
quite stiff; however, advances in materials and construction have
allowed the major hose manufacturers to reduce the bend radius
significantly.

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HOW TO SELECT THE RIGHT
HYDRAULIC HOSE FOR YOUR
APPLICATION

W
ith a new hydraulic machine design, or with a machine
that has undergone a rebuild process, there comes the
moment when it is time to specify and install the hoses
that conduct fluid from point to point throughout the system.

While the main functions of a machine and perhaps the most clever
aspects of its design are likely contained within the mechanical
works including the valves and actuators, the required hoses are not
minor accessories. Careful thought and consideration are needed in
order to make the best hose selection.

While inside diameter and the working pressure rating of a hose

are typical factors to start with, outer diameter and the weight of a
particular hose model are often critical on mobile machines.

Don’t twist hydraulic hose. It severely compromises hose integrity.

The types of fittings to be used, the nature of the fluid, abrasion

resistance, the flexing cycles of a hose and a range of installation
challenges all add to the list of factors to be considered.

Objective information concerning the properties and construction

Make sure to leave at least two hose widths of space between the crimp
and any bends when determining hose length. Here’s an example of a
correct length, one that is too long and one that is much too short.
A press in a factory setting or a mining drill maker may be quite
concerned with the expected life of a hose as indicated by the
pressure impulse cycle rating. Impulse cycles are sudden on-off
pressures that cause stress to a hose. The test is typically conducted
with pressure impulses at 133% of the working pressure rating. A
rating of 200,000 cycles is considered minimal, with 1,000,000 cycle
products available for those who wish to pay for them.
Many readers might be accustomed to selecting a different hose
product line for the larger diameter applications. Typically the
working pressure decreases as the hose diameter gets larger within a
single product line. A hose manufacturer may also offer a convenient
single-pressure option where all diameters within a particular
product line have the same working pressure rating.
of the common 100R-series hose can be found in the standard,
SAE 517. Recommended Practices for Hydraulic Hose Assemblies,
covered under SAE J1273, provides a wealth of advice on
installation and on wear/maintenance issues. If you’ve seen Society
of Automotive Engineers (SAE) approval markings on hoses and
have wondered what they mean, simply purchase the matching
standards and practices documents from the www.sae.org website.
For those who work with ISO standards, similar documents are
available from the ISO website.
IMPORTANT WORDS ABOUT SAFETY
It shouldn’t need to be said that a hose burst failure is always a
catastrophic incident. In the best case scenario, a hose failure might
cause production downtime or environmental contamination concerns.
In a worse scenario, persons could be seriously injured or even killed.
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(continued)
HOW TO SELECT THE RIGHT
HYDRAULIC HOSE FOR YOUR APPLICATION
The hose layline should always include the maximum working pressure
(WP). In addition, pertinent information such as inside diameter,
manufacturer and model name, size, etc. can be found on the layline.
Using economics as the only or primary hose selection criteria can
easily leave human risks at a very high level. A colleague recently
contacted me regarding concerns about the pressure ratings of
hydraulic hoses in use at the plant where he had just been hired on.
He noticed that the normal system pressure was routinely at levels
that were slightly higher than the working pressure rating of the hoses.
Management assured him that with the known burst pressure rating for
the hose at several multiples above the working pressure rating, there
was no cause for concern and that the added expense for a higher
rated hose was unnecessary. This is one example of a very poor hose
selection process. In this case, safety was being neglected.
Never use hoses regardless of their age if you are aware of incidents
of system over-pressuring that have exceeded the normal working
pressure. Cracked, blistered or abrasion worn hoses should never be
put back into service.
What is “hose whip?”— Hose whip, (a shorter name for what
happens if a hose or fitting breaks, and the hose then flails freely)
can easily dismember or kill. Most hydraulic hoses are made up of
layers of wire braid and include steel fittings on the end of the hose
assembly. Imagine getting hit by a steel cable moving at high speed,
and you’ll have an idea of the damage a hydraulic hose can do if it
breaks away. In the case of a compressed fluid, the distance traveled
and acceleration rate add to the carnage.
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HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
CORRECT SELECTION FOR YOUR APPLICATION
Whether you are replacing an existing hose, or building a new
system, you’ll need to select a hose of the correct pressure rating,
diameter, and length and with the best material properties for your
application. Here are a few factors to consider carefully.
Pressure rating — A hose must be chosen with a maximum working
pressure (WP) rating that is at or preferably above the normal
maximum hydraulic system pressure. Momentary pressure surges
for a hydraulic system are not to exceed this pressure rating. Hose
fittings that are rated below the working pressure of the selected
hose cause the entire hose assembly to be derated to the lower
rating of the fittings.
Hoses typically become heavier for any given length, with added layers
of reinforcing wire, as the working pressure requirement increases.
Many of the hose models in the common 100R series have lower
working pressure ratings at the larger diameters. Often a -16 (1 in.)
hose has a working pressure that is half of the rating for the -8 (½ in.)
hose in the same product line. This can be inconvenient and costly
for a machine manufacturer. Look for SAE 100R17 series compact
hoses to find a constant working pressure of approximately 3,000
psi for all available diameters, or consider ISO 18752 rated hoses
for a constant working pressure of approximately 4,000 psi for all
available diameters. Many of the ISO 18752 rated hoses also feature
test impulse pressure cycle ratings of 500,000.
Burst pressure is a built-in safety factor for a hydraulic hose. A hose
manufacturer verifies the burst pressure in a destructive test. The
SAE standard J517 for the common series of 100R hydraulic hoses
also categorizes leakage and also hose separation from hose fitting, as
burst pressure failures. The hose does not have to violently break apart
completely to have suffered a burst failure. The burst pressure rating of
a hydraulic hose is often 4x the working pressure rating or greater.
Inside diameter — It’s very important to use a hose of the correct
inside diameter. If the diameter is too small for a given rate of flow,
the linear velocity will be too high. Excessive velocity will translate
into friction and turbulence, which when combined will surely result
in noticeably higher system pressure and heat.
Hose manufacturers typically supply a nomograph or a table that
allows for the easy calculation of the optimum diameter for a given
flow rate and hose length. Long hose lengths require a larger inner
diameter to avoid excessive restriction and friction.
Length — Correct hose length needs to allow for bending and
flexing as a machine moves and articulates, and to make sure
that no undue stress is caused at the crimped fittings. A hose
that connects in a perfectly straight path from one component to
another may shrink in length up to 4% at maximum pressure. Allow
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
HOW TO SELECT THE RIGHT
HYDRAULIC HOSE FOR YOUR APPLICATION

this extra length when making up the hose assembly. An excessively

long hose adds restriction to flow, increasing system pressure and
reducing system efficiency.

Material — Next, consider the conditions that a hose will operate

under. The outer layer or cover of a hose can come in a variety
of synthetic rubber materials. Some compositions can help with
applications where abrasion may occur but may not bend as readily.
Neoprene is one popular synthetic cover material that remains
flexible across a wide range of temperatures, yet handles abrasion
well. Most rubber hoses perform reasonably well from –40°C (–40°F)
to 100°C (212°F). Look for the date of manufacture code on any
rubber hydraulic hose that you are considering. The maximum shelf
life is generally ten years at the most.
Use the hose layline to access the full hose specifications from the
manufacturer’s catalog.

Hose laylines — Hoses should have their part number, pressure

rating, and size stamped along the outer cover. Industry standards
and approvals will also be shown. They may also display
manufacturer-specific information, such as the trade name of the
specific product line. Different manufacturers will have slightly
different ways of presenting this information. This strip of information
is called the layline.

Let’s decode this generic layline shown in the pictures.

Section by section:

• ACME = Manufacturer

• Jupiter = Hose Model

Our imaginary hose from Acme has 2 layers of reinforcing braided wire
Where weight and space are a concern, as is often the case with
mobile machines, look for hoses with a thin-wall inner tube.
Advances in synthetic rubber compounds allow for higher wall
strength allowing for a final product with a smaller outside diameter.
Some manufacturers have moved to a reinforcement wire with an
oval cross-section as opposed to round, offering additional outside
diameter (O.D.) and hose weight savings. These smaller O.D. hoses,
referred to as compact models in many catalogs, also offer much
tighter bend radius.
Thermoplastic hoses are generally much lighter than rubber
hoses. The inner tube of copolyester or nylon is typically braided
or spiral wrapped with a synthetic reinforcement fiber instead of
steel. Synthetic fiber is also needed for electrically non-conductive
(orange cover), aerial lift hoses. In many cases the outer cover of
thermoplastic hoses will be polyurethane and provide a longer shelf
life than rubber, better flexibility at low temperatures such as –60°C
(–75°F), and higher resistance to UV and chemicals.
• 170-04 = Manufacturer’s Product/Part Number (Note: dash size
-04 denotes the inside diameter in 1/16 in. increments, ie. 4/16
in. or ¼ in.)
• ¼ in. = Inside Diameter in inches
• 5,000 PSI WP = Maximum Working Pressure
• SAE 100R2AT = SAE (Society of Automotive Engineers)
specification for a hose with two layers of reinforcement wire.
• MSHA IC-215/0 MSHA (Mine Safety and Health Administration)
approval
Information is not always presented in the same order. However,
you should always find the maximum working pressure, the size,
and the hose product number. The product number can be used
to gather other information you’ll need from the manufacturer’s
catalog and website.

Thermoplastic hoses are not always available for diameters above 1 in.
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
HOW TO SELECT THE RIGHT
HYDRAULIC HOSE FOR YOUR APPLICATION

ENSURE PROPER INSTALLATION
So now that you’ve selected the correct hose, let’s talk about best
practices for installing it.
Minimum bend radius — You’ll find the minimum radius for a hose
in the product catalog. This refers to the arc that the hose follows
in order to prevent restriction and damage due to kinking. Bends
should not begin immediately after the hose end fitting.
Bending and twisting — Twisting is a very serious stress that can
lead to failure on most any hydraulic hose. Prevent twisting of the
hose as it is installed between two ports or fittings. Pay attention to
the layline to make sure that is not spiraling around the hose, as you
tighten fittings. The use of fittings with swivels also helps in this regard.
A hose that actively bends in two or three planes during machine
motion may produce stresses and twisting that dramatically shorten
hose life. Work towards single plane bends as much as possible.

For example, the manufacturer’s catalog tells us that our hose has a Brackets/support — For lengthy hydraulic hoses you may need
minimum bend radius of 3.9 in. Let’s look at what this really means. to install brackets or another method of support. Don’t rely on the
fittings to hold a hose in the correct position. Install brackets or
other means of support as necessary.

The first hose is making too tight of a corner (represented by the red
circle.) The green circle indicates the minimum bend radius allowed for
this hose. The second hose is correct.

Plan out the hose path to avoid tight bends. This will improve the life
of your hose, and it will promote laminar (straight) flow inside of the
hose. Turbulence from excessively tight bends can cause the inner
tube to become eroded and damaged.

Support hoses to avoid stress on fittings, eliminate trip

hazards, and prevent flailing when the hose pressurizes
and contracts.

Cleaning projectiles and the hand tools (guns) that propel

the projectiles through the hose are an affordable way to
ensure a hose is clean after it has been sawed to length. Sponsored by:

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(continued)
HOW TO SELECT THE RIGHT
HYDRAULIC HOSE FOR YOUR APPLICATION
Cleanliness — New rubber hoses need to be cleaned after they are
cut to length. Cleaning projectiles and the hand tools (pneumatic
launchers) that propel the projectiles through the hose are more
affordable than ever and pay for themselves quickly. With particle
contaminants clearly identified as the leading cause of hydraulic
valve malfunctions, the days of cut-and-crimp should be behind us.
A freshly cut length of hydraulic hose has rubber and also metal
wire particles within it. It is the cutting process that produces these
particles. It takes only seconds in most cases to complete the hose
cleaning process before crimping the fittings onto the hose end.
Thermoplastic hoses are cleaner from the start as they are cut/
sheared to length as opposed to being cut to length.
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HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
CONCLUSION
Using a hose with a working pressure rating that is too low is a very
serious safety concern. Always err on the side of caution by choosing a
hose with a working pressure rating that provides a safety margin. Burst
pressure ratings should never be used to deliberately allow a system
to work above the working pressure rating. If you are concerned about
pressure surges, look for hoses with a high impulse cycle rating.
When choosing a hose you should consider the pressure rating,
temperature range, cover material and bend diameter among
other factors. Before assembling a rubber hydraulic hose, clean it
internally! Use brackets and supports wherever required to maintain
the best hose position, and to avoid unnecessary flexing. Ensure that
the hose is never forced into a tighter bend than the minimum radius
allowed. Consider thermoplastic hoses for lightweight options and
for tighter than normal bend radiuses.
Finally, if you are not sure how to objectively sort through the
information provided by a sales rep, purchase and read the
standards documents (SAE, ISO, ANSI, DIN etc.) for the types of
hoses you are considering.
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What are hydraulic fittings and flanges?
H
ydraulic fittings connect tubes, pipes, or hoses to
components (pumps, valves, cylinders, and so on) or
together to create a system through which hydraulic fluid
can flow without leaking. Fittings are meant to withstand high
pressures and be leak resistant. Fitting variations allow designers
to change the direction of flow, split flows, and change the
elevation of lines. Fitting geometries include plugs, unions,
elbows, cross, and others. Care needs to be taken in identifying
the threads of the connections. Some connectors from one
standard appear to thread into another standard port but do not
have enough thread engagement to be safe. Documents from
the organizations SAE (sae.org), NFPA (nfpa.com), and ISO (iso.
org) help identify problems. Hose fittings are designed to work
best with only one brand of hose and may not work with others.
It is also critical to remember that hoses will eventually fail and
need to be replaced—preferably before failure.
Connection types include: welded (socket weld, butt weld, slip
on, etc.), threaded (NPTF [not recommended but used], SAE
straight thread, ISO 6149, BSPP, BSPT, etc.), flanged, barbed,
quick-disconnect, push-to-connect, 37˚ flare, 24˚ cone, inverted
flare, staple lock, face seal, push-fit and others. When selecting
a type of fitting some important considerations are working
pressure, vibration, type of fitting, desired attachment, size
of piping, flow, material of the conductor or component, and
price. The fluid power industry is trying to shift to fittings with
an elastomeric seal, generally O-rings, to prevent leakage.
These fittings include the SAE straight thread, face seal, ISO
6149, SAE J518 (Code 61 and Code 62) flanges, and others.
The elastomeric seal must be compatible with the fluid in use.
Although leakage is sometimes needed for lubrication, there is
no reason for unplanned leakage.
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When selecting the fitting, several items are important
dimensionally. Most hydraulic fittings have two types, called
male and female, that are joined together to form a union. Most
fittings are sized based on the size of the conductor (size of
hose, pipe, or tube). Overall dimensions can vary greatly based
on fitting type even for the same size conductor.
Additionally, most fitting types are available in a multitude of
materials, including plastic, brass, steel, stainless, Monel, etc. Each
is used in different environments and has different performance
characteristics that allow a lot of customization within a fitting
type. Often the first choice is to match the fitting to a similar
material to the conductor or component that it is connecting
plastic to plastic, steel to steel, and stainless to stainless.
Geometry is an important consideration. Fitting geometry is
identified by letters that the fitting diagrams resemble. Fittings
are available in-line [–]; to change the angle of flow in various
increments (37˚, 45˚, or 90˚ elbows [L]), or swivel either through
a range or all around. They can also split or combine flows with:
Run and Branch Tees [T], Wyes [Y], and Crosses [+]. Fittings,
particularly elbows, are offered in a variety of drop lengths. The
drop length is the distance from the centerline of one opening—
called a port—to the end of the other port.
The sizes of the ports can
vary to compensate for
changes in flow. Connection
size often is expressed in
terms of 1/16th of an inch
in the U.S. A dash 32 size
is about a 2-in. (32/16)
connection. A wye flange
may split a 2-in. flow into two
1-1/2-in., instead of two 2-in.
flows, to more closely match
the cross-sectional area.
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
WHAT ARE HYDRAULIC FITTINGS AND FLANGES?

O-ring face seal, SAE straight thread, and ISO 6149 fittings have
an elastomeric seal, normally Buna N, contained within a groove
to seal the fluid. It is important for the seal to be compatible with
the fluid and the temperature range. An elastomeric seal greatly
reduces the possibility of leakage cause by vibration, thermal
cycling, and pressure cycling.
SAE J518 split flange fittings are used on larger line sizes,
starting at 1/2-in. (-8) but coming into predominance at 2 in.
(-32) and above. A flange head with an O-ring groove on its
face is attached to a conductor (hose, tube, or pipe) and is
secured to the port, which could be a flat-face fitting or a pad
on a pump, valve, or cylinder, by a clamp with 4 bolt holes in it.
The clamp can be whole but is often split. The split is designed
so that a quarter of the diameter of the flange head is on either
side of the centerline of the bolt holes to help minimize torque
on the clamp. The screws used are tightened to a high torque
value to avoid problems with fatigue. In many cases, using pipe
or tubing, the flange connections have operated within their
specified working pressure for decades.
It is different from the quick disconnect fittings. The quick
disconnect allows multiple reconnections of the connections.
Some fittings allow the disconnection to be under pressure, others
not. Some safety quick disconnects allow the pressure from one
side of the line to bleed off eliminating one source of energy.
A newer fitting is called a push-to-connect fitting. It differs from
the quick disconnect in that it is a connect one time fitting. It
helps eliminate the use of wrenches in assembly.
Staple and band fittings are low pressure fittings. Band fittings
are attached to the hose by a barbed or beaded end being
inserted into a hose and a band clamp securing the connection.
This is only for very low pressures. Staple fittings have a cylinder
with an O-ring and a bead further up on it that slides into a
socket. The connection is secured by a staple that goes through
both sides of the connection behind the bead.

Flare fittings, such as the 37˚ flare, are fittings with a conical end
called a seat. The seal is formed along a line when this seat is
forced against a mating surface generally by a swivel nut on one
fitting engaging with a threaded portion of the mating fitting.
The angle of the cone is used in the callout, 37˚ being popular,
but existing in 24˚ and 45˚ that are not interchangeable. The
fittings can be designed to clamp on to a tube by means of a
sleeve or ferrule. Care needs to be taken in that the correct size
is used because of inch and metric tubing.

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How do I specify
hydraulic hose
fittings?

H
ydraulic hose fittings connect hoses to pumps, valves,
cylinders and other components used throughout a
hydraulic system. These secure connections help contain
and direct the flow of hydraulic fluid to where it is needed while
preventing leaks and safely maintaining pressure.

Experts say that it pays to differentiate the hose from a

completed hose assembly. While selection of the hose is
obviously important, selecting the hose without considering the
fittings can be a costly mistake. Any hose assembly includes
fittings that are specific to the application. An industrial hose
assembly must have the hose, fittings, and a way to attach the
fittings to the hose. For most hydraulic hoses, the fittings have
a barbed end that inserts into the hose ID, and an outer shell or
ferrule that attaches to the cover or reinforcement.
Crimping is the most common method for assembling hoses and
fittings. Once the crimp specifications have been checked for a
specific hose and fitting, a crimping machine is adjusted to the
appropriate crimping diameter setting. The next step is to lubricate
the fitting, push it into the end of the hose, and then insert the
fitting into the crimper dies. Actuating the crimper closes the dies
and compresses the fitting permanently onto the hose.
Many companies offer no-skive options on their hoses. Skiving
refers to a process where part of the hose cover or even the
inner tube is removed—exposing the reinforcement layers—
before a hose end is attached. No-skive hoses do not require
this step. Many users prefer no-skive options because it makes
hose assembly quicker and reduces the risk of hose damage
during crimping.
Hoses come in many different types made of various rubber
compounds, elastomers, plastics, PTFE, composites or even
metals. Fittings are made of different materials, too, including
steel and stainless steel but also brass, “exotics” like Monel and
more. This multitude of materials creates fittings with a wide
array of performance capabilities.
Hydraulic hose fittings from European-manufacturer Tieffe are
built for a wide range of OEM and aftermarket uses.Photo
courtesy of Tieffe S.P.A.
Therefore, in addition to the hose, users must choose fittings
for chemical compatibility, as well as the security of the
connection. Most hydraulic fittings have designated pressure and
temperature ratings as well as size and dimension standards set
by organizations like SAE International. There is also breakdown
by application to consider, such as operating pressure, flow
capacity, environmental and temperature extremes, and the
operating fluid.
When installing a hose assembly, it’s important to pay attention
when identifying the threads of the connections. Often,
connections from one standard appear to thread into another
standard port but do not have sufficient engagement to be safe.
Furthermore, most fittings are brand-specific for certain hoses
and may not work with other brands. While fitting dimensions
often correspond to the size of the conductor there can still be a
variance in fitting options for one size of hose.

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(continued)
HOW DO I SPECIFY HYDRAULIC HOSE FITTINGS?
That brings up a common question, “Can I use hose and fittings
from different manufacturers in the same system?” According to
many experts, the short answer is “no.”
Mixing and matching components from different manufacturers is
the traditional way of life for many industrial hose distributors and
end-users, but this approach to making hose assemblies leaves
fabricators and users open to greater liability than ever before.
The “right” components for safe, long-lasting hydraulic
assemblies are couplings, hoses, and crimping equipment and
accessories that are designed to work together. Tolerances vary
from one manufacturer to another and are not interchangeable.
Different components from different manufacturers can adversely
affect coupling retention. Casual mixing and matching can
lead to hoses bursting, couplings leaking and blown-off ends
maiming or even killing workers.
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HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
In addition to the dangers involved, mixing and matching brand
names will void the manufacturer’s warranty and could also
exclude manufacturers from liability should someone get injured
from a failed hose assembly.
Companies that make their own hose and fittings say their
products are combined into finely engineered hose-assembly
systems that are specifically designed to work together.
However, companies that only make fittings often have their
products certified by third-party testing organizations to work
with specific types and brands of hoses. For the user, when in
doubt, always consult with an expert to guide you through the
selection process.
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WHAT MEASUREMENTS
ARE REQUIRED FOR HOSE
ASSEMBLY SIZES?
W
ith hydraulic hose assemblies, one should consider
several measurements to ensure their correct size — ID
(inner diameter), OD (outer diameter), and length.
Inner diameter is the bore of the hose and the size of the orifice
that the fluid has to travel through over a particular length. The
OD of the hose could be critical for various things like where the
hose is going to fit and how strong the hose is. A very strong
high-pressure hose tends to have a larger thickness as a ratio
to its ID. And of course, the length will help you determine
what kind of flow rates you can handle, factored in with your ID.
Obviously a smaller hose will have a higher pressure drop or an
overall long length than will a larger diameter hose.
Figure 1. Measured length is critical
A hose must be sized appropriately to handle the flow with as
little pressure drop as possible because that pressure drop is
wasted just trying to move fluid through a conduit. The total
amount of pressure drop should be as minimal as possible, not
only for efficiency, but because you want all the energy you’re
putting into your prime mover to eventually do useful work at
one of your actuators, whether they are a motor or cylinders.
Specifying the wrong length is a common mistake. You absolutely
cannot use a hose that it is too short, because it won’t either fit or
will break if stretched too far. If it’s too long, it could have too much
slack. A hose with slack can rub, fray or cause a catastrophic failure
from moving too much around the machine. These longer hoses can
also sag, which creates forces on the crimp and hose interface. This
can cause wear and leakages over time.
In addition, hanging and sagging hoses can get caught on
something or be a tripping hazard. If a hose is only mildly too long
— an inch, say — you can bolt that down to ensure safety.
Overall length is not the tip-to-tip of all the components. What really
matters is measuring the interface point between the fittings on the
16 I www.hoseassemblytips.com
assembly. For example, if you have a swivel JIC, you do not measure
to the end of the nut, but instead, will measure to where the seat
attaches to the face of the JIC interface. In the example in Figure
1, you’re measuring the male fittings. If you have your hose or tube
that has a male JIC, you want to measure to the interface point on
that male. This ensures accurate hose length.
This procedure is a little more difficult when you have something like
a 45° or a bend fitting. With those, you must measure in the center
of the fitting because the angled interface crosses various points of
the entire hose length, so the middle point is obviously the average
length that the hose would expand over that period.
When making the hose assembly, you must consider the cutoff
length, as seen in Figure 2. If looking at this hose assembly, you see
the hose cut length. On the coupling on the left-hand side, there’s
a CA dimension which is your hose cutoff length. What that means
is after you have your entire hose length determined, you want to
subtract the amount of space that’s taken up by the fitting itself, and
that goes from the actual measured length, so you can see that it
goes to the female part of the JIC.
Figure 2. Hose cutoff length should be subtracted to obtain hose length
Coupling number two is a male NPT, so that cutoff length goes right
to the tip, because you’re measuring to the tip of the male fittings,
while the female fitting is going to be the point of interface. But
those two dimensions of your overall length must be subtracted.
Note, you can’t assume that they’re the same for each coupling,
and you can’t average it out. You actually have to know what that is
based on the catalog information of your hose and fitting supplier.
This allows you to subtract that from the total length, and just say it’s
1 in. on one side, 1 ¼ in. on the other, so you must subtract to 2 ¼
in. from that cutoff length to get your actual total hose length.
Remember, sizing a hose assembly doesn’t just mean you measure
your application and cut the hose to length. Considering pressure
drop and fitting size is critical, too.
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THE EVOLUTION OF
HYDRAULIC HOSE
CRIMPING
Y
ou’d be hard-pressed to find anyone in this hydraulic
industry who has never made a hydraulic hose assembly.
Hydraulic technicians make their livings fabricating
plumbing of various configurations. Still, even designers and
engineers likely got their hands dirty in school as part of an
intro class on the subject. More often than not, fluid power
professionals cut their teeth in the local hose shop before
moving through the ranks of a distributor or manufacturer.
Nevertheless, many of you now reading this are familiar with the
techniques used to crimp a hydraulic hose.
As you’d expect, hose crimping equipment originated with humble
beginnings. Any machine capable of exerting radial force upon the
outside diameter of a hose-end ferrule would do the trick. Early on
in their designs, engineers took advantage of the cone and seat
arrangement for the crimping dies, a system still most popular today.
The collet acts as a seat, and when it pushes against the cone shape
of the dies, the dies are forced inward (see figure 1).
Illustration shows how the collet of a hose crimper acts as a seat, and when
it pushes against the cone shape of the dies, the dies are forced inward.
HAND-SWAGERS CAME FIRST
So long as you could push either the dies or collets to achieve the
desired inward force vector, the conical shape offers a mechanical
advantage to aid in the compression of the hose end ferrule. The
first hose crimping technology used good old-fashioned human
power to achieve the desired result. Early swaging presses operated
by turning a large T-handle, rotating a machine screw through a fixed
head, forcing the end against the two-piece die set.
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In the case of these portable hand swagers, the dies move downward
against the fixed collet, and as the dies move downward, they also
compress inward. The technician must hold the hose end carefully
with one hand as they spin the handle with the opposite hand. Once
the dies grasp the fitting firmly enough, the technician then uses both
hands to muscle the crimper until it bottoms out. It’s essential to use
only the matching dies and hose ends specific to the application.
These portable hand-operated units don’t offer the same automatic
crimp diameter technology as new systems employing micrometers.
You simply clamp the unit until the two-piece dies bottom out and
hope you achieve your crimp spec. Measuring the crimp still offers the
technician confirmation that the crimp resides within specification, but
they need to count on their experience with the device to produce
consistently accurate results. I should also mention, many technicians
still use portable hand-swaging machines today.
HYDRAULICS ADD SPEED AND POWER
Something is satisfying about a hydraulically powered hose crimping
machine. An all-electric machine just doesn’t feel right, like a
meatless burger or a Mazda Miata with an automatic transmission.
The addition of hydraulic power density to the crimping machine
offered the technician a quicker and more powerful method of
crimping hose ends. The collet on the hydraulic crimper is essentially
an annular hydraulic cylinder. In some cases, two cylinders push on
such an annular ring. The force created from the cylinders pushes
either the collets or dies, forcing the latter to close upon the hose
end with high force.
The primary difficulty with early crimping machines was their lack of
versatility. The dies used were specific to the hose end, encouraging
the technician or hose shop to use only products sourced from the
same manufacturer. If a shop wished to use various hoses and ends, a
method to vary the crimp diameter had to offer variability in the crimp
OD while still offering accuracy down to the thousandths of an inch.
Rather than limit the technician to fixed diameter dies, instead
offering dies capable of a range of internal diameters brought in that
variability to allow multiple types and sizes of assemblies. Instead of
an exact diameter of, say, 0.733 in., the dies now offer a range from
0.700-0.788 in. for example. What could previously only crimp a ½
in. hose end may now crimp 1- and 2-wire hose from 3/8 to ½ in.
Dies designed for variable diameter applications present the
challenge of accuracy, of course. The dies can only bottom out
on their smallest setting, which may not always be helpful for any
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(continued)
THE EVOLUTION OF HYDRAULIC HOSE CRIMPING
hose or fitting the shop offers. Crimp machine designers had to
engineer a method to stop the crimping procedure at the desired
size accurately. No technician is skilled enough to stop the hydraulic
pump by feel with 0.002 in. accuracy or better.
ACCURATE AND REPEATABLE
Installing an adjustable limit switch offered the most accurate and
repeatable solution to the variable die set. An adjustable micrometer
attached to the limit switch allows the technician to set the depth of
the limit switch to within a thousandth of an inch or less. When the
crimp actuator contacts the limit switch, the pump stops automatically.
So long as the micrometer has been calibrated, the crimp diameter is
both accurate and precise for every single operation.
Portable hand crimpers, such as this design from Finn-Power, use manual
hand power to turn a T-handle, rotating a machine screw through a fixed
head, forcing the end against the two-piece die set.
Hydraulic crimpers using the micrometer were the standard for
decades, offering precise control to make hose assembly quick
and straightforward. Much of the advancement, until recently, has
been improvements to the practicality of the machine. Dual-stage
hydraulic pumps provided the technician with rapid die travel until
the clamping pressure was met, where the stages switched to the
smaller, high-pressure pump for maximum force.
Convenient die storage systems to offer rapid and precise tooling
changes also sped up the pace for busy hose shops changing
between sizes. A die-set loader offered the technician ease of
pulling dies from their holder where they’re inserted into the
crimper before being clamped in place. The tidy die storage and
replacement systems so widespread today beat the old habit of
sifting through drawers or bins where every die of every size mingled
with no organization.
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HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
ELECTRONIC CONTROL
Just as the rest of the industry moved towards electronic control,
so too did the hose crimping machine. Some technicians found
the traditional dial-micrometer hard to read and adjust, and often
found itself out of calibration. Linear position sensors replaced the
limit switches, and then the adjustment option went digital. A small
LCD screen shows the crimp setting, which increased accuracy and
reduced the chance for error. The precision of the linear transducer
all but guarantees perfect, repeatable crimps.
Some hydraulic hose assembly equipment manufacturers have
produced semi-automated hose assembly stations. One such
machine requires only that the operator load the parts into the
machine. The operator loads the stems and ferrules separately, two
at a time, and then inserts the hose ends into the machine. The
operator starts the sequence that inserts the stems into the pre-cut
hose ends along with the ferrules.
Industry 4.0 is making its way into hydraulic crimping technology. Here,
Gates’ GC20 with Gates Cortex Intelligence features intuitive touch-
screen controls, on-board training, integrated eCrimp settings and remote
support. These technological advances safeguard crimper operations, and
take the guesswork out of crimping operations.
The operator unclamps the hose assembly, and if it’s long enough,
simultaneously inserts each end into the automatic crimper. A moment
later, the technician pulls out a complete hose assembly. If the hose
length isn’t long enough to span the gap and into the two openings,
the ends are done individually but in parallel. The insertion and crimping
functions are completed while the technician works on the opposing
operation. Capable of two hundred complete hose assemblies per hour,
this machine quickly offers a return on its investment.
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 HYDRAULIC HOSE ASSEMBLY DESIGN GUIDE
(continued)
THE EVOLUTION OF HYDRAULIC HOSE CRIMPING

CRIMPERS GET SMART

The industrial world continues to find new and creative ways to

utilize Industry 4.0 concepts, and hose crimping technology is no
different. Busy hose shops require speed and versatility, leaving little
time for thumbing through catalogs looking for crimp specs. Many
top crimp manufacturers offer high-end machines with touch screen
HMIs employing wireless links to the manufacturer database.

This system might not be impressive for the technician who has
memorized the crimp specs for their standard 100R1 or 100R2
assemblies. But when they’re asked to crimp various assemblies
of stainless wrapped thermoplastic hose, they’ll be elated to know
the required die information pulls up on the touchscreen. A quick
selection of hose, dash size and stem results in readily available
crimp specs populated right into the crimper settings.

Just like the fluid power industry at large, crimping technology will
continue to advance. Expect to see augmented reality identify the
hose and fittings visually, such as with QR codes, then automatically
populate crimp specifications. Expect hydraulic hose crimping
technology to become more versatile, more productive and more
easily maintained.

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 WHAT IS SKIVING,
and when should you use it on
your hose assemblies?

S
kiving is removing the outer cover at the end of a hydraulic
hose in the location of the crimp fitting. For some high-pressure
applications, the hose’s inner tube ID may be skived to allow
the hosetail to better fit. Using a specialized machine with externally
rotating mandrels, the tooling cuts and then peels the outer carcass.
Depending on the machine, the skiving process may take thirty to forty-
five seconds.

The assembly technician must reference the manufacturer’s catalog to mark

the skive’s length, which corresponds to the mark length used to subtract
the coupling length from the overall length. The coupling length is the
distance from the tip of the cut hose to the outside tip of the hose end
when the hose is installed. The total length of a hose assembly equals the
hose cut length plus the sum of each of the two coupling lengths. Skived hose Image courtesy of Uniflex

Once the skiving process removes the inner or outer rubber layer(s), the
remaining hose end is left with its steel braids or windings nearly exposed.
A single skive leaves only the outer layer exposed, while its combination
with a tube skive is often referred to as a double skive. Where single- or
double-skived are chosen depends on the rated pressure, with double
skiving more often used in very high-pressure applications.

Once skived, the hose end may be fitted and crimped to the hose. Skived
hose assemblies require crimp ends specific to the application and are
not compatible with non-skive fittings. A skived hose assembly bites into
the reinforcement wires, and as such, is dimensioned differently to avoid
breaking through the cover.

Skived hose assemblies are used in applications where ultimate reliability

under high-pressure conditions is an absolute must. Because the crimp
occurs directly on the wire braiding or spiral, the force exerted is across a
more stable surface. A skived hose assembly has less chance of failure, and
when done correctly, these hoses rarely fail. Many machinery manufacturers
swear by the reliability and safety of a skived hose assembly, requiring them
for all applications.

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 WHY SHOULD
YOU CLEAN YOUR
HOSE ASSEMBLY?

Hydraulic hose assembly — from manufacture to delivery and cutting and

assembly — can be a huge source of contamination, so cleaning the inner
tube is crucial to the assembly process.

H
ydraulic hoses may appear clean upon arrival in your
facility, but every step of the hose fabrication process
creates internal contamination that needs to be removed.
For instance, they may have contamination from the
manufacturer — residual mandrel lubrication may still be inside
the hose. Additionally, unless they are sealed from manufacture
to your shelves, hoses may have picked up dirt and debris
during transport.
But once at your facility, three main reasons exist as to why you
should clean your hydraulic hose assembly. This step is crucial
more so today because hydraulic systems are more sophisticated
than what they were in the past, featuring tighter clearances and
running at higher pressures.
Although it is not recommended, many users will use an
abrasive wheel or a metal scallop blade which will create
internal contamination. It is better to use a production saw or
one specifically designed to cut hose, because there will be less
contamination and heat generated.
introduce contamination into the hose assembly. Many lubricants
are contaminated out of a brand-new container because they
are not prefiltered. Another problem with lubricants is you never
know whether they’re going to be compatible with the tube
stock in the hose. If incompatible lubricant is used, it could
soften the tube and shorten the life of the hose assembly.
Finally, if contamination is left at both ends and hose stems
are inserted, some of the contaminants will be pushed deeper
into the hose, and other particles will get trapped between
the O.D. of the stem and the I.D. the rubber tube. After the
crimping process, the trapped contaminants — depending on
the amount and the size of the particles — can create a leak path
for the hydraulic fluid when the system is under pressure. That
can basically be avoided by having a clean tube and doing the
proper hose stem insertion.

You should first clean the hydraulic hose immediately after

your cutting process and always before completing hose stem
insertion. Note that as the blade cuts through the hose, it will
generate heat. The rubber and metal particles that are sheared
off during the cutting process will cool inside the tube, and these
will have a tendency to stick or adhere to the tube. It is therefore
important to clean the tube while it is still warm as contamination
is easier to remove before it adheres to the inside. For example,
if using projectile cleaning, you should fire the projectiles
through immediately after the cut.

Secondly, cleaning makes hose stem insertion easier.
Contamination can create friction when pushing the hose stems
in. Cleaning the hose tube can create a somewhat lubricated
or polished tube, making hose stem insertion easier. This also
reduces the need for lubricating the hose stem, which can also
Cleaning hydraulic hose makes stem insertion easier, as it helps to
smoothen and lubricate the inside and reduces the chance fittings will push
contaminants further inside.
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HOW DO YOU CLEAN
HYDRAULIC HOSE
ASSEMBLIES?
Even hose that looks clean can have plenty of dirt and contaminants

A
nyone who works in the hydraulic industry knows the
importance of reducing contamination. Particles, dirt, debris
and even water that enter a system can quickly wreak havoc,
causing system failure and even possibly destroying a component or
machine. This is why it is essential to keep these contaminants out.
To ensure hydraulic fluid remains contaminant free, it is imperative
to clean all new hoses before installation. If contaminants are left
in a hose after it has been shipped to a user or has been cut and
crimped, those rubber and dirt particles will easily end up in the
reservoir and flow throughout the entire system.
Three common methods are used to remove contaminants from the
inner tube of a hydraulic hose: high-pressure air, fluid flushing and
projectiles.
Air — High-pressure air can be blown through a hydraulic hose or
assembly, as long as it is clean and dry. This works best with shorter,
smaller hoses, as the longer the hose, the more likely particles may
get caught within the assembly. This method is not always effective,
however, as air can often be hot and dirty.
Fluid flushing — As long as the fluid is clean and compatible
with the hose assembly’s inner tube, you can flush an assembly
with high-pressure fluids to create turbulent flow. This will remove
contaminants from the inner tube wall. However, to ensure the
fluid is clean, you must use filtration to ensure that the fluid is
contaminant free. Before you can install the hose, you must ensure
that the inside of the hose is then dry.
inside. Image courtesy of Ultra Clean Technologies Corp.
These projectiles should never be inserted directly into the I.D. of
the hose by hand. This ill-advised insertion method will not allow the
projectile to enter the hose tube cleanly and may transfer additional
contaminants into the hose I.D. The projectile may get caught on
the wire reinforcement, and you also run the risk of cutting your
fingers. Instead, insert the nozzle into the hose tube, which will make
an airtight seal. Depress the trigger and the projectile will enter and
exit the hose cleanly. Remove the nozzle from the hose I.D. and
wipe any loose contaminants from the nozzles O.D. Turn the hose
180 degrees and repeat the cleaning process. The hose tube is now
clean and free of unwanted contamination.
KEEPING FITTINGS CLEAN
It is also necessary to clean hose stems before insertion. Keeping
hose stems clean prior to insertion is vitally important. If they’re
delivered in a sealed bag or in a box, it is recommended that you
leave them in the bag until they’re ready for use or in the box with
the lid on the box. Oftentimes, users will open the bag and dump
the fittings into a plastic acro bin or a cardboard bin. This simply
allows for easy airborne contamination to get into and onto the
fittings. Once the fittings are cleanly inserted into the assembly, the
ends should be capped to ensure they remain contaminant free.

Projectiles — Perhaps one of the most effective methods is through

the use of foam projectiles that are shot through a hose assembly via
dry compressed air or another inert clean gas. Special hand-held or
bench-top launchers should be used to ensure the projectile travels
completely through the tube and is not left behind inside the hose.
The projectiles must be approximately 20 to 30% larger than the
ID of the hose tube, as they compress against the wall of the hose
assembly to “grab” any dirt and debris.

As the foam projectile travels quickly through the assembly, it picks
up any dust, debris and particles and gives the user a visual look at
how much contaminants it has removed. It is recommended to use
these foam projectiles from both ends of the hose assembly, and to
do two or three pass-throughs until the projectile comes out clean.
Shooting foam projectiles through hydraulic hose assemblies
ensures dirt and debris is effectively removed. Image courtesy
of Ultra Clean Technologies Corp.
Sponsored by:

22 I www.hoseassemblytips.com
www.ultracleantech.com
WHY SHOULD YOU
CAP YOUR HOSE ASSEMBLY
O
nce a hydraulic hose assembly has been properly
cleaned and crimped, there is still one more important
step to ensuring they remain clean and contamination-
free before use. Plumbing systems are often the largest locations
for built-in contamination versus the rest of the hydraulic system.
So, immediately capping the hose ends with either protective
injection molded plastic caps and plugs, or heat-shrinkable
capsules is vital.
Plastic caps and plugs can be manufactured in a variety of
materials to protect most styles of hydraulic hose fittings,
flanges, and couplings, and can be made with several attributes
to ensure a good fit and match. Caps come with a female-
threaded end that screws into the male-threaded hose end
and cover the openings. The male plugs have a male thread
and various head shapes. Because they come in many shapes,
sizes, and styles, it is imperative to ensure that the caps and
plugs are compatible to the specific type of fitting to keep hose
contaminant free.
Heat-shrinkable capsules simply encapsulate either hose end
— the crimped fitting or tube end — of an assembly through a
quick heat-shrinkable process and installation. For example, Ultra
Clean’s Clean Seal Capsules shrink approximately 45% during
the process which takes about one second.
23 I www.hoseassemblytips.com
Because they are heat-sealed, encapsulated designs do not
generate contamination. Injection molded caps and plugs, if
specified correctly, prevent contamination as well. However,
if the wrong size or design is chosen, and depending on how
tightly they fit over a male thread or into a female thread, they
can create contamination.
Built-in tear strips on the encapsulated designs ensure fast and
clean removal and reduce the risk of contamination by keeping
the hose covered until the exact moment of installation. On
caps and plugs, however, the sharp threads can shear bits of
the plastic off, which would end up inside of the cleaned hose
assembly. Or, if they are not tight enough, contaminants can slip
through the gaps. Therefore, it is imperative to select the correct
material, style and thread type for plastic caps and plugs.
Another advantage of the heat-shrinkable capsule is that it will
not fall off during transportation or storage of the assembly.
Once it shrinks on, it conforms to the shape of the fitting. The
heat-shrinkable capsules are pre-stacked in stick form so when
you pull that top capsule off, it’s always clean on the inside. They
are available in a number of sizes from the smallest hose fitting
on a dash four hose all the way up through a dash 32.
Finally, both designs can be customized. Injection-molded caps
and plugs can be manufactured in a variety of colors to suit
customer preference, while the heat-shrink capsules can be
private-labeled with customer name and logo.
Cleaning and capping your hose assemblies gives them a
professional look and more importantly, eliminates the risk of
contamination before it’s installed on its intended machinery.
Sponsored by:
www.ultracleantech.com
 Knocking Out
Contamination
WITH INNOVATIVE CLEANING
AND SEALING SYSTEMS
HOSE, TUBE AND PIPE CLEANING | SEALING SOLUTIONS

CLEAN EASY. SEAL EASY.

The Ultra Clean System Clean Seal Systems protect your
eliminates unseen dirt clean assemblies utilizing heat
s
r Exceed and grime the cutting and shrink technology to secure a Clean
Meets o & SAE
S
ISO, NA ess crimping process leaves Seal Capsule onto the end of a
C le a n lin behind — contaminates hose or tube assembly. Eliminating
ds
Standar that could shut down your unwanted contamination and
machinery indefinitely. excessive cap and plug inventory.

ULTRACLEANTECH.COM
1274 HIGHWAY 77, BRIDGETON, NJ •08302 • TOLL FREE: 800.791.9111 • INTL: +1 856.451.2176 • EMAIL: SALES@ULTRACLEANTECH.COM