TODAY'S ADVANCED

HOSE AND HYDRAULIC SYSTEMS

CHAPTER 1

As its tools and technologies advance, modern fluid power systems

Innovative
Solutions for
Hydraulic System
Challenges

are under greater pressure than ever before to perform safely and
precisely. Stronger performance leads to greater productivity and profits
across a wide range of industries from oilfield and mining to mobile
equipment and marine. This multi-chapter Gates Fluid Power eBook
explores challenges in the field and highlights innovative approaches
to testing, safety measures, and diagnostics and monitoring.
In this chapter, we present solutions to these common
hydraulic hose assembly issues: mismatched
components, poor performance, the environmental
impact of failed systems and corrosion.

MISMATCHED COMPONENTS
Every hydraulic system includes a series of hoses and
couplings that transport fluid under pressure from a pump
to an actuating mechanism, which in turn converts the fluid
into motion or force. That makes the hose and couplings a
critical sub-system of the larger hydraulic circuit.
Suppliers offer countless types and styles of hydraulic hoses,
couplings and fittings. Because of industry-wide pressures
to contain costs and solve challenges quickly, engineers
often match hose from one manufacturer with couplings
from another. Mixing components, as opposed to taking a
systems approach, can have consequences ranging from
minor leaks to major safety hazards. With the high pressures
and temperatures of todays compact hydraulic systems,
employing systems with mismatched components leads to
unanticipated downtime and maintenance costs.

Taking a Systems Approach

When selecting an OE hydraulic hose and coupling system
or fabricating an aftermarket assembly, ones first step
should be matching hoses and couplings from the same
manufacturer.

QUICK TIP
The Society of Automotive Engineers (SAE)
recommends against using couplings from one
manufacturer with hoses from another manufacturer
interchangeably. SAE documents are available
through its customer service line 724-776-4970.
Although most American-made hydraulic hoses and many
imported hoses are built to conform to SAE specifications,
SAE allows a wide range of materials to be used. Different
materials result in a variety of hose styles, and each
manufacturer designs its hose and coupling components to
fit distinct tolerances.
1

Hoses from various manufacturers may have similar

dimensions and constructions but different rubber
compounds and reinforcement materials, for example.
In addition, couplings are individually designed and
tested to handle the hose manufacturers unique product.
The proliferation of thread ends from around the world in
recent years has dramatically increased the possibility of
mismatching threads and seats on various couplings.
The following sections include recommended approaches to
selecting hose and couplings.

Hose Selection

Size
The inside diameter of the hose must be adequate to keep
pressure loss to a minimum and avoid damage to the hose due
to heat generation by excessive turbulence. Velocity of hydraulic
fluid in suction lines should always fall within a specific range
recommended to ensure efficient pump operation. To determine
the replacement hose size, read the layline printing on the side
of the original hose. If the original hose layline is painted over
or worn off, the original hose must be cut and inside diameter
measured for size.

QUICK TIP
Before cutting an original hose assembly,
measure the overall assembly length and coupling
orientation. This measurement will be required to
build the replacement assembly or match the hose
I.D. to the port size.
Temperature
When selecting a replacement assembly, two areas of
temperature must be considered. These are fluid temperature
and ambient temperature. The hose selected must be capable
of withstanding the minimum and maximum temperatures of
the system.

To take into account the hose performance characteristics and

the demands of a particular application, a simple and easy
method is used to properly select hydraulic hose: STAMPED.

STAMPED
S = Size
T = Temperature
A = Application
M = Material to be conveyed
P = Pressure
E = Ends or couplings
D = Delivery (volume)

Application
Determine where or how the replacement hose or assembly
is to be used. Consider every factor, including the type of
equipment, working and surge pressures, fluid and ambient
temperatures, fluid compatibility, environmental conditions,
routing requirements, minimum bend radius, expected service
life and beyond. Most often, only a duplicate of the original
hose will have to be made, provided the original hose assembly
gave acceptable service life.

Material to Be Conveyed
Some applications require specialized oils or chemicals to be
conveyed through the system. Hose selection must ensure
compatibility of the hose tube, cover, couplings and O-rings
with the fluid used. Additional caution must be exercised in
hose selection for gaseous applications where permeation
can occur.
Permeation is seepage through the hose resulting in loss of
fluid. This may occur when hose is used with fluids such as
liquid and gas fuels, refrigerants, helium, fuel oil or natural
gas. Consider whether there are potential hazardous effects
of permeation through the hose, such as explosions, fires and
toxicity. Refer to applicable standards for specific applications
2

such as fuels and refrigerants. If gas permeates through the

tube, consider pin-perforated covers to prevent gas build-up
under the cover. Also consider the compatibility of the system
fluid not only with the tube but also with the braid, cover,
fittings and other components since permeation may expose
the entire hose assembly to the system fluid.

Pressure
In the hose selection process it is essential to know the
system pressure, including pressure spikes. Published working
pressures of the hose must be equal to or greater than the
system pressure. Pressure spikes greater than the published
working pressure shorten hose life.

QUICK TIP
Burst pressures are reference pressures
intended for destructive testing purposes and
design safety factors only. Typically, for dynamic
hydraulic applications, the minimum burst pressure
rating is four times that of the maximum working
pressure rating.
Ends or Couplings
Identifying the proper end connectors, the hose barb end and
the port-connecting end for a hose assembly is critical. Find
additional information in the Coupling Selection section of
this chapter.

Delivery
The amount of fluid that must pass through a hose determines
the size of hose needed. Under-sizing a hose leads to increased
pressure loss, while over-sizing the hose adds unnecessary cost,
weight and bulk.

Coupling Selection

becomes more global. The primary difference between a

conventional SAE coupling and a foreign coupling is the thread
configuration and seat angle.
It is important to be aware of these differences and be able to
correctly identify all the different types of couplings.
International thread ends can be metric, measured in
millimeters, but also include British Standard Pipe (BSP)
threads, which are measured in inches. Knowing the country
of origin for a piece of equipment provides a clue as to what
type of thread end is used. Deutsche Industrial Norme (DIN)
fittings indicate a German or Swedish manufacturer, while BSP
is found on British equipment. Japanese Komatsu machinery
uses Komatsu fittings with metric threads, while other Japanese
equipment most likely uses Japanese Industrial Standard (JIS)
BSP threads, or in some cases, BSP straight or tapered threads.
Three determinations are required for correct identification of
these couplings:
S
 eat: Inverted (BSPP & DIN), regular (JIS & Komatsu)
or flat (flange, flat-face)
S
 eat Angle: 30 (JIS, BSP, DIN and Komatsu) or
12 (DIN)
T
 hreads: Metric (DIN or Komatsu), BSP (BSPP,
BSPT or JIS), or tapered (BSPT or JIS tapered)
The coupling or hose interface must be compatible with the
hose that is selected. Follow the hose manufacturers coupling
recommendations only. The proper mating thread end must
be selected so that leak-free sealing can be made to mating
components.

ASSEMBLY
PERFORMANCE ISSUES
Just as components from different manufacturers cause
hydraulic system issues and lead to failure, hose assembly
performance suffers when parts are not properly installed. All
systems must be compliant with SAE or ISO (International
Organization for Standardization) requirements, so most
engineers choose hoses based on the published specifications.
Often they assume that assemblies will be built correctly and
perform as intended. Of course, that does not account for
human error, and over-crimping or under-crimping certainly
affects performance.

The amount and types of machinery being imported into the

United States is growing dramatically as the marketplace

Basic Crimp Procedures

Always reference the operators manual for
instructions specific to individual crimpers. Also
remember to wear safety glasses and to keep hands
and clothing away from moving parts.
1. R
 efer to a crimp data chart for skive data,
die selection, finished crimp diameter and
approximate crimp setting.
2. L
 oad the selected dies into the crimper. When
using a die set for the first time, apply a thin
coat of lubricant to the contact surface and
cone but not to the bore of the die. This layer
of lubricant must be thinly re-applied when
contact surfaces become shiny. Locate dies in
the crimp position.
3. Adjust the machine to the proper crimp setting.
4. Adjust the depth stop if necessary.
5. Insert the assembly, and locate it with the die
fingers.
6. Install a die cone if needed.
7. Activate the crimp mechanism.
8. R
 emove the assembly from the dies, and
measure the crimp diameter.

If the extra component does not meet system requirements, it

is likely that other items in the kit will not. If time and again the
part is correct the right length, the right cleanliness, etc. it
is likely that the assemblies are being built properly. This is
an especially useful process when applications are custom and
there is greater room for error.

MegaSys Products
MegaSys hoses from
Gates Corporation feature
an exclusive layline
treatment that helps
users identify crimping
specifications, match
hoses with the right
couplings and identify
hoses in stock and in
service. The distinctive design and pressurerelated, color-coding system is just one benefit
of the constant pressure spiral-wire and wirebraid hoses.
Other benefits of MegaSys include:
B
 ends up to one-third SAE bend radius
specifications
Saves overall hose assembly length
F
 acilitates easier plumbing and routing in
tight applications

QUICK TIP
Always check the crimp diameter to ensure that it
is within the published limits. Record your actual
crimper setting to achieve the specified crimp
diameter for future use.

Eases installation with higher flexibility

Lowers inventory requirements
Reduces costs by as much as 64 percent
To learn more about the hoses and their innovative
coupling counterparts MegaCrimp and
GlobalSpiral visit the Gates Hydraulics Site.

Confirming Proper Components

During the assembly process, crimp specifications are often
unknown, but other basics (like hose length) are clear. One
solution for ensuring that proper components are selected, and
that a system will perform as expected, has been instituted
by leading manufacturers, including Gates Corporation. The
manufacturers help OEs document and verify parts supplied
by third parties. How? Every fifth component in a parts kit is
certified by an independent laboratory or by internal quality
control personnel.

QUICK TIP
When replacing hose that has no visual indicators
or specs, refer to the system manual for guidance as
to the correct hose type. And always remember the
three Fs: Fit, Form and Function.

ENVIRONMENTAL IMPACT

Environment-Friendly Hoses

One challenge for those working with hydraulics is system

failure. An even greater problem can be the environmental
impact that results. Where the failure occurs, the size of
the spill, the type of fluid leaked and the involvement of the
industrys governing bodies are some of the key factors that play
into the costly cleanup needed to remedy the situation.

Todays most environment-friendly hydraulic hoses were

designed to transfer fluid that degrades more easily than most.
While restrictions around such fluid are still tight and leaks of
such fluid can still be costly, the hoses are one way in which
the fluid power industry is working toward cleaner, greener
solutions.

Hydraulic system failure is common especially when systems

have not been built with the right components, properly
assembled or correctly installed. In fact, it is not rare that any
given fleet experiences two or more spills per year. In addition,
everyday drippage is a common problem with environmental
implications.

The biodegradable fluid is an especially useful solution for

environmentally sensitive applications where there is significant
risk associated with an oil spill from a ruptured line, such as
farm tractors and marine dredging.

QUICK TIP
The biodegradable oils are available as ISO 32,
ISO 46, and ISO 68 specification oils. Also reference
American Society for Testing and Materials (ASTM)
standards ASTM-D-6006 (Guide for Assessing
Biodegradability of Hydraulic Fluids)
and ASTM-D-6046 (Standard Classification of
Hydraulic Fluids for Environmental Impact).

Even low leakage rates from hydraulic systems

can lead to gallons of oil lost over time.
Source: Totten, George E. (2000). Handbook of Hydraulic Fluid Technology.
New York: Marcel Dekker, Inc. Pg. 514.

The costs and legal repercussions of environmental damage can

be significant. Complete all certifications and testing offered by
equipment manufacturers and organizations in your industry,
such as the Mining Safety and Health Administration (MSHA)
or the Society of Automotive Engineers (SAE), to help prevent
failures that could have disastrous effects on the environment.

EnviroFluid Hose
Biodegradable fluids can seep through ordinary
hose tubes, causing cover blisters and sweat
and resulting in premature and expensive hose
failures. EnviroFluid spiral-wire hose from
Gates is specially designed for biodegradable
hydraulic fluids and other aggressive oils like
synthetic esters, polyglycols and vegetable oils.
Its nitrile tube handles biodegradable fluids
at operating temperatures up to 250F without
performance loss, and it offers significantly lower
permeation than neoprene tubes when used with
petroleum-based oils.
Learn more about EnviroFluid Hose.

CORROSION
Corrosion is a common challenge in hydraulic applications,
which makes coupling selection particularly critical. Part of the
process in choosing the right coupling for any given application
is ensuring that is has the proper plating. Often, environmental
factors must be considered, as equipment operating near
the ocean, for example, contends with salt corrosion. For
equipment operating inland, on the other hand, traditional
plating often works. Standard plating options will not suffice
when agricultural chemicals or fertilizers are moving through
the system. Because there are such varied uses of hydraulic
systems, manufacturers have created plating technologies for
virtually every situation.

TuffCoat Plating
Introduced in 2001, TuffCoat plating sets the
standard for corrosion resistance. Tested under SAE
J516 and ASTMB117 salt-spray conditions, the
plating provided more than 400 hours of protection
against the formation of red rust for 500+ percent
improvement over the 72-hour SAE standard.

Hose & Coupling Section

Due to environmental concerns, Gates has

EQUIPMENT
eliminated hexavalent chrome from the TuffCoat
manufacturing process. This green approach to
HOSE/CPLG.
manufacturing has not affected coupling corrosion
SELECTION
resistance or changed torque recommendations.

Chemical Resistance Ratings for Gates Hose

Polymers, Couplings and Adapter Materials

Learn more about TuffCoat Plating.

GLOBALSPIRAL

QUICK
TIP
The Chemical Resistance
Table
lists the relative
How to Use the Chemical Resistance Table
COUPLINGS
resistance of hose and coupling materials to more
If you see red rust on your coupling, it is time 1. Chemicals are listed alphabetically.
PCM/PCS
common chemicals. These ratings do not cover
FERRULES
toallreplace
it. When it rusts, metal loses strength 2. Find the hose, coupling and adapter material
possible variations of all factors, such as
becomesdegradation
unreliable.or fluid
type that has a resistance rating of 1 or 2
temperature,and
concentration,
MEGACRIMP
(SeeWhile
Rating
theScale).
hydraulic system challenges outlined in this chapter
contamination, etc. Testing under actual conditions
COUPLINGS
are not new, leading manufacturing companies are constantly
is the best way to ensure chemical compatibility for
3. Find hose(s) with compatible polymer(s) in
To determine the right coupling for your application, reference
innovating solutions to respond. Sometimes the solutionsPOWER
are in
critical applications.
the Gates Hydraulic Hose Selection Guide.

CONCLUSION

the chemical resistance tables that manufacturers include in

the form of new products, developed and tested to offer CRIMP
greater
COUPLINGS
specific information, contact Gates Hose/
their For
catalogs.
4. Look
for
compatible
couplings
for
the
selected
features or unprecedented capabilities. Other solutions are less
Connector Product Application, Denver, Colorado.
hose(s)
by following
the in
hose
tangible
and come
thepage
formreferences
of new practices in the field,
LOW
in the
Selection
Guide.
application engineering support or training that minimizes
the
PRESSURE
Rating Scale
effects of ordinary human error. Gates Corporation is COUPLINGS
at the
forefront of such advancements, and future chapters of this
POLARSEAL
NOTE: O-Rings used with couplings also must be
1
Excellent resistance
eBook will explore changes in testing, safety measures,
and
COUPLINGS
considered for chemical compatibility with the fluid
diagnostics and monitoring.

Good resistance

Not recommended

Testing recommended

to be conveyed. This includes couplings containing

C14
Resources
internalAdditional
O-rings; for example,
MPX (Male Pipe Swivel).
COUPLINGS
Gates Find
standard
O-ring
is
made
of
Nitrile.
If
O-rings
information on Gates Fluid Power hydraulic hose,
other than
Nitrile are
required,
contact
Gates Denver.
PCTS
couplings,
crimpers
and
accessories
at www.gatesprograms.

As the need to replace couplings arises, purchasing them from

a reputable source is the best defense against poor performance
or failure.

THERMO-

com/hydraulics. For resources on safe hydraulics practices

PLASTIC
COUPLINGS
and preventive maintenance, visit www.gatesprograms.com/
safehydraulics. Gates also offers a special hydraulic preventive
FIELD
maintenance training program called Safe Hydraulics
ATTACHABLE
designed to help maintenance managers, repair technicians
G1 & G2
and machine operators identify component weaknesses COUPLINGS
before
failure. For information, contact pa0000@gates.com.
FIELD
ATTACHABLE
C5
COUPLINGS
SURELOK AIR
BRAKE
COUPLINGS
QUICK
DISCONNECT
COUPLERS
NEW BALL
VALVES

TODAY'S ADVANCED
HOSE AND HYDRAULIC SYSTEMS

CHAPTER 2

As its tools and technologies advance, modern fluid power systems

are under greater pressure than ever before to perform safely and

Successful Product
precisely. Stronger performance leads to greater productivity and
Testing Through
New Technologies & profits across a wide range of industries from oilfield and
mining to mobile equipment and marine. This multi-chapter Gates
Collaboration

Fluid Power eBook explores challenges in the field and highlights

innovative approaches to testing, safety measures, and diagnostics and
monitoring.
In this chapter, we examine product testing as an important
component of driving innovation in the fluid power field.

NEW PRODUCTS & EXISTING

EQUIPMENT
Todays testing equipment and facilities for industrial
hose assemblies and product prototypes are incredibly
sophisticated. Engineers, chemists and technicians freeze,
heat, abrade, impulse cycle, age and otherwise simulate
real-world conditions for thorough testing of both existing
assemblies and new concepts. They evaluate compounds,
metals and designs to learn what works and what needs
improvement and create microenvironments to expose
materials to everything from dry air to ozone.

Gates Corporation has made major headway in creating processes for efficient product and equipment testing. On site
or at the companys Customer Solutions Center (CSC), Gates
PA engineers effectively work side-by-side with OEMs, their
development teams and their engineers on novel and existing
platforms. Components are positioned within platforms to
improve hose routing and reduce hose, coupling and adapter
cost, and custom solutions are delivered to customers.

Testing is most successful when product application (PA)

engineers from fluid power system manufacturers collaborate
closely with OEMs to solve their specific challenges. Changes
are immediately put into effect, rather than requiring a
back-and-forth process where systems have to be
re-engineered and problems repeatedly corrected.

Gates Customer
Solutions Center
The CSC is a state-of-the-art facility leading the fluid
power industry in customer-focused product research,
development, testing and training.
Staffed by approximately 45 of the top engineers, scientists
and technicians in fluid power technology, the CSC is
headquarters for understanding challenges and meeting
fluid power needs on a global basis. The center features
these testing areas:

Materials Test Lab: A fully environmentally controlled space, ideal for developing and testing new
materials, compounds and reinforcements and ensuring compliance with stringent industry standards

Finished Hose Test Lab: Where engineers put completed assemblies through a series of strenuous
physical tests and environmental extremes

Prototype Equipment Bay: Provides customers with a secured workplace for sensitive R&D projects
Sample Build & Metrology Lab: Where engineers make assemblies for testing across a broad range of
Gates crimpers and have access to sophisticated measurement equipment for analysis and microscopic
examination
Impulse Test Lab: An advanced lab that puts hoses and connectors through their paces
Watch a video to learn more about the CSC.

New Product Testing

In developing new products, important properties of the
product materials are tested in a controlled environment and
detailed plans are put in place to ensure that final products
will meet or exceed industry requirements.

DNV Det Norske Veritas for North Sea Floating Vessels

EN European Norm/Standard
GL Germanischer Lloyd
IJS Industrial Jack Specifications

Agencies That Set

Manufacturing Standards
Many governing bodies set manufacturing standards
for a variety of applications around the world. They

RCCC Regular Common Carrier Conference for Fleet

Truck and Bus
SAE Society of Automotive Engineers

United States Government Agencies

include:

DOT/FMVSS Department of Transportation/Federal

ABS American Bureau of Shipping

Motor Vehicle Safety Standards

AS Australian Standard

MSHA Mine Safety and Health Administration

DIN Deutsch/German Industrial Norm

USCG U.S. Coast Guard

Even with the most careful testing processes, outcomes are

not always easy to predict. When Gates began designing its
LifeGuard line-of-sight sleeving system, the first true
protection in line-of-sight hydraulic applications,
unexpected obstacles arose. When the aluminum collars
are crimped on the assembly, it has to be done in a way
that allows fluid to escape the sleeving. During testing, the
desired effect could not be consistently produced using
standard field
tooling, so a new tool that would retrofit existing machines
was designed.
In addition, since LifeGuard
sleeving was designed to
protect operators in cases of
failure, field testing outside
of fit was not an option.
During product testing Gates
had to be able to subject the
sleeving to specific types of failure in a burst chamber. This
allowed Gates to safely create pinhole leaks of specific sizes
and generate bursts. Capturing video of the failures allowed
the testing team to review and analyze how the sleeve and
clamps reacted in each instance.

QUICK TIP:
Many hose products go through multiple testing
iterations before meeting requirements. Even once
requirements are met, couplings can blow off or
leak during impulse testing, especially when high
temperatures are involved. In some cases, full
testing requires months of effort.

The Prototype Testing Process

Over the years, the testing process for new products has
been refined. Everyone involved with the assembly assesses
it, including application engineers, materials engineers,
hose engineers, coupling engineers and even marketing
representatives.

The Engineering Change Notice (ECN), also referred to as

an Engineering Change Order (ECO), is documentation of
design changes made throughout the prototyping and
life-cycle phases of a product. This documentation contains
the justification for changes made to a component or
system once the initial design is complete. It also forces
changes to be approved by the relevant authorities.

What to Include in an ECN

According to David G. Ullman in his 2009 book The
Mechanical Design Process, an ECN must contain the
following information:
Identification of what needs to be changed. This should
include the part number and name of the component
and reference to drawings showing the component in
detail or assembly.
Reason(s) for the change.
Description of the change. This includes a drawing
of the component before and after the change. The
drawings must clearly show the detail(s) affected by
the change.
List of documents (and in industry, the departments)
affected by the change. The most important part of
making a change is ensuring all pertinent groups are
notified and all documents updated.
Approval of the change. As with the detail and
assembly drawings, the changes must be approved by
management.
Instruction about when to introduce the change
immediately (scrapping current inventory), during the
next production run or at some other milestone.

Generally, the process follows these steps:

1. Test procedure written

2. Procedure submitted to lab
3. Lab technicians prepare samples
4. Initial tests conducted
5. Engineering Change Notification (ECN) submitted
6. Changes made
7. Further tests conducted
8. Requirements met
9. Team sign off

For Gates, working directly with customers has made the

greatest difference in creating prototypes that not only
meet but exceed requirements. The companys customized
process, from design and development to testing, efficiently
generates innovative solutions.

Improving Existing Equipment

When improving existing equipment, a preliminary meeting and onsite evaluation must take place in order to
determine the projects parameters. For Gates, once this step is complete, the machine is shipped to the CSC for
prototyping and VEVA Value Engineering/Value Analysis.

VEVA
Gates Value Engineering/Value Analysis is a method used to achieve necessary product and/or service functionality
at minimum cost with an increase in overall value. Rather than just replacing hose and couplings with cheaper
versions, engineers find ways to increase throughput and reduce labor costs. Warranty claims provide valuable
insight into possible areas of improvement, and systems are retooled to eliminate leak points. At times, components
can be entirely eliminated an option that is often better than downgrading them.

At the CSC new technologies are applied to units under analysis, and hose and coupling engineers are readily
available to assess and find solutions for problem areas. Once a platform has been plumbed, Gates proposes changes to the
customer who chooses which recommendations to pursue. Ultimately, the machine is sent back to the facility or proving
grounds for testing.

CONCLUSION
Advanced testing processes and technologies are required to create innovative fluid power products and improve the value
of existing equipment. Gates is leading the industry by combining the most sophisticated tools available with hands-on
expertise from knowledgeable engineers and technicians. Only through close collaboration with OEMs are the most
productive, cost-saving solutions created.

Additional Resources
Find information on Gates Fluid Power hydraulic hose, couplings, crimpers and accessories at www.gatesprograms.com/
hydraulics and resources related to E2E industrial hose products at www.gatesprograms.com/hosesystems. Questions?
Contact pa0000@gates.com.

TODAY'S ADVANCED
HOSE AND HYDRAULIC SYSTEMS

CHAPTER 3

As its tools and technologies advance, modern fluid power

Maintaining a Safe
Working Environment

systems are under greater pressure than ever before to perform

safely and precisely. Stronger performance leads to greater
productivity and profits across a wide range of industries
from oilfield and mining to mobile equipment and marine. This
multi-chapter Gates Fluid Power eBook explores challenges in
the field and highlights innovative approaches to testing, safety
measures, and diagnostics and monitoring.
In this chapter, we explore best practices for hydraulic and
industrial hose system safety.

SAFETY & FLUID POWER

PREVENTIVE MAINTENANCE
Small hose problems can turn into catastrophes when
industrial and hydraulic hose systems are not properly
maintained. And as demands on fluid power applications
increase, risk rises.

Implementing a preventive maintenance program helps

identify component weaknesses before system failure.
Start by selecting the proper hoses and fittings. Take time
to ensure that theyre properly assembled, routed and
installed. Then schedule periodic inspections and
troubleshoot any issues that arise. Make sure that those
working on and around the equipment are properly trained
to handle any safety issues they may face.

Armed with the knowledge that comes from performing

preventive maintenance, companies can take action to
replace or repair hose systems, reducing the instances of
workplace injuries while protecting the environment and
their equipment.

Preventive
Maintenance
Benefits
Increased equipment productivity
Better utilized in-shop maintenance
(less emergency work)
Improved control of spare part inventory and
reduce parts usage
Decreased equipment downtime
Reduced safety hazards
Increased equipment service life
Less environmental fines and clean-up costs
due to leaks

Safety Factors for Hydraulic Hose Systems

Maintaining a safe working environment is a necessity when
working with hydraulic systems. Employees who operate
or work near these systems should know the risks and
potential for danger and thoroughly understand how the
equipment works. There are several key factors to be aware
of, including pressure, temperature, flammability,
mechanical and electricity.

Pressure: Operating pressures of hydraulic systems can

be up to 10,000 psi. With this much hose pressure, even
the tiniest of pinhole leaks can cause a serious medical
crisis. And if the assembly is not properly installed, the
couplings could come off and hit an operator or cause the
hose to spray dangerous fluids. In other instances, the
fitting could come apart and the loose hose could whip
around, endangering those in the vicinity.

Hydraulic Hose Safety Tips

When working with hydraulic hose systems make sure
to take caution in dangerous circumstances.
Do not touch or go near a pressurized hydraulic hose
assembly. If fluid punctures the skin, even if no pain
is felt, a serious emergency exists. Obtain medical
assistance immediately.
If whipping hose is a potential hazard, make sure to
restrain or guard the hose using clamps or protective
shielding.

Temperature: Most hydraulic systems typically operate

Precautions should be taken to eliminate all ignition

sources from contact with escaping fluids, sprays or
mists resulting from hydraulic failures.

at 150 to 180F, while others may go as high as 300F.

Hoses, liquids, fittings, adapters and other metal parts can
be extremely hot and, if touched, can burn skin.

When using mobile equipment, always chock the tires

to prevent rolling.

Flammability: Most hydraulic fluids that are not

comprised primarily of water are flammable when they
come into contact with sources of ignition, such as sparks,
open flames, extremely high temperatures, and hot
manifolds. Leaking pressurized hydraulic fluids can develop
a fine spray or mist that can explode when ignited, causing
serious injury, even death.

Mechanical: Hydraulic equipment parts move or rotate

at high speed with significant force. When a hose fails,
objects supported by fluid pressure can fall, causing serious
damage.

Make sure to turn hydraulic equipment off before

working on it. If you are performing maintenance on
plant equipment, lock the control box and tag it with
a warning sign stating DOWN FOR MAINTENANCE.
DO NOT TURN ON POWER. Or, if the equipment is
mobile, take the key and/or disconnect the battery so it
cannot be started.

Understanding the safety factors for hydraulic hose systems

and taking proper precautions to create a secure
working environment will help reduce accidents, injuries
and production loss.

Electricity: Electricity can create the spark that causes

a fire, explosion or even electrocution. During normal
equipment operation, workers may be exposed to electrical
hazards such as high-voltage power lines and underground
power sources. Most hydraulic hose is wire-reinforced,
making it conductive to electricity. Even non-wire
reinforced hose may be conductive through the rubber
compound itself or moisture that penetrates a pin-pricked
hose cover.

QUICK TIP:
Take responsibility for personal safety. Always wear safety
glasses, keep appendages away from moving parts, do not
wear loose-fitting clothing and make sure equipment is
securely mounted and connected.

Hydraulic Safety Solutions:

A Systems Approach
Selecting the right hoses and couplings for hydraulic
equipment is a key part of preventing safety hazards.
Suppliers offer hundreds of different types and styles of
hydraulic hoses, and thousands of different couplings
and fittings, but not all are ideal matches. Both Gates
Corporation and the Society of Automotive Engineers (SAE)
recommend against using couplings and hoses from different
manufacturers.

Although most American-made hydraulic hoses, and many

imported hoses, are built to conform to SAE specifications,
SAE allows a wide range of materials to be used. Hoses
from various manufacturers may have similar dimensions
and constructions, but different rubber compounds and
reinforcement materials, while couplings are individually
designed and tested to handle the hose manufacturers
unique products. Also, the proliferation of thread ends from
around the world in recent years has dramatically increased
the possibility of mismatching threads and seats on various
couplings. Just one improperly matched coupling could
cause a hose leak or the ends to blow off.

Taking a systems approach to hose selection ensures that

the hydraulic assembly is tested together with matching
components and is less likely to fail, reducing injuries.

LifeGuard Line-of-Sight
Sleeving System

Gates has engineered the first sleeving system

specifically designed to protect operators, equipment
and the environment from the hazards of catastrophic
hydraulic hose failure.
How it Works
The LifeGuard sleeve is slipped onto the hose and
clamped at each end. If a hose burst or pinhole leak
occurs, escaping pressures and fluids are contained
by the sleeve material and then exit the system via
openings at each end, creating a noticeable pool
of leaking fluid, alerting operators to the need for
replacement.
The LifeGuard sleeve was rigorously tested both in
the lab and in the field to verify its performance and
capabilities at typical fluid pressure and temperature
levels. It meets a variety of industry standards,
including ISO 3457, which requires operator protection
within a three-foot line-of-sight of any hose conveying
fluid above 725 psi at 120F (49C), and MSHAs
flame-resistance requirements.

Safety Factors for Industrial Hose Systems

Industrial hose applications are demanding. They operate at
higher working pressures and temperatures than hydraulic
applications and transfer hazardous materials, such as
corrosive chemicals, LP gas, petroleum products and steam.
However, much like hydraulic hose systems, If they arent
designed, installed and maintained properly, they can be a
huge safety risk, causing leaks, bursts, whipping hose, fire,
high force movement, explosions and electrocutions.

Industrial Hose Applications

Choosing the Right Hose

Typical industrial hose applications, as identified

An improperly matched hose can be a safety

by the National Association of Hose & Assembly

Distributors (NAHAD) include the following:
Air Hose
Asphalt
ChemicalPlastic Lined
ChemicalRubber Lined
Food HandlingRegulated
Food HandlingNon-Regulated
Lay Flat
Material HandlingBulk Transfer

nightmare. To find the proper hose for an application,

use the STAMPED acronym to remember important
characteristics.

Size
I.D. (inside diameter)
O.D. (outside diameter)
Length
Flow rate requirements (GPM for liquids;
CFM for gases)

Temperature

Material HandlingCement

Ambient temperature

Petroleum

Internal temperatures

Push On

Temperature impact on material being conveyed

Sandblast

Application

Steam

Where the hose will be used

Water/Multi-Purpose

How the hose will be used

How often the hose will be used

Industrial Safety Solutions:

A Systems Approach
As with hydraulic hose systems, if an industrial hose
is improperly matched with fittings from a different
manufacturer, it can pose a safety risk. Taking the time to
properly match all the components, or taking a systems
approach, is important for a safe working environment

Environmental conditions
Special hose construction needs
Conductivity requirements
Critical applications (flammable fluids,
compressed gas, steam, etc.)
Government or industrial standard requirements

Material Being Conveyed

Chemical name(s) and state(s)
Food, pharmaceuticals, cosmetics

Selecting the right hose will ensure proper performance for

the material being transferred. It will also minimize the risk
of property damage or bodily injury due to leaks, bursts or
ends blowing off. Use STAMPED to remember hose selection
characteristics.

Dry or powder
Liquid

Pressure
Working pressure
Maximum surge pressure

Keep in mind that taking a systems approach involves more

than a quick glance at a hose manufacturers chemical
resistance tables; it takes careful study and analysis.
Hose compounds with identical names are more complex
than they might appear. For example, a tube made from
the EPDM elastomer may differ from another EPDM tube
because of differing ingredients such as accelerators, age
resistors, vulcanization agents, carbon black or processing
aids. Due diligence in hose selection can create a safer
working environment and prevent costly accidents.

Vacuum

End Requirements
Type of end connections/couplings

Delivery
How many items and when they need to
be supplied
Special packaging or branding requirements

Other Industrial Hose

Selection Factors
Some additional industrial hose selection considerations from NAHAD are:
Abrasion

Permeation (vapor conveying hose)

Electrical conductivity

Pressure drop

Environment

Routing

Flammability

Salt water

Flow rate

Static electricity

Fluid velocity

Ultraviolet light

Movement (type, distance, frequency)

Vibration (frequency rate Hz,

amplitude G load)

Ozone

Dont forget to carefully consider fittings as well. Some factors to consider in selecting the proper hose couplings include:
Hose size
Compatibility with the material being conveyed
Installation design and attachment options
Corrosion resistance
Thread type (hose end and thread end)

CONCLUSION
Injuries incurred while working with hydraulic and industrial applications are avoidable. For a safe working environment, start
by taking a systems approach to selecting your components and follow up with regular preventive maintenance to ensure that
the proper precautions are taken to decrease injury and loss of life.

Additional Resources
Find information on Gates Fluid Power safety at www.gatesprograms.com/safehydraulics and resources related to E2E
industrial hose products at www.gatesprograms.com/hosesystems. Questions? Contact pa0000@gates.com.

TODAY'S ADVANCED
HOSE AND HYDRAULIC SYSTEMS

CHAPTER 4
Advancements in Hose
Monitoring, Diagnostics
& Identification Practices

As its tools and technologies advance, modern fluid power

systems are under greater pressure than ever before to perform
safely and precisely. Stronger performance leads to greater productivity and profits across a wide range of industries from
oilfield and mining to mobile equipment and marine. This
multi-chapter Gates Fluid Power eBook explores challenges in
the field and highlights innovative approaches to testing, safety
measures, and diagnostics and monitoring.
In this chapter, we examine the evolution of hose life monitoring
and diagnostic solutions.

HOSE MANAGEMENT
SOLUTIONS
When fluid power equipment fails, it is costly in terms of
time, money and production loss. All types of equipment
in the field, from drilling rigs to wind turbines, rely on hose
systems to operate efficiently. Monitoring the condition and

performance of hose systems and properly predicting hose

life can mean the difference between routine maintenance
time and catastrophic downtime.

Gates Hose Management

Services

Flexible Hose Assembly Standard (FHA) and

is designed to reduce risk in all aspects of
operations by:
Quantifying productivity requirements, safety
risks, and environmental risks.
Understanding customer FHA program and
usage.

Evaluating client practices and recommending

steps for improving FHA, QA and HSE.
Performing necessary installations and services
on-site.
Gates Engineering & Services (E&S) offers Gates
Hose Management, a risk-based management
program for hose assemblies. It is based around
the UK Offshore Operators Association (UKOOA)

Developing integrity-based inspection,

maintenance and recertification strategy.
Providing hose monitoring and diagnostics
powered by Gates Sentry Services for reliable
operation and continuous improvement.

For more information about Gates Hose Management Services, call 1-972-664-9287.
1

Temperature, Pressure & Hose Life

Traditional Hose Monitoring

& Identification Practices

Hydraulic hose life is impacted by a number of conditions,

but most instances of failure arise from issues found inside
the hose: extreme temperatures and significant changes in
hose pressure.

For years, mobile equipment operators and fleet

managers have relied on basic identification and monitoring
processes. Hoses have stainless steel tags affixed to them
that are logged for identification and operators keep records
of which hoses have been replaced and when. Hoses and
connectors are visually inspected at regular intervals to
check for signs of cracking, abrasion, wear, leaks, corrosion
or other indicators that indicate failure is imminent.

Exposure to internal or external temperatures that exceed a

hoses specifications can cause its synthetic rubber
compounds to harden, reducing flexibility and making it
more susceptible to cracking. Similarly, when a hose
operates at low ambient temperatures (-40 and lower),
it may become less flexible, brittle and crack.

Pressure also affects hose integrity. While a drop in

pressure from the time the fluid enters a hydraulic hose
assembly to the time it leaves is to be expected, it may be
necessary to control it for optimum system performance.

For most dynamic hydraulic applications, the minimum

burst pressure is four times the maximum working pressure
rating. The working pressure of any hose used should be
greater than or equal to the maximum system pressure.
This generally increases cycle life. In fact, Gates testing
has found that using a hose at 50% below its rated working
pressure will approximately quadruple the cycle life.

QUICK TIP:
The minimum impulse cycle life found in SAE J517 can be
used as an indicator of expected hose cycle life. However,
remember that different hose types, and in some cases
hose sizes, have different expected cycle lives.
Some hose manufacturers have products
that far exceed SAE minimums.

While its necessary to ascertain the external condition of a

hose with a visual inspection, to get a clear picture of the
state of the hose, internal factors such as temperature and
pressure need to be closely monitored as well.

While visual inspections have been the most common way

to inspect the hose assembly, operators have the option of
paying for costly fluid chemical analyses and filter
inspections to try to establish internal hose conditions.

Unless there are warning signs, there is no clear indication

that a hose will fail simply due to age. Typically, hoses are
replaced in accordance with manufacturers suggested life
and operational experience.

Traditional hose monitoring methods rely heavily on visual

examinations and require a lot of maintenance time.
Factors on the inside of the hose play a large part in the
overall hose life, and relying solely on the external
conditions of the hose misses that key component. An
operator may replace a hose that has valuable service life
left too soon based on the manufacturers recommendations. Or he may not realize that pressure spikes and
temperature within the hose have degraded the hose quality
so much that failure (and possibly injury or costly cleanup)
is imminent.

New Technology for Hose Monitoring,

Diagnostics & Identification
Todays technology enables companies to streamline their
hose management processes. Identification, monitoring
and diagnostics are no exception. While stainless steel
tags and manual logs have long been standard, new radio
frequency identification (RFID) and tagging have
revolutionized monitoring practices.

Instead of identifying hoses using stainless steel tags,

high-tech RFID tags can be affixed to all hose assemblies
in the field. Each tag, when scanned by a hand-held RFID

reader, provides data including hose type, size, length, end

fittings, location, orientation, test certifications, assembly
notes, bill of materials (BOM) and other important data.
The information can be read or updated on-site and
synchronized with a PC database. If a hose needs to be
serviced or replaced, personnel can easily scan the tag to
obtain its information and determine the correct assembly.
Taking the process from manual to digital, RFID tagging is
efficient, saving time and money.

Gates Sentry Services

RFID 101
Radio Frequency Identification (RFID) is a technology
that uses radio waves to transmit information from
electronic tags to a reader in order to identify or
track objects. An RFID system consists of a tag that
includes a chip and antenna, and a reader. The RFID
reader transmits radio waves to the tag at a specific
frequency. Upon receiving them, the tag sends back
information to the reader. The reader then translates
the waves into digital information and pulls relevant
data from the computer database. RFID tagging is
used on several objects, from pets microchips to
library books. Even casinos use the technology.
They place RFID tags on high-value chips in order
to identify counterfeit chips and instances of card
counting, and to track betting habits.

Gates Sentry Services, a comprehensive preventive

maintenance solution, allows fleet managers and
equipment operators to estimate remaining hose life
and accurately identify hoses that need to be replaced.
Sentry Services consists of Sentry IQ and Sentry
ID:
Sentry ID offers real-time monitoring and diagnostic
information about the current operating condition and
performance of hose assembles. It provides warnings
based on a pre-established set of reporting parameters:
Service warning for any of the monitored hoses
Warning of over-temperature or over-pressure
conditions

While visual hose inspections are still necessary, installing

sensors on different parts of each hose in a system allows
operators to monitor pressure pulsations and temperatures
for each hose. This information is sent to an electronic
control unit (ECU), which can be programmed to calculate
a hoses remaining service life and warn users of
out-of-spec conditions. The data can help personnel
determine when to order replacement parts and anticipate
downtime, reducing the likelihood of unexpected
catastrophic hose failure and helping control costs.o

Warning of any system faults such as failed sensors,

cabling or ECU
Sentry ID is an RFID tagging system that identifies and
tracks specific hose assemblies worldwide.
High-frequency Sentry ID tags provide easy field access
to any hose data deemed important. This includes,
but is not limited to, hose type, length, location, size,
bill of materials (BOM), assembly notes, maintenance
records, photographs and installation instructions.
For more information about Gates Sentry Services, visit
www.gatesprograms.com/sentryservices.

CONCLUSION
Visually inspecting external hose components is an important part of preventive maintenance. However, to truly understand
hose condition and predict remaining service life, it is necessary to use available technology to monitor temperature and
pressure changes inside the hose. Recent advances in RFID technology help streamline the maintenance process, preventing
catastrophic hose failure, reducing downtime and saving money.

Additional Resources
Find information on Gates Fluid Power hydraulic hose, couplings, crimpers and accessories at
www.gatesprograms.com/hydraulics. and resources related to E2E industrial hose products at
www.gatesprograms.com/hosesystems. For information about Sentry Services, visit
www.gatesprograms.com/sentryservices. Questions? Contact pa0000@gates.com.