Man Uli Technical Manual

cop manuale:cop manuale 17-03-2009 12:13 Pagina 1
MRI 030974
MANULI RUBBER INDUSTRIES S.p.A. MANULI HYDRAULICS FAR EAST Pte. Ltd.
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TECHNICAL MANUAL
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001_008_introduction:001_008_introduction 31-03-2009 17:50 Pagina 1
INDEX
1. INTRODUCTION 3
• Introduction 4
• Warning on safety 6
2. BASICS OF HYDRAULICS 9
• Hydraulic systems and fluids 10
• Basics of hoses and assemblies 14
• Hoses description 14
• High pressure hydraulics: main applications 17
3. HOSE SELECTION 19
• Introduction 20
• Rubber hose structure 20
• Hydraulic hose international standards 22
• Hose selection criteria 24
• Storage and shelf life conditions 39
• Manuli recommendations 41
• Service life considerations 43
• Hose assembly routing 47
4. COUPLING SELECTION 49
• Introduction 50
• How to identify fluid connections 53
• End-thread measurement 55
• Couplings selection criteria 56
• MF2000 Manuli part numbering system 60
• Termination ends and torque values 66
• SAE Standard connections 66
• Metric couplings 71
• BSP (British Standard Pipe) 74
• Japanese Style fittings - JIS B 8363 76
• NF French Standard connections 77
• OEM Special connections 78
• Torque values details 79
• O-Ring recommendations 82
• Adaptors 84
• Port dimensions 85
5. MINING 91
• Introduction 92
• Mining product range 92
• MDG41 Compliance 96
• MF2000 Manuli partnumbering system 97
• Mining adaptors part numbering system 98
• Mining staples part numbering system 101
• Mining ball valves part numbering system 101
6. QUICK COUPLINGS 103

• Introduction 104
• QSafe applications 104
• Structure of a quick-coupling 105
• QSafe product range 108
• QSafe part numbering system 113
7. REFRIGERATION 117
• Refrigeration applications 118
• Hoses and fittings 120
• Refrigerants and lubricants 123
• Specifications 123
8. HOSE ASSEMBLY 125

• Hose assembly data 126
• Cleaning, inspection, testing 128
• Hose assembly installation tips 129
• Hose protection 131
• European legislation on safety and conclusion 134
9. MAINTENANCE 135
• Maintenance 136
• Periodic inspections 137
• Hose assembly troubleshooting guide 140
10. APPENDIX 147

• System of units and conversion 148
• Glossary 152
• Type approvals 165
www.manuli-hydraulics.com
info@manulirubber.com
Introduction
INTRODUCTION
The purpose of this booklet is to provide technical information Remark
to support customers, OEMs and users for a proper selection,
4 Information contained in this document is
installation and use of the Manuli products. intended for guidance only and may be
subject to change. Any change will be
Manuli offers an integrated hydraulic product range of fluid notified (at the discretion of Manuli
connectors, hose assemblies, hydraulic hoses, couplings, Rubber Industries) via selected communi-
cation channels.
adaptors, accessories and crimping machines.
Catalogue describes the complete product range, while the

present technical manual has the target to advise you how to
proper install and maintain hydraulic products. FLUID CONNECTORS
PRODUCT RANGE
All Manuli hydraulic products will provide you with a long ser-
vice life if they are properly selected, installed and maintained;
the best way to achieve this, is a preliminary deep study of
the application in order to select the proper components
considering the mission profile and a preventive mainte-
nance programme.
Your system/equipment applications study will drive you in

the correct choice of the right Manuli components to achieve
reliable solutions, ergonomics and suitable hose configura-
tions, etc. This booklet suggests how to study the applications,
evaluating their severity and technical aspects, in order to
avoid potential mistakes since the preliminary design activities
ENGLISH / ESPAÑOL
of the system/equipment.
Preventive maintenance is especially important, in fact the

high pressures and temperatures which characterise hydraulic
applications make hose and fitting selection, installation and
maintenance critical. If done incorrectly, the risk of injury
and/or excessive and costly downtime increases. That’s why
there are several good reasons to implement a preventive
maintenance programme:
• improving workers safety;
• avoiding production downtime;
• reducing repairs costs, etc.
A preventive maintenance programme will enhance also the

productivity because your equipment will be in good operat-
ing condition at any times, minimising safety hazards.
Combining the proper Manuli high quality products with a

regular preventive maintenance programme, will keep your
hoses and fittings trouble-free for a long time. An effective pre-
ventive maintenance programme can be summarised in the
following key elements:
• proper hose and fitting selection, evaluating the application
type;
• proper assembly installation;
• maintaining a safe work environment;
• regularly scheduled inspections;

• troubleshooting (identifying problems and solutions);
5
• well-trained personnel.
Additional technical information on components and acces-

sories, are supplied in order to support the assemblers and
users: O-Rings dimensions, torque for coupling installation,
routing tips, appendix with measurement units conversion,
etc.
Safety applications training
The information and details provided in this manual are also
available through dedicated training courses. In addition,
Manuli application engineers are always available to assist
assemblers and OEMs on product applications. In case of
need, please contact your closest Manuli representative.
WARNING ON SAFETY
Never underestimate the power of a
blown hydraulic assembly. Serious injury,
6
death and destruction of property can
result from rupture or blow-off of a
hydraulic hose assembly.
Hoses:
• damaged or worn out
• incorrectly assembled or installed
• not properly selected for the intended use/application
are serious hazards.
Be aware of the dangers connected with hydraulic pres-

surised systems/components
Hydraulic fluid under pressure is dangerous and can cause
serious injury. Here are listed few common problems that may
arise during the use of hydraulic hose assemblies and systems
under pressure:
Pinhole
Hydraulic fluid, when released as a fine stream through a pin-
hole in the hose, can easily penetrate the skin. If this happens,
seek medical assistance immediately. Fluid injections are con-
sidered a serious injury requiring prompt medical attention.
Leak
Leaking hydraulic fluid is hazardous. In addition to making
workplace floors slippery and dangerous, leaks also contami-
nate the environment. Before cleaning an oil spill, always
check local regulations.
Burst
Whether due to improper selection or damage, a ruptured
hose can cause injury. If it bursts, people can be burned, cut,
injected or injured because of equipment malfunction.
Coupling blow-off
If the assembly is not properly made or installed, the coupling
could come off with subsequent risk for severe personal injury.
Whipping hose
If pressurised hose ends or end fittings come apart, the loose
hose ends can flail or whip with great force and fittings can be
thrown off at high speed.
Stored energy
Hydraulic systems sometimes use accumulators to store poten-
tial energy or absorb shock. This energy can create pressure
that keeps the system’s components moving. Charged accu-
mulators can be lethal. Always open the accumulator’s valve to
release pressure. Stay out of hazardous areas while testing
hoses under pressure. Use proper safety protection.
Due to the serious criticalities of hydraulic applications it is impor-

tant to select and install assemblies with proper criteria:
7
• select proper hose assemblies for the application, considering
the numerous factors and conditions affecting the function-
ality and technical ability of the hose to meet the require-
ments;
• hose assembly routing must not create an injury hazard or
damage to the hose;
• select hydraulic components so that the application's tem-
perature, pressure (including the possible peaks) and bend
radius do not exceed recommended component limits;
• never mix products from different manufacturers: evaluation
of hose and couplings combination requires relevant qualifi-
cation programs, including in particular impulse testing and
cannot be determined by a simple burst or proof pressure
test. Manuli disclaims all liability for any hose assembly made
in violation of Manuli recommendations, procedures and
current swaging data (the swaging chart is updated every
year);
• hoses must not be stretched, kinked, crushed or twisted
during installation or use;
• hoses must not be bent to less than the minimum bend
radius;
• do not use hydraulic hose to convey high pressure gases
unless specifically designed and qualified for these applica-
tions;
Follow good maintenance practices
• establish a program of inspection and eventual replacement
of hose assemblies, considering factors including:
- severity of application
- frequency of equipment use (mission profile)
- past performance of hose assemblies on the same equip-
ment (historical data)
• record maintenance data regarding inspections and testing
or substitution of assemblies, etc.
• only properly trained personnel should inspect, test or serv-
ice hose assemblies.
Avoid injury for operating personnel and users/others
• fluid under pressure can cause serious injury. It can be
almost invisible escaping from a pinhole, and it can pierce
into the body;
• do not touch a pressurised hydraulic hose assembly with
any part of your body;
• if fluid punctures the skin, even if no pain is felt, a serious
emergency exists and a medical assistance is necessary
immediately. Missing assistance can result in loss of the
injured body part or death;
• stay out of hazardous areas when testing hose assemblies
under pressure. Use proper safety protection;
• operating personnel must receive training on the use of

hoses, couplings and assembly equipment, hose installation
8
practices following the current operating manuals and
swaging data;
• use only new (unused) recommended hose and fittings
with the recommended swaging machines and correct
crimp information; ensure that your assembly equipment is
properly maintained and calibrated;
• operating personnel must wear safety glasses and proper
protective clothes;
• if there are risks impacting safety requirements install proper
protective shields and/or restraint systems (whipcheck) to
protect the personnel from potential failures of the pres-
surised hydraulic components;
• be aware that some hydraulic fluids are highly flammable.
Refer to SAE J1273 par. 4 specification for further details on safety aspects.
J1273
Recommended Practices
for Hydraulic Hose
Assemblies
009_018_basichydraulics:009_018_basichydraulics 3-04-2009 9:51 Pagina 9
Basics of Hydraulics
HYDRAULIC SYSTEMS AND FLUIDS

Energy transmission systems Load
Motors supply mechanical energy.
10
An electric motor gets its motion from an electric flow of ener-
gy, transforming it in mechanical power: supplying another
form of energy to be used otherwise. Also chemical energy is
transformed: a good example are diesel or petrol engines Actuator
whose movement supply energy.
Unfortunately this first transformation is often unsatisfactory for

the actual needs of many applications.
Not always the place where the action is required can be
equipped with a motor and a proper operator.
The solution to this problem can be found making energy flow Pump
from the prime mover to the application point.
A common way to do this is by the use of hydraulic systems.
Motor
Any mass can have potential and kinetic energy; a fluid can
also "transport" it from one point to another.
Tank
For example, waterfalls take advantage of the potential ener- fig. 1 - Hydraulic circuit with cylinder
gy linked to the different heights at which the water is before
and after the transmission. Load
Some turbines get their motion from the kinetic energy of the
used fluid.
Other systems (the ones we will deal with in this manual) use
Cylinders
an energy flow under form of pressure.
discharge lines
potential criticalities
Hydraulic circuits for hose assemblies:
negative load surges
A hydraulic circuit is a system to supply energy, transported by
means of a fluid under pressure.
Pump outlets
A prime mover drives generally a pump whose task is to send potential criticali-
a fluid into a circuit: it converts the mechanical energy of the ties for hose
assemblies:
motor into fluid power.
- pressure surges
The fluid moves along a pipeline and reaches an actuator: - vibration
generally a cylinder but often also a hydraulic motor (rotary - temperature
- severe
actuator). installations
The described circuits can be represented by simple schemes
related to a system with a linear actuator (cylinder), similarly in
the case of rotative actuators (hydraulic motors). fig. 2 - Basic hydraulic circuit
The pipeline
The pipeline conveys the fluid; it may be built either with rigid
steel pipes or with flexible hoses or also using a combined
solution.
Many applications would hardly accept a rigid pipeline; often

the connected parts are in relative motion between them-
selves and a flexible hose suits at best the needs.
Moreover, using fluid transmission mainly in engines operating fig. 3 - Hydraulic cylinders
at high speed, the systems have also a lot of vibrations; a

flexible part in the system can better absorb them so to create
11
a sort of insulation.
Flexible hoses will be widely described in this manual; basically

the hose consists in a rubber tube winded up by a reinforcement
and covered with a rubber or textile layer. The reinforcement
consists in steel wires or textile yarns spiralled or braided
around the tube (generally 4÷6 wire spirals or 1÷2 wire or tex-
fig. 4 - Hydraulic motors tile braids).
The actuator
The most frequent actuator met in hydraulic systems is a cylin-
der. Cylinders may be single or double effect:
• Single effect cylinders consist in a tube in which a piston is

pushed by the pressurised fluid. These applications generally
use gravity to end their cycle and return to the start position.
fig. 5 - Single acting cylinders • Double effect cylinders have a piston with a non constant
diameter: for the whole length the piston's diameter is smaller
than the internal diameter of the cylinder; generally in the
centre of the piston the diameter is nearly equal so to have
at disposal two surfaces to "convert" pressure in force.
The circuit will direct the fluid to one or the other of the inlets
moving the piston, in one or the other direction.
The cylinder bears two oil inlets at each end.

fig. 6 - Single acting cylinders
Single acting cylinders and Double acting cylinders are repre-
sented in the schemes at side.
Other types of actuators, for example hydraulic motors, are

currently used to transform hydraulic energy into mechanical
power.
The fluids
The most common fluid is certainly water; yet most of the cir-
cuits we are describing use oils to convey energy.
fig. 7 - Double acting cylinders
Actually the first systems used water and only with increasing
complexity of technology oils started to be used.
The necessity to change came because water couldn’t assure
the required properties: first of all a lubricant action, but also
the absence of corrosive action and sediments, no evapora-
tion at higher temperature and therefore a higher boiling tem-
perature. These properties can be found with mineral oils.
An oil pump can work at about 2000 cycles/1'. This means it
can be directly connected to the motor. Using a water pump
fig. 8 - Double acting cylinders between it and the motor requires a speed reducer as the
maximum number of cycles of this pump is about 200 (the

motor can't work directly at such a slow rate).
12
The necessity of a reducer leads to greater sizes of the whole
equipment creating space problems.
Furthermore while water causes oxidation and corrosion, oil
protects the material of the pump assuring a longer life of the
engines.
From a chemical point of view oils have generally higher boil-
ing temperatures than water, so they can be used at higher
intensity gaining productivity. fig. 9 - Pump
The difference in price purchasing oil instead of water is certain-
ly covered by the advantages here mentioned.
The most common oil used in hydraulics is mineral based.
Lately it is becoming necessary to use environment-friendly
fluids. These fluids are bio-degradable and commonly called
bio-oils. Their use is constantly increasing replacing mineral oils.
Basically bio-oils can be divided in four families depending on

the base material they are made of:
1. Polyethylene glycol base
2. Rape-seed oil base
3. Synthetic-ester base
4. Water based oil
1. Polyethylene glycol base - This family presents raw mate-
rial available at a relative low price and a wide temperature
range. Yet these oils are watersoluble so they can let water
inside and damage the motors they are used for. Furthermore
they are absolutely not mixable with mineral oils.
2. Rape-seed oil base - These oils have cheap raw materials

as well and have a good compatibility with paints.
Unfortunately the operating temperature range is not very
wide due to bad working conditions at low temperatures and
low stability at high temperatures. They are mixable with
mineral oils but this mixability isn't very good.
3. Synthetic-ester base - Long life and a very wide tempera-

ture range are the top performances of this family. Of course
their price is higher than the others. The compatibility with the
mechanics of hydraulic systems is also very good.
4. Water based oil - Water based oils are fire resistant, envi-
ronmental friendly and acceptable. Their price is quite high,
and present limited maximum service temperature.
Also water is still used in certain applications but mainly where

it is directly used as working fluid and its consumption is sub-
stantial: water cleaning and water blasting are examples
where the pressurised fluid carries out its function and gets
lost. The main difference between these two applications is
the level of pressure at which the water is used.
While water cleaning applications utilise pressures from 100 to

400 bar, water blasting reaches 1450 bar and, water cutting
13
even to 2000 bar. It's clear that the first is for domestic applica-
tions while the second for industrial ones.
Important characteristics to define a fluid are its density and vis-
cosity.
The density (usually identified by ρ) is the quantity of mass per
volume and measured in kg/m3.
Usually the reference is taken at 20°C and the value is about
870-900 kg/m3 (water has ρ = 1000 kg/m3).
The viscosity is a measure of the resistance of a fluid to creep.
Both kinematic viscosity ν and dynamic viscosity η can be
used; their relation is η = ρν.
Kinematic viscosity is measured in centiStoke (cSt): 1cSt=10-6 m2/s.

Dynamic viscosity in centiPoise (cP): 1cP=10-3 N s/m2.
Hydraulic energy
Hydraulic energy is usually identified by the letter H and meas-
ured in meters.
It can as usual be divided into two parts: potential energy and
kinetic energy; the potential energy itself can be considered as
due to position (identified by z) and to pressure. Kinetic ener-
gy is due to the fluid’s velocity and goes with its square value.
The corresponding equation is:
γ is the specific weight
The applications we are interested in, using hydraulic hoses,

transfer energy under form of pressure; that is the second term
of the equation above, remains the one to be considered.
Just to give an idea about the importance of the three terms

let's suppose a 4m long hose of 12,7 mm of diameter, operat-
ing at 100 bar, with a water flow of 50 l/1’:
z can be at maximum 4m (hose completely vertical)

100 bar = 10000000 N/m2;
γ = 1 kg/l = 9810 N/m3 --> p/γ = 1019 m
Q = 50 l/1’ = 0,000833 m3/s
Q = v . πd2/4 --> v = 4Q/πd2 v = 6,58 m/s
g = 9,81 m/s2 --> v2/2g = 2,21 m
It can be noticed how pressure energy takes part for 99,39 %

to the total so it can be considered alone for any calculation.
BASICS OF HOSES AND ASSEMBLIES

A flexible conduit to transfer fluids or gases from one point to
another is called hose assembly.
14
An assembly is basically built with the hose itself, and the
extremity connections, solid couplings or fittings.
The hose is the flexible part of the assembly; its structure

depends on the application and on the environment.
Basically the inner most part of the hose is the tube, winded
up by a reinforcement and completed with a cover.
To connect the hose to the outer system and prevent leakage,

dedicated fittings are used. They are put at each end of the
hose and crimped to force a tight seal on the tube.
Fittings can be either permanent or reusable depending on
the application.
The interface between hoses and fittings is a very important

point in the design of the system: their functionalities are of
utmost importance for a correct application.
HOSES DESCRIPTION
Tube
As described above the inner part of a hose is the tube; its
function is to contain and convey the service fluid.
Furthermore it also protects the outer elements of the hose
from the possible aggression of the conveyed fluid.
The material of the tube is chosen among a great number of
synthetic rubbers. The chemical composition of the com-
pounds should be selected to meet the requirements of the
applications.
Basically there are some typical families of material assuring
special properties; the following list shows the most used:
Tube materials
NBR (Nitrile Butadyene High resistance to mineral and
Rubber) biodegradable oils and fuels
CR (Chloroprene) Mineral oils resistant
Polyammide Resistant to wide range of fluids

High temperature, oil, fuel and
PTFE chemicals resistant
EPDM (Ethylene Propylene Used for phosphate ester based fluids
Diene rubbers)
Reinforcement
The tube itself can surely not assure the resistance to the pres-
sure of the conveyed fluid; in fact, as mentioned above, the
design of the tube considers only its compatibility with the fluid
to contain, while the very wide range of pressures present in
hydraulic applications must be analysed otherwise.
Rubber cover This element was properly called reinforcement as its duty is to
give pressure performance to the hose.
Steel braid 15
The type of reinforcement classifies hoses in two basic families:
Rubber tube
• Braided hoses
• Spiral hoses
The pressure resistance of the hose must be higher than the

working pressure. The safety factor is defined as the ratio
fig. 1 - Single braided hose between the burst pressure and the max working pressure; for
Rubber cover the hydraulic applications the safety factor is set to 4:1 by
2nd braid International Standards, some special static applications as
Adhesive rubber layer water cleaning for example (ISO 7751) have 2,5:1 safety factor.
1st braid For low pressure applications (up to 100 bar for example), tex-
Rubber tube tile reinforcements may be used. So nylon, rayon or polyester
fabrics are woven, braided or wrapped around the tube.
When the pressure gets higher stronger materials are needed
and steel wire spirals or braids are used.
Wire braided hoses bear generally one or two layers of rein-
fig. 2 - Double braided hose forcement (in some cases even three) while spiral ones have
Rubber cover commonly four or six spirals (layers).
Body spiral carcass The application of braids and spirals can also be mixed
depending on the most appropriate design.
Inner Between each layer of braids or spirals an interlayer or breaker
breaker strip is put to create a bonding effect and to prevent frictional
wear between the wires.
Adhesive
rubber layer Cover
Rubber tube Environment, machines and operators themselves can damage
fig. 3 - Spiral hose (4 spirals) the reinforcement. The cover, outermost element of the hose,
Rubber cover is used to protect it.
Body spiral carcass There are several types of cover, each designed depending on
specific requirements: economy, safety, abrasion resistance,
Inner
chemical resistance, etc.; even aesthetics are features linked to
breaker the choice of the cover (e.g. colour).
Adhesive
Rubber cover can have wrapped finish: instead of the smooth
rubber layer finish a wet nylon tape is used around the hose during the vul-
Rubber tube canisation; at last the nylon tape is removed and leaves the
fig. 4 - Spiral hose (6 spirals) hose bearing its imprint.
Free steam vulcanisation is also used: the hose is directly vul-

canised without any wrapping or shaping method.
The vapour steam at high temperature is directly in contact
with the outer rubber cover of the hose.
This allows to save some steps of the entire manufacturing
cycle saving time and materials.
Particular attention must be paid to maintain the tolerances
and to avoid local defects on the cover.
Cover finish is smooth.
Also fabric braided cover are yet used: the cover is braided
fabric, often impregnated with rubber adhesive. This is the
16
best solution when minimum weight and heat dissipation are
required. This solution is usually used on low or medium pres-
sure hoses due to its relative weakness (e.g. R5 hose type).
Coverless type is usually only used for stainIess steel braided

hoses, mostly PTFE hoses.
HIGH PRESSURE HYDRAULICS: MAIN APPLICATIONS

Construction and public works
• road pavers
17
• construction equipment
• earth moving equipment
Well known applications use Manuli Rubber Industries universal
product range. Tractor® hoses are widely used; for heavy
applications Rockmaster ® covers is better suited for high abra-
sion resistance. On big machines the Manuli Rubber
Industries Extreme product range is recommended in order
to offer performances exceeding the standard requirements.
Underground and open pit mining

• long wall support
• open pit mining equipment
• drilling machine
For these applications Manuli Rubber Industries recommends
Rockmaster ® and Shieldmaster ® product ranges offering the
highest abrasion resistance, flame retardant properties of the
cover (MSHA approval, etc.), ozone resistance, cover shield.
Energy
• off-shore oil platforms
The very severe atmospheric conditions require hoses with
cover compounds offering particular characteristics, such as
resistance to ozone and sea water. Manuli Rubber Industries
recommends the use of the Extreme Product range in parti-
cular NoZone hose are suitable for extended life exposed to
harsh weather conditions and ozone attack.
Logistics
• port equipment
• material handling
Applications working in continuous long term aging condi-
tions, where hose flexibility and high abrasion resistance are
required. Sometimes the twin hose version is requested.
Industrial machines
• production machinery
• injection moulding
• steel works
• marine fleets
Applications with continuous long term aging conditions,
where pressure rates and related peaks, together with the
heavy mission profiles require heavy duty hoses with specifics
well over the actual working pressures. The Manuli Extreme
hose range is suggested.
Industrial and maintenance services

• aerial platforms
• street cleaning machines
• airport equipment
Applications with continuous long term aging conditions, where

pressure rates and related peaks require, ozone, weather and
18
abrasion resistance.
The Manuli Extreme hose range is suggested.
Agriculture
• tractors
• combined harvester
• implements
Light duty applications for which the Manuli Universal product
range is fit for use.
Water blasting
• cutting
• waste removal
• descaling
Water blasting applications are growing in the industrial and
construction sectors. A key factor for water blasting equipment
is safety and key performances required are compactness,
lightness, flexibility and high abrasion resistance.
The Manuli Goldenblast TM range is dedicated to these appli-
cations
Water cleaning
• industrial cleaning
• paint removal
Water cleaning systems are used not only in the hobby appli-
cations but also in industrial sectors such as: agriculture, food
production, etc. Resistance to high temperature water and
high pressure are required, together with abrasion resistance
(for those hoses dragged along the ground).
Manuli Rubber Industries water cleaning offer is included in
the Universal hose range.
Refrigeration applications
• mobile refrigeration
• bus air conditioning
• off-highway vehicles a/c
Mobile refrigeration, bus air conditioning and off-highway
vehicles air conditioning use special hose assemblies offered
by Manuli Rubber Industries Refrigeration Connectors.
019_048_hoseselection:019_048_hoseselection 17-03-2009 16:45 Pagina 19
Hose Selection
INTRODUCTION
This section is presented as a guide through the basics of
hydraulic hose, fittings and assemblies to give the reader a
20
better understanding of proper hose selection, care and use,
as important component in modern hydraulic equipment.
RUBBER HOSE STRUCTURE

cover reinforcement inner
tube
Traces of history and reasons of development
The first really flexible rubber hose, was developed during the
1870's. This was a rubber-coated canvass fire hose that was fig. 1 - One braid hose
developed to replace leather hoses in use since the early
1600's. The first pressure rated hydraulic hose was on the mar-
ket in the mid 1920's, but development still had a long way to
go. The German Government did a lot to push development
of a reliable hydraulic hose because of a need to be able to
retract airplane landing gear to increase the plane's speed.
Braid
This was the beginning and from then it has grown at a spec-
tacular rate.
fig. 2 - Two braids hose
The primary reasons for this growth are:
• hydraulic systems can do more work and occupy less space
than mechanical systems that use gears, pulleys, belts or
chains;
• movement can be obtained between the various compo-
nents when using flexible hose;
• hose will act as a system shock absorber while rigid steel
tubing will not;
• hose will allow positioning of components almost anywhere;
no required alignment as with conventional mechanical
drives. fig. 3 - Wire spiral hose
Hose structure
Hoses that are used to convey liquid and or gas under pres-
sure are constructed in layers, and each layer is designed to fit
a particular need in the overall performance requirement.
Most hoses have at least three layers, which include the tube
or inner liner, one or more layers of reinforcement and the
cover. There are some hose types where the cover is also the SAE 100R4 Helix Wire
reinforcement.
fig. 4 - Suction hose with helix wire
Tube
The tube or inner liner is generally made of some type of syn-
thetic rubber or thermoplastic like nylon or polyester. The main
function of the tube is to convey the liquid, gas or a combi-
nation of the two. For this reason it must be chemically resist-
ant to the Fluid conveyed. Always consult the Manuli’s
chemical resistance information for proper selec-
tion.
Reinforcement
The reinforcement layer or layers, provide the strength to resist
21
system pressure. They can be made from textile materials or
wire. Some of the most common textile materials used are
polyester, polyamide and aramide. Wire materials can be car-
bon steel, stainless steel of different strength and thicknesses.
There are three common methods of applying the hose rein-
forcement. The most common is braiding, where the wire or
textile materials are interwoven, to realise hoses from the low
to high pressure range. For very high and ultra high pressure
applications the reinforcement is generally applied in spiral
configuration on the hose. Depending on the pressure range,
multiple layers of reinforcement can be used. Another type of
reinforcement is a combination of textile braiding and a helix
wire inserted between the layers of braid. The helix wire pre-
vents collapse under vacuum and is used in suction hose. (See
Figures 1, 2, 3 & 4)
Cover
The cover, as the name implies is the outermost layer of the
hose. It's main function is to protect the tube and reinforce-
ment from external damage. Cover materials are selected
based on their ability to resist abrasion, sunlight, chemicals and
extreme temperatures with consequent ageing effects.
Another function of the cover is to provide a place for the
manufacturer to identify the product. This branding or layline,
as it is called, will often contain the manufacturer's name, part
number, pressure range or application, size, date of manufac-
ture, industry specification, etc. A common industry specifica-
tion on hydraulic hose would be an ISO or SAE rating.
HYDRAULIC HOSE INTERNATIONAL STANDARDS

In order to have a better understanding of the selection crite-
ria for engineering, design and structure of hoses, it is useful
22
to introduce the main International Standards for wire braided
and wire spiral hoses.
Generally speaking, Europe and the markets traditionally
linked to Europe have the tendency to refer to EN standards,
while American markets and the market traditionally linked to
America have the tendency to refer to SAE standards.
Both standards specify the minimum requirements and char-
acteristics for all the different categories of hoses; among oth-
ers, these are the ones relevant to the scope of this manual:
* 100R1A, 100R1AT, 100R2A, 100R2AT
The norms specify mainly:

• the physical dimensions (internal, external diameters, cover
thickness etc.)
• hydrostatic requirements as the maximum working/burst
pressure
• the minimum bend radius
• the testing and qualification requirements.
In an effort to consolidate all norms, ISO standards are designed

to merge both SAE and EN. Gradually ISO specifications are
going to take place in the whole market:
Manuli Rubber Industries has a wide range of products that

covers all specifications of the international standards.
Manuli Product Range 23

Traditional
Current EN Manuli
ISO Standard International
Standard Hose Line
Standard
ISO 1436 - 1 ST EN 853 - 1 ST DIN 20022 - 1 ST
ISO 1436 - 1 SN EN 853 - 1 SN DIN 20022 - 1 SN Tractor / 1T
ISO 1436 - 2 ST EN 853 - 2 ST DIN 20022 - 2 ST Rockmaster / 2ST
ISO 1436 - 2 SN EN 853 - 2 SN DIN 20022 - 2 SN Tractor / 2T
ISO 1436 - R1A -- -- SAE J517 - 100R1A
Wire Braid ISO 1436 - R1AT -- -- SAE J517 - 100R1AT Harvester / 1T
ISO 1436 - R2A -- -- SAE J517 - 100R2A
ISO 1436 - R2AT -- -- SAE J517 - 100R2AT Harvester / 2T
ISO 11237 - 1 SC EN 857 - 1 SC -- -- Tractor / 1K
ISO 11237 - 2 SC EN 857 - 2 SC -- -- Tractor / 2K
ISO 11237 - R16 -- -- SAE J517 - 100R16 Lyte-Flex
ISO 11237 - R17 -- -- SAE J517 - 100R17 Harvester / 17
-- -- -- -- SAE J517 - 100R5 Cover
-- -- -- -- SAE J517 - 100R4 Spyrtex / K
ISO 4079 - 1TE EN 854 - 1 TE DIN 20021 - 1TE Multitex
ISO 4079 - 2TE EN 854 - 2 TE DIN 20021 - 2TE Astro / 2
Textile ISO 4079 - 3TE EN 854 - 3 TE DIN 20021 - 3TE Astro / 3
ISO 4079 - R6 EN 854 - R6 SAE J517 - 100R6 Multitex
ISO 4079 - R3 EN 854 - R3 SAE J517 - 100R3 Adler / 2
ISO 3949 - R7 EN 855 - R7 SAE J517 - 100R7 Hydroplast
ISO 3862 - 4SP EN 856 - 4SP DIN 20023 - 4SP Goldenspir / 4SP
ISO 3862 - 4SH EN 856 - 4SH DIN 20023 - 4SH Goldenspir / 4SH
ISO 3862 - R12 EN 856 - R12 SAE J517 - 100R12 Goldenspir / 12
Wire Spiral
ISO 3862 - R13 EN 856 - R13 SAE J517 - 100R13 Goldenspir / 13
ISO 3862 - R15 -- -- SAE J517 - 100R15 Rockmaster / 15
EN and SAE standards do not cover all the requirements in the

market. Therefore Manuli Rubber Industries also manufactures
hoses that have characteristics well beyond the international
specifications.
HOSE SELECTION CRITERIA

Proper hose selection is critical in order to realise a safe
hydraulic system. The first step in having a safe hydraulic sys-
24
tem is selecting components that meet the needs.
Compromises in hose selection may create situations of dan-
ger, as well as affect the performance and durability of the sys-
tem. The choice may work for the short run, but may not be
a good long-term decision.
The most important target in this activity is the safety.
Many interacting factors influence the hose service life and the
ability of each fluid-power system to operate satisfactorily. The
combined effects of these factors on service life are often
unpredictable.
Each system has to be carefully analysed in order to proceed
with a proper hose and related components selection, to cor-
rectly design routings, to meet the system performance and
reliability (hose service life requirements), and to minimise the
risks of personnel injury and/or property damage. The
“SEVEN EASY STEPS” is a useful method that must be carried
out for a preliminary analysis of the critical factors.
An effective way to remember the hose selection criteria is to

remember the word STAMPED, acronym of:
S = Size
T = Temperature
A = Application
M = Material to be conveyed
P = Pressure
E = Ends of coupling
D = Delivery (flow rate and fluid velocity).
Hose Size (Dash numbers)

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 or
excessive turbulence. Dedicated nomographics for
pressure loss and fluid velocity can be used to
determine the most proper hose size following the
over mentioned criteria. Alternatively the traditional calculation
schemes are also available on the Manuli web site.
In case of substitution of a hose on field applications, read the

hose size on the branding of the original hose; in case the
original hose branding is worn off, the original hose must be
cut and inside diameter measured for size.
Remark
Before cutting an original hose assembly, measure the overall
assembly length and fitting orientation. These measures will be
necessary to build the replacement assembly.
The hose size numbering systems

Different hose size numbering systems are currently used by
25
hose manufacturers to identify hose sizes:
• the “dash” numbering system: the I.D. (Inside Diameter) of
the hose is expressed in 1/16-inch increments. The dash size
coincides with the number of 1/16-inch increments of the
hose I.D.
Hose I.D.
Standard hydraulic R5 and PTFE hoses
hoses (ref. ISO 4397)
Dash No. Inches mm Inches mm
-2 1/8 3.2 --- ---

-3 3/16 5.0 --- ---
-4 1/4 6.3 3/16 4.8
-5 5/16 8.0 1/4 6.4
-6 3/8 10.0 5/16 7.9
-8 1/2 12.5 13/32 10.3
-10 5/8 16.0 1/2 12.7
-12 3/4 19.0 5/8 15.9
-14 7/8 - --- ---
-16 1 25.0 7/8 22.2
20 1 - 1/4 31.5 1 - 1/8 28.6
-24 1 - 1/2 38.0 1 - 3/8 34.9
-32 2 51.0 1 - 13/16 46.0
-36 2 - 1/4 - --- ---
-40 2 - 1/2 63.0 2 - 3/8 60.3
-48 3 76.0 --- ---
-56 3 - 1/2 89.0 --- ---
-64 4 102.0 --- ---
-72 4 - 1/2 - --- ---
• “inch” and corresponding “mm”

• also the DN (Nominal Diameter) ref. ISO 4397 in mm are
currently used as reference.
For example 3/8” ID=6/16 inch therefore the dash size is –06.
The corresponding value in mm is 9,53mm, the Nominal
Diameter by ISO 4397 is 10.
Exceptions to the hose size numbering system are PTFE hoses

and SAE 100R5 hoses (see the scheme here below).
The hose size numbering system
Hose is sized Hydraulic Tubing

on I.D. is sized on O.D.
SAE 100R5
and PTFE Tubing
Their size is designated by the tubing O.D. dash size which

they would replace. PTFE and SAE 100R5 hoses have the
26
same I.D. as that of the equivalent dash size hydraulic tubing
(SAE 100R5 hose type was the first hydraulic hose developed
to replace rigid tubing: that’s why it remains traditionally iden-
tified with the same sizing as tubing).
See the enclosed table of correspondence.
In order to select the hose ID, which suits the flow rate of oil
being pumped through the hydraulic system, the nomograph
provided in this Technical Manual can be used.
This diagram will help you to calculate the optimum hose
diameter starting from 2 known values:
a) max. recommended fluid velocity

b) flow rate of your system
As the correct fluid velocity choice is important to avoid turbu-

lence and excessive pressure loss (for suction lines the poten-
tial pump cavitation must be considered). Manuli reports the
following maximum recommended values:
Nominal diameter calculation
Flow Rate
500
100
400
75 350
Velocity 300
250
50
0,1 200
40
Diameter 150
0,5 30
0,2 4” DN 102 100
20
0,3 3” DN 76
1 70
60
0,4 2” DN 51 50
1,5 10
0,5 40
1 1/2” DN 38
2 1 1/4” DN 31,5 30
2,5
1” DN 25
3 5
1 3,5 20
3/4” DN 19 4
4
5/8” DN 16
1,5 5 3
1/2” DN 12,5
6
2 7 10
3/8” DN 10 2
8
9 5/16” DN 8
3 10
1/4” DN 6,3
4 5
15 3/16” DN 5 1
5 4
6 20
3
8 ft / s
0,5
10 2
0,4
m/s
0,3
0,25
1
gal / m
l / m
Max. fluid velocity limits m/sec.:

• Pressure lines up to Max. 8-10 m/sec.
• Return lines up to Max. 3-4 m/sec.
• Suction lines up to Max. 1,5 m/sec.
See also ISO 4413 specification
Knowing the flow rate of your system draw a line from this
point to the limit velocity and read the intersection with the
27
diameter line, the first upper value can be chosen for your
system. For example 70 l/1’ for pressure lines leads to a choice
of DN 19 (3/4”) considering maximum fluid velocity 5 m/s;
30 gal/1’ for return lines need DN 38 (1-1/2”)
Unlike hoses, hydraulic tubing is sized by its O.D. (Outside
Diameter). The number of 1/16-inch increments in its O.D.
represents its dash size.
Temperature
When selecting a hose, care must be taken to
ensure that the system fluid and ambient tempera-
tures, both static and transient, do not exceed the
limitations of the hose.
Operating temperatures specified refer to the
maximum temperature of the fluid being
conveyed. High heat conditions may have an adverse effect
on hose due to degradation of the rubber which will limit
hose usefulness and reduce fitting retention.
In some cases the fluid being conveyed will slow down this
degradation whereas other fluids may accelerate it. Therefore,
the maximum temperature of each hose does not apply to all
fluids.
Continuous use at maximum temperatures or near

the maximum rated temperatures will materially
reduce the service life of the hose (e.g. ref. DIN
20066, SAE J1273, etc.) and should always be avoided.
Continuous use at or near the maximum temperature rating
will cause a deterioration of physical properties of the tube and
cover, deterioration that will reduce the service life of the hose.
Also the external ambient temperature must be carefully con-

sidered:
• extreme cold environmental temperatures for the potential
hose cracks due to bend efforts;
• extreme hot ambient temperatures, in presence of irradia-
tion inside engine compartments, etc.,may have a high
ageing effect on the rubbers.
Most standard hydraulic hoses are designed to operate in the

temperature range between -40°C (-40°F) and +100°C
(+212°F), range generally considered as standard.
But also other categories of hoses exist: some hoses manufac-
tured with special rubber compounds are designed to operate
between:
• -40°C (-40°F) and 121°C (250°F): range considered high
temperature
• -55°C (-67°F) and 150°C (+300°F): range considered
extended temperature, etc.
For example, for extended temperature range applications use

Manuli EQUATOR™ hose (see the Manuli temperature range
28
categories).
Three main categories of temperature range
-40 100 continuous
ST
Standard Temperature 125 peaks
-40 121 continuous
HT
High Temperature 135 peaks
-55 135 continuous
ET
Extended Temperature 150 peaks
When selecting a replacement assembly, the same considera-

tions must be applied: fluid temperature and ambient temper-
ature must be carefully considered. The hose selected must be
capable of withstanding the minimum and maximum temper-
ature seen by the system. Care must be taken when routing
near hot manifolds: in extreme cases, heat shield may be advis-
able.
Additional information and limits on Manuli Rubber Industries
hydraulic hoses temperature ranges referred to specific fluids
must be checked on the catalogue or contacting Manuli
Rubber Industries specialists.
Application
When selecting a hose, it is basically important
determining where or how the hose or assembly is
to be used. To fulfil the requirements of the appli-
cation, additional questions may need to be
answered, such as:
• where will the hose be used?
• equipment type and mission profile?
• fluid and ambient temperature?
• working and surge pressures?
• minimum bends radius?
• excessive flexing movement?
• fluid compatibility?
• environmental conditions?
• external abrasive stress?
• what about vibrations?

• hose flexibility/structure?
29
• coupling termination end type and thread type?
• suction or return line application?
• routing requirements?
• safety and industry specifications to be met?
• external mechanical loads and/or unusual forces that need
to be considered
• antistatic and/or flame retardant cover requested?
• critical nature of the application (e.g. mines, etc.)
Let’s consider for example the harsh conditions covers, often

cause of failure. In general covers of hoses are subject mainly
to abrasion and ozone attacks. Working life can be substan-
tially reduced in conditions where the cover of the hose is
dragged against hard rough surfaces. The work in mines for
example or in some industries where the hose is rolled on
pulleys or rubbed against sharp angles is very demanding.
In this conditions standard covers are not recommended.
Rockmaster ® is a heavy duty hose line specially engineered for
applications such as marine & off-shore, forestry and mining.
Shieldmaster ® is a hose line with characteristics of abrasion
resistance even more extreme!
Under ISO 6945 abrasion resistance test, Rockmaster ® cover
outperformed the standard requirements by an order of mag-
nitude specifications requirements and Shieldmaster ® cover
was so resistant that the result has lost significance: the cover
offers a resistance at least 1000 times higher than required by
standards.
Abrasion Resistance ISO 6945 (2000 cycles, 2,5kg)
grams
lost 0,50
OFFERS
0,6
AT LEAST 1000 TIMES
0,5 HIGHER RESISTANCE
0,25 THAN STANDARD
0,4
0,3
0,05
0,2 0,01
1 < 0,001
<0,001
0,1
0
EN 853 Conventional PU
Rubber
In any case it is important always to ensure that the hose is fit

for the intended purpose.
Ensure also that the selected hose and fittings are either com-
patible or protected from the specific environment to which
they are exposed: severe environmental conditions such as
salt water, chemicals, air pollutant, ozone and sunlight,
etc. can cause degradation and lead to premature failure.
In order to support application engineers to carry out their

application analysis, a useful scheme is here enclosed as
30 a guideline. It is also useful for field test analysis.
Even though each application must be carefully analysed,

these are some general guidelines for the Manuli product
selection criteria and application families:
Hydraulic earth moving machines

The standard product are generally fit for use. The extreme
products meet and exceed the requirements. On big
machines the extreme products must be preferred.
Hydraulic agriculture machines

Light duty applications: the standard products are fit for use.
Hydraulic mobile equipment (trains, trucks, etc.)

They are very particular applications, where the pressure plays
a secondary role while the ozone, vibrations at high frequency,
high temperature, powder, mud, water and cleaning water
jetting with aggressive detergents require the use of the
Extreme hose range with eventually external protections.
Hydraulic continuous long term aging (industrial

machines, etc.)
Let’s take as reference the world of the presses (moulding
machines, etc.), where the pressure rates and the related peaks,
the heavy mission profiles (continuous 24 h per day), etc.
require selection of hose overdesigned respect to the actual
working pressures, because of the long term aging conditions.
Hydraulic systems on marine and off shore applications

The atmospheric conditions very severe require hoses with
cover compounds with particular characteristics, like the resist-
ance to ozone and sea water. The extreme products are for
sure the most indicated. Stainless steel fittings are generally
requested for naval and marine applications.
Mining applications, underground and open-pit mines

Critical applications. Recommendations: Extreme products
high abrasion resistant, flame retardant property of the cover,
skive fittings, avoid very small diameters, robust fittings, etc.
Forestry machines
Critical applications: high abrasion resistant cover, resistance to
high pressure, fatigue and twist, low bend radius, 3/4” and 1”
are the most common used sizes and 1/2” also. Wire spiral
solutions are suggested for the most severe conditions.
Lift
Large size braided hoses are fit for use.
Field analysis data
31
Customer Earth moving
Machine Agriculture
Hose
Transportation
Fittings Industry
Working pressure Static Dynamic Certification requested
Working pressure max/min Pmax bar Pmin bar
Pressure peaks P bar
Relief valve setup P bar Pump press. bar
Impulse frequency mi -1
Fluid velocity m/sec l/min.
Oil MINERAL BIO
Medium oil temperature T ∞C
Working time hrs/day h Total working h

time
Installation Fix Flexing
Vibrations
Anverage nr. of flexing per hour (frequency Hz,
amplitude +/- mm)
Near the
Min. bend radius mm mm fittings?
theoretical effective
External temperature T ∞C
Environmental conditions Weather Environmental Industrial cleaning
Abrasion Ozone
Date Name
Material to be conveyed
Some applications require special oils or chemicals
32
to be conveyed through the system. Hose selection
must assure compatibility of the hose tube, cover,
couplings and O-Rings with the fluid used.
Additional caution must be used in hose selection

for gaseous applications such as refrigerants, compressed air
or LPG, etc. When selecting a hose for gaseous applications
where permeation of fluid through the hose wall may occur,
consider the possibility of hazardous effects, such as explo-
sions, fires and toxicity. Refer also to applicable standards for
specific applications such as refrigerants. If fluids permeate
through the hose tube, consider the use of perforated covers
to prevent fluid cover blistering under the cover (pin-pricking).
Also ensure the compatibility of the system fluid not only with
the hose tube, but also with the braid, cover, fittings and other
components since permeation may expose the entire hose
assembly to the system fluid.
Regarding the hydraulic fluids, mineral & biological oils,

Manuli wire braided and wire spiral hoses have a wide inner
tube compatibility: spiral hoses are also identified by the BIO
logo on the hose lay-line. Anyway each single oil brand name
has to be carefully checked, seen the wide differentiation of
the additive packages used by many hydraulic oils producers
in their fluids. That’s why an intense activity of oil compatibility
is currently performed on the Manuli rubbers, as support to
customers and OEMs.
The hose selection activity must ensure compatibility mapping

of the hose tube, cover and fittings with the type of fluid to be
conveyed. If the end fitting type requires an O-Ring for sealing,
ensure that the O-Ring compound is also compatible with the
system fluid.
For tube compound evaluations, please refer to the Manuli
Rubber Industries Approved fluid compatibility chart following
the evaluation criteria supplied here below reported. For spe-
cific information, contact Manuli Rubber Industries.
For the mineral and biological oil classification you can refer to
the following table, summarising the main characteristics of
each family, advantages and disadvantages, and cost estima-
tion compared to the traditional mineral based.
For particular or unusual fluids check compatibility together

33
with MRI’s specialists.
Hydraulic oils classification

Oil Family Oper. Advantages Disadvantages Cost
Temp.
Mineral oils Low: -40 ∞C • The traditional solution, widely industrially • Not ecologically acceptable 1
High: +150 ∞C available, suitable for the majority of relevant
applications
• Low cost if compared to alternative solutions
Natural oil Low: -30 ∞C • Suitable for the majority of relevant • Limited by their poor oxidative 2 to 3
based High: +80 ∞C applications thermal and hydrolitic stability
Rape-seed • May bio-degrade in the system:
the oil stability is very susceptible
to water contamination
HETG • Possible strong odours in use
and formation of gums
Water based HF-A • FIRE RESISTANCE hydraulic fluids • Moderate hydraulic fluid 3 to 6
fluids Low: -5 ∞C • Similar applicability than polyglycols properties
High: +60 ∞C • For their high water content they
can be considered ENVIRONMENTAL
HF HF-C FRIENDLY & ACCEPTABLE
Low: -40 ∞C
High: +60 ∞C
Polyglycols Low: -50 ∞C • Limited to areas where water solubility is • Due to the high water solubility 5 to 7
High: +130 ∞C advantageous, for example, inland their use is somewhat limited or
(HEPG) waterways, spillage of non soluble products prohibited (Switzerland) due to
PEG results in a perceivable surface film the risk to pollute the
PAG • Areas where cleaning by simple water water-bearing stratum
PPG washing is employed may also benefit • Absorbed water can effect the
performances
Synthetic Low: -30 ∞C • Better stability than vegetable oils, wider • Stability can be affected by water 6 to 10
esters High: +90 ∞C range of successful applications contamination
• Diesters: used mainly in aviation, automotive, • The high cost tends to limit their
HEES compressor applications use
• Hindered esters: application similar to
diesters and also steel rolling or industrial
hydraulic
The hydraulic hoses of the Manuli product range are not designed for immersion in the service fluid. This type of special applications should be avoided or care-
fully studied with additional external protections for the hoses, selection of special hose types, e.g. with thermoplastic cover and validation on the specific appli-
cation. The turbulence of the fluid, the high temperature and nature of the fluid as well as other elements may impact the properties or integrity of the hose
cover material (the cover compound of the hose is designed may impact the properties or integrity of the hose cover material (the cover compound of the hose
is designed to resist to oil drops and extrernal agents, not immersion in the service fluid). For more detailed information conact Manuli Rubber Industries.
Pressure
Knowing the system pressure, including pressure
spikes, surges, etc. is of the greatest importance for
the hose selection process. The hose catalogue
working pressures must be equal to or greater than
the system pressure, including peaks. Pressure spikes
greater than the published working pressure will shorten hose
life and must be taken into consideration (e.g. ref. SAE J1273).
Pressure peaks must be measured with electronic devices
capable to record very short transients not measurable with
traditional analogical instruments.
The rated pressure of primary and eventual secondary valve of
the system gives an additional information of what can be the
maximum pressure peak inside the system. The Max working
pressure inside the system in fact cannot be simply equal to the

pump rated working pressure, but must consider also the
34
functional activities of the equipment (negative loads, vibra-
tions, etc.) and the consequent pressure peaks.
Be aware that hydraulic fluid under pressure can be potential-
ly dangerous!
Hose WP selection
hose WP
system WP
spikes
system pressure
history
time
"The hose working pressure should include the pressure surges

(spikes) that, even if not indicated on many common pressure gages,
must be identified on electronic measuring instruments
with a high frequency response"
• An explosive bursts or stream of escaping fluid can cause

damage to equipment or serious injury to persons nearby
• Highly pressurised fluid escaping from a small pinhole can
be almost invisible and yet exert extreme force capable of
penetrating the skin and other tissue, causing possible
severe injury
• Pressurised fluids, if released uncontrolled, can exert an
explosive force
• Hot fluids or chemicals can cause severe burns
• Some fluids are highly flammable, etc.
The maximum rated working pressure of any

assembly will be defined by the lowest working
pressure of the hose, the end fitting or any adaptor
(consequently it is recommended to select the proper cou-
plings and adaptors with working pressure higher or equal to
the hose one, never lower). Always take into consideration
any pressure spikes or potential pressure surges in the system,
but also the fatigue mission profile of the application, number
of pressure impulses per hour/day/year, in order to proper pro-
vide eventual oversizing of the hose reinforcement compared
to the minimum theoretical requirement. In particular also the
position of the hose inside the system must be considered,
seen the different functions: see the following scheme and
mission profiles of the applications.
35
Note Pressure (Power) lines

High pressure, may be also over 400-500 bar
For a proper hose selection in terms of
pressure resistance, it is also useful to Fluid velocity: Max. 8-12 m/s
consider the following working pressure Heavy duty working conditions (high fatigue stress) can be
classification, with progressive fatigue present, Manuli wire spiral and two wire braids hoses are
stress and consequent necessary design generally requested
criteria:
• low pressure up to 70 bar
• medium pressure up to 210 bar Suction lines
• high pressure up to 210-350 bar Low pressure (max 5-10 bar)
• very high pressure up to 350-420 Fluid velocity: Max. 1,5 m/s (to avoid pump cavitation)
bar or higher Resistance to vacuum is requested up to -0,83/-0,90bar
Large I.D. requested to reduce pressure drop
Spirtex/K and two wire braided hoses are designed for this
applications and in particular for vacuum resistance
Drain lines
Low pressure (Max 20-30 bar)
Fluid velocity: Max 3-4 m/s
Small bend radius requested
Large I.D. requested to reduce pressure drop
Return lines
Low pressure (Max 30-50 bar)
Fluid velocity: Max. 3-4 m/s
Vacuum resistance
Large I.D. requested to reduce fluid velocity and pressure drop
Multitex and Astro hoses line generally suitable
Pilot lines
Medium pressure (Max 100 bar)
36
Fluid velocity: Max. 5 m/s
Compact dimensions & flexibility are a “must”
Lightness is appreciated
The Manuli solution for pilot lines is Pilot hose
Ends of coupling
Select the proper end fitting from the Manuli cata-
logue, being careful to the maximum working
pressure of the termination end (by the reference
international specifications), in consideration of the
hose to which it is applied.
Additional considerations of mechanical robustness and seal-
ing capabilities of the termination ends can be advisable for
heavy duty applications and/or specific installations: refer to
the coupling selection criteria supplied in the relevant section
of the manual; contact Manuli Rubber Industries for specific
detailed information.
When replacing an assembly, identify end connections and
sealing surfaces. Once thread ends have been identified, con-
sult the appropriate section of the Manuli Rubber Industries
catalogue for specific part number selection.
Do not mix and match hose and fittings from different
suppliers: in fact relevant testing qualification programs are
necessary to validate the hose and fittings compatibility.
Hydraulic hose from one supplier is seldom compatible with
fittings from another; in any case the assembler is responsible
for the guarantee of proper compatibility existing between the
hose and fitting if the manufacturer prescriptions are not
correctly followed.
Ensure that the correct inserts and ferrules are chosen for the
hose type.
Delivery (Flow rate and fluid velocity)

When replacing an assembly, we can assume the
system is properly sized to efficiently transport fluid,
that’s why the same I.D. of the original hose can be
used.
Eventually it can be useful to determine if the
system is properly sized to efficiently convey the max. flow rate:
in this case follow the recommendations below.
If the system is new or altered, determine the hose I.D. needed

to convey the max. flow rate considering the maximum
recommended fluid velocities for each application type (pres-
sure lines, return lines, suction lines) and a max. pressure loss
inside the line, in order to avoid excessive friction, vibrations
and heat generation. The use of Nomographic Charts or cal-

culation schemes (see Manuli web site tool and the enclosed
37
table) can be useful to determine the minimum size needed
for the application, ensuring that the required system flow rate
is available avoiding excessive pressure drop from occurring.
Data needed to determine pressure drop are:

• Fluid type (specific gravity) and viscosity
• Fluid temperature (in order to calculate the correct viscosity
value)
• Flow rate
• Hose size and length
• Number and type of fittings
The traditional formula from hydraulics is the following:
dimensionally:
λt = friction factor (generally close to 0,03 for rubber smooth

tube hoses. It is an adimensional coefficient). λt depends on
viscosity and therefore on the fluid temperature.
l = length of hose (m)
δ
= fluid density (volumetric mass : kg/m^3)
v = fluid velocity (m/s)
d = Inside Diameter (m)
In addition the following parameters are requested:

ν = fluid viscosity (cSt): to determine the friction factor
Q = flow rate (l/minute) to determine the fluid
See the following table reporting pressure loss data for the
most common applications.
38
Pressure loss (bar) per meter of hose

viscosity (cSt) 20 - oil specific gravity 0,85
diameters (mm) 4,8 6,3 8,0 9,5 12,7 16,0 19,0 25,4 31,8 38,1 50,8
flow (l/m)
1 0,216 0,073
2 0,433 0,146 0,056 0,028
5 1,082 0,364 0,140 0,070
10 3,457 0,729 0,280 0,141 0,044
15 1,931 0,421 0,211 0,066 0,026
20 3,195 1,027 0,454 0,088 0,035 0,018
25 0,671 0,169 0,044 0,022 0,007
30 0,923 0,233 0,078 0,026 0,008
40 1,528 0,385 0,128 0,057 0,011
50 0,568 0,190 0,084 0,021 0,006
100 1,912 0,638 0,282 0,239 0,024 0,010 0,003
200 2,147 0,949 0,486 0,082 0,035 0,009
300 1,930 0,804 0,167 0,071 0,018
400 1,188 0,276 0,117 0,030
500 1,635 0,409 0,173 0,044
600 0,562 0,238 0,061
700 0,736 0,312 0,080
800 0,930 0,394 0,100
900 1,143 0,484 0,123
1000 0,582 0,149
See also the calculation tool on www.manuli-hydraulics.com
Table of oil viscosity according to temperature

3000
2000
1000
1) ISO VG 320
500 2) ISO VG 150
300 3) ISO VG 68
200 4) ISO VG 46
5) ISO VG 32
100 6) ISO VG 22
7) ISO VG 16
Viscosity mm2/s
50
30
20
15
1
10
8 2
6 3
4
5
5
4
7 6
-30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 200
Temperature °C
Note: Oil viscosity decreases when the temperature increases
STORAGE AND SHELF LIFE CONDITIONS

Hose, Connectors & Adaptors Handling,
Storage & Traceability – Hose
4 years 6 years
39
maximum age maximum utilisation
of hose material limit of hose line It is well known that, with time, rubbers age and their physical
2 years maximum properties change. Eventually, the same rubbers can lose their
storage duration optimal characteristics for the applications to which they are
production date production date dedicated.
hose material assembly
Consequently the targets for the storage methods of rubber
based products are aimed to avoid or reduce at minimum
fig. 1 - Hose storage and utilisation limits level the aging of rubbers:
according to DIN 20066, part 5.
• reduce the storage period to a minimum, considering rub-
bers are subjected to ageing with time;
• guarantee the best storage conditions, carefully considering
all the main parameters influencing the ageing process.
Also, hose storage requires particular conditions for the best

results in maintaining the products initial properties and
characteristics.
The following table lists the main specifications regarding

storage conditions for hoses:
specification issue date
ISO 8331 Ed. September 1991 - New Release 2007

BS 5244 Ed. 1986, reaffirmed 1996
DIN 20066 Ed. October 2002
SAE J1273 Ed. August 2004
Summary of their recommendations:
ISO 8331: Rubber and plastics hoses and hose assemblies –

Guide to selection, storage, use and maintenance
Max. storage duration
<4 years before assembly operation
<2 years for hose assemblies
If further storage periods cannot be avoided, hoses should be
inspected and/or tested before use (tests are not specified).
This specification does not state any max. service life duration
for the hose assembly.
The new release of 2007 doesn't report any storage life
duration requirements and refers to ISO 2230.
ISO 2230: Rubber products - guidelines for storage

Not specific for hoses but for rubber goods, classified in 3
groups (A, B, C).
Manuli products are classified as B, with this storage requirement:
• 7 years as initial storage period
• 3 years as possible extension after test
DIN20066: Hydraulic fluid power; hose assemblies; assessment

of service performance (fig. 1)
40
<4 years before assembly operation
<2 years for the assemblies
Stress conditions are quoted which are potentially able to reduce
the hose assembly service life.
A max. functionality period of 6 years is indicated including the
storage period as assembly. As a consequence each storage
period consumes an equivalent part of the service life of the hose.
BS 5244: Application, storage and life expiry of hydraulic rub-

ber hoses and hose assemblies
Max. storage duration for hoses and assemblies
<3 years: no tests required on the hose
• 3 - 5 years: hydraulic proof pressure tests required
• 5 - 8 years: hydraulic proof pressure tests, impulse test, burst
test, cold flexibility test, electrical test required
>8 years: hose to be scrapped
Max. storage duration for assemblies installed on stored equip-
ment
<3 years: no tests required on the assemblies
• 3 - 5 years: hydraulic proof pressure and burst test required
>5 years: assembly to be scrapped
The service life duration of a hose assembly is quoted as being
“dependent on the equipment” (to which the hose has been
fitted), therefore stating that a general estimate is not possible.
It advises that “records be kept for each type of equipment
with a view to establishing a working life for each particular
application”.
SAE J1273: Recommended Practices for Hydraulic Hose

Assemblies
Rubber hose:
<10 years in bulk form
<10 years for assemblies passing visual inspection and proof test
Thermoplastic or PTFE hoses: considered unlimited
The specification reports general requirements on factors that
can affect hose products in storage.
The specification does not give indications on hose assembly
service life duration, stating that it is unpredictable, considering
the combined effects of all the factors involved. Each system
has to be carefully analysed for the purpose.
The specification gives general criteria for a maintenance pro-
gram of hose assemblies, to be carried out by the users. The
maintenance program must suit the specific application and
each specific hose on that application.
The specification asks to evaluate factors such as the nature
and severity of the application, past history, etc., to establish
the frequency of visual inspections and functional tests.
In all the specifications, general storage conditions and installa-

tion guidelines are supplied. Generally the following parame-
41
ters are listed and relative qualitative suggestions are included.
Manuli recommendations for hose storage:

Max. 6 years storage for hoses, including max. 2 years
as assembly.
MANULI RECOMMENDATIONS
Temperature
Generally 0 to 35°C (preferably 15°C)
Humidity
Very humid or dry conditions should be avoided: the recom-
mended conditions are around and/or not higher than 65%
of relative humidity
Light
Hoses should be protected from sunlight or strong artificial
lights: it is generally suggested to paint the warehouse win-
dows with red or orange colours, and/or to maintain the
hoses stored in closed boxes.
Oxygen and Ozone

Mercury vapour lamps or tubes, closeness to high-voltage
electrical equipment, etc., should be avoided because of the
harmful effect of ozone on rubber based products.
Hoses should be protected from the circulating air and packed
in closed boxes.
Oils, solvents, greases

The potential contact of stored hoses with aggressive sub-
stances must be avoided.
Heat sources
Hose should be stored away from potential heat sources,
electric and magnetic fields
Storage areas should not be in the proximity of equipment that
may generate electrical or magnetic fields, or may be able to
induce currents in metallic parts, which in turn, generate heat.
Storage methods
Whenever possible hoses should be stored in a relaxed state,
without imposed stresses and strains.
Coils should be as large as possible and at least to the mini-
mum recommended hose bend radius.
Hydraulic hose should be stored in such a way to avoid abra-
sion of the external cover through accidental contact with
storage systems.
Handling methods
Hydraulic hose should be handled in a way that avoids possi-
42
ble impact damage or hose cover abrasion.
Additional Manuli Rubber Industries observations and

considerations:
Manuli Rubber Industries fully meets all the above mentioned
requirements regarding the storage conditions for hoses and
assemblies. Warehouses are designed to guarantee the best
storage conditions without any decay of the rubbers proper-
ties and product performances, ensuring that hoses are deliv-
ered to customers in optimum condition.
Should there be a problem related to a batch of hose then it

may be necessary to trace it back to the manufactured batch.
This can be achieved by recording the manufacture code
within the quality system. The batch number of Manuli hose is
the production date branded on the back of the hose.
In addition:
• Consideration should be given to stock rotation. Hose with
an older manufacture date should be sold first, (unless a spe-
cific manufacture period is requested). Manuli hose boxes
have a coloured circle on the box indicating the year of
manufacture.
• There appear to be no general international recommenda-

tions for the storage of connectors and adaptors, however,
it is important to take precautions to prevent damage or
deterioration.
• Connectors and adaptors are supplied in boxes with internal

protective plastic bag. It is preferable that they remain in those
boxes until ready for use. This will prevent accidental damage
and environmental attack. Connectors and Adaptors will dete-
riorate if subject to external influences such as dampness,
humidity and contamination. Contamination may become
lodged in the connectors & adaptors and cause eventual
problems when fitted to a hose assembly on an application.
Damage to the hose assembly and/or the application may
result!
• Connectors with O-Rings should be stored in their original

boxes and not exposed to day-light. They should also be
stored away from electrical equipment to prevent ozone attack.
• Care has to be taken to avoid damage to threads, as a result

of storage, handling and after installing onto a hose.
• External male threads & flange faced inserts are particularly

vulnerable and extra care during handling needs to be taken.
• All inserts fitted to hose assemblies should be capped to pre-

vent accidental damage and ingress of contamination.
43
• Should there be a problem related to a connector or adaptor
then it may be necessary to trace back to the actual manu-
factured batch. This can be achieved by recording the
manufacture code within the quality system. The box num-
ber gives this trace-ability.
• Connectors and Adaptors also have a coloured circle on the

box indicating the year of manufacture, therefore, the old-
est boxes would be bought to the front of the shelves with
newer ones being stored behind.
SERVICE LIFE CONSIDERATIONS
Hydraulic hose and hose assemblies have a limited (finite) serv-

ice life depending on the service conditions to which they are
subjected. A very severe application will result in a reduced life
duration, a less demanding application will result in a longer
service life for the same hose.
Submitting hose and hose assemblies to conditions more

severe than the recommended limits significantly reduces serv-
ice life; but also the exposure to combined functional parame-
ters closed to the recommended limits, for example constantly
at the maximum recommended operating temperature, use at
maximum rated working pressure and minimum bend radius,
etc. will reduce service life.
Eventual failures due to the missing use of proper selection cri-

teria for the components, installation and maintenance, may
result in injury to personnel and/or damage to equipment.
Hose assemblies must be preliminarily selected according to
the detailed guidelines supplied in this manual. In addition
when in service, they should be regularly inspected for dam-
ages according to the equipment preventive maintenance
program. Assemblies showing signs of wear or damage
should be replaced immediately; criteria to evaluate the hose
assemblies and their eventual replacement are (see also SAE
J1273) signs of significant deterioration, for example:
• leaks at hose, fitting or in hose;

• damaged, cut or abraded cover;
• exposed hose reinforcement;
• kinked, crushed, flattened or twisted hose;
• hard, stiff, heat cracked or charred hose;
• blistered, soft, degraded, or loose cover;
• cracked, damaged or badly corroded fittings;
• fitting slippage on hose, etc.
Maximum service life results can be achieved if the hose

assembly is subjected to correct functional conditions, com-
44
plying with recommendations outlined in this manual and the
catalogue.
The actual service life of a given hose assembly in a given
application is dependent on many variable factors, including
those below, the main ones affecting service life duration:
Hose selection and routing

Carefully analyse each system and application: design routings
(installation configurations) and select hose and related com-
ponents to meet the system-performance and hose-service-life
requirements, and to minimise the risks of personal injury
and/or property damage.
Torsions, reduced bend radii, external tensile loads and/or
crushing stress applied on the hoses should be avoided.
Excessive vibrations and/or severe flexing installations should
be properly studied in order to find suitable solutions.
Operating temperatures
Operating temperatures specified refer to the maximum tem-
perature of the fluid being conveyed. High heat conditions
may have an adverse effect on hoses due to degradation of
the rubber which will limit hose usefulness and reduce fitting
retention. In particular the applications for which permanent
high temperature level is present, may be in continuous
service 24 hours per day, must be carefully treated: continuous
use at maximum temperatures together with maximum pres-
sures should always be avoided. In fact they may cause a dete-
rioration of physical properties of the tube and cover, thus
reducing the service life of the hose.
Also consider that different fluids conveyed can cause involve
a different degradation of rubbers: that’s why the maximum
temperature of each hose does not apply to all fluids but must
be checked also in correlation to the fluid being conveyed.
Pressure surges
Generally, all the hydraulic systems develop pressure surges
(rapid transient rise of pressure) which may exceed also the
relief valves set up. Exposing the hose to surge pressures
above the maximum operating pressure will reduce the hose
life and must be carefully considered. It is also necessary to
know that most of the surges can be recorded only with elec-
tronic sensors due to their short duration, not being indicated
by many common pressure gauges: the hose selected must
have rated pressure higher than the maximum pressure peak
or surge of the system.
Ambient temperatures and environmental conditions

Very high or low ambient (outside the hose) temperatures, will
affect cover material and the hose structure, coupling area,
etc. thus reducing the service life of the assembly, involved by

the rubbers aging phenomenon, also affecting the fitting
45
retention capability.
Also the extremely severe environmental conditions such as
sunlight exposure, powder, abrasive contacts with stones, on
the ground, external bodies, etc. (e.g. under carriage applica-
tions on mobile equipment, marine/ships applications) must
be considered with a proper selection of the hose, for exam-
ple special cover compounds, special fittings, or dedicated
protections of the assemblies.
The severe environmental conditions, if present, must be prop-
erly considered in the selection of special compounds or the
study of proper protections and safety systems for the assem-
blies in order to avoid the life reduction due to fast aggressive
actions of the external agents on the hose/rubbers.
Chemical resistance
Consider the chemical resistance of the tube compound with
the working fluid, following the chemical compatibility chart
recommendations.
But also the cover compound has to be considered in this
analysis: covers are generally resistant to oil drops rather than
for complete immersion in the fluid, are resistant to cleaning
solvents diluted in the water, dust of grease, powder, drop of
fuels, etc.
Also fittings and O-Rings must be considered in the chemical
resistance analysis.
Improper selection of the products will lead to a potential pre-
mature failure of the assemblies.
Hose fittings
Manuli manufactures hose fittings to meet applicable interna-
tional standards. It is possible to select a fitting with a connect-
ing end that has a performance rating lower that the hose rat-
ing. In selecting hose fittings, please consider the performance
rating of the connecting end, avoiding potential leaks at the
termination end.
Maintenance
Hose assemblies in operation should be inspected frequently
for leakage, kinking, abrasion, corrosion or any other signs of
wear or damage. Worn or damaged hose assemblies should
be replaced immediately.
The influence of design on the expected life of hose

assembly.
46
Pressure surges and pressure spikes have tremendous effects on
working life of pressure hoses. For a quantitative approach on
the damage caused by pressure fluctuations it is possible to refer
to SAE J1927. Note that this spec. and its interpretation is only
valid for applications with variable amplitude pressure where the
majority of the peaks are between 100 and 200% of the rated
pressure. Within this range the damage is considered to be an
increase of the fatigue stress and therefore a reduction of the life
of the hose, higher peaks will create permanent damage of the
structure and eventually will burst the hose.
Considering the structural specifications defined in the norms it
is possible to construct a P-N “cumulative damage curve” based
on the tests (burst tests and impulse cycle tests).
As an example consider SAE 100R2 hoses: burst pressure is

defined as 400% of pressure rated and impulse point is defined
as 200,000 cycles at 133% of pressure rated.
Considering a cumulative damage curve following the equation,
Pa = Pb (N)S, where:
Pa = Zero to max amplitude of pressure cycle
N = Cycles of failure at pressure amplitude Pa
Pb = Burst pressure (one cycle life)
S = Slope of curve on a log-log plot
The curve can be represented as a straight line on a log-log curve.
% RATED 1000
PRESSURE
BURST
400
REF
P-N
CUR
VE
133% IMPULSE
100
1 10 100 1,000 10,000 100,000 1,000,000
IMPULSE CYCLES
The effect of the amplitude of spikes can be inferred from the

graph: consider that if 200,000 spikes of 133% of pressure rated
will not fail the assembly, while only 2,000 impulses of 200% of the
pressure rated can seriously impact the service life of the assembly.
On a system architecture design, the use of this graph is para-
mount: in applications where the maximum pressure and the
probability of occurrence of the spikes and surges are known, it
allows to select the proper hose. As long as the application defined
as a P-N combination is below the curve the hose is appropriate.
HOSE ASSEMBLY ROUTING

Here below some useful examples of correct routings in order
to design reliable solutions and increase the hose life duration.
47
Please refer also to the examples supplied by the SAE J1273
specification and ISO/TR 17165-2.
Under pressure, a hose may change in length. Always provide

some slack in the hose to allow for this shortening or elonga-
tion. It’s not recommended to have excessive slack (fig. 1).
If a hose is installed with a twist, operating pressures tend to force

it towards the straight position. The internal stress due to the twist
can cause reinforcement separation and the hose could burst at
the point of maximum strain or near the fitting (fig. 2).
On bended configurations, provide sufficient hose so that it

does not have a bend radius less than its recommended
minimum bend radius, in addition the hose is not pulled.
Too tight a bend may kink the hose and restrict or stop the
fluid flow. In many cases the proper use of adapters and hose
fittings (elbows 45°, 90°, etc) can eliminate tight bends or
kinks (fig. 3).
Avoid contact with objects that can cause abrasion or damage.

On moving applications, pay particular attention when specify-
ing hose length to avoid tensile stress or abrasion (fig. 4).
In applications where there is considerable vibration or flexing,

allow additional hose length. The metal hose fittings, are not
flexible, and proper installation protects metal parts from
undue stress, and avoids kinks in the hose (fig. 5).
When hose lines pass near an heat source, they should be

insulated by a heat resistant sleeve or shield, firesleeve or a
metal protection. In addition, the use of proper clamps keep
hoses in the right position and reduce risks of abrasions. For
installations where abrasion to hose cover cannot be prevented
with the use of clamps or brackets, a steel or plastic protective
spring or an abrasion resistant sleeve should be installed over
the hose (fig. 6).
Prevent hose bending in more than one plane: fix the assem-
bly into separate segments, by clamping hose at change of
plane (fig. 7).
Refer to SAE J1273 par. 5 for further details on hose selection and routing.
J1273
for Hydraulic Hose
Assemblies
Hose assembly routing

48
NO YES NO YES
wrong use correct use wrong use correct use
r < r min
abrasion
fig. 1 min. dist.
abrasion
fig. 4
fig. 5
fig. 2
High temperature parts
r < r min
r min fig. 6
fig. 7
r min 1,5 d
r min
For detailed information concerning

the recommended practices for Hydraulic
Hose assemblies, please refer to SAEJ1273.
This document should be used as a guide
to be considered when selecting, routing,
fabricating, installing, replacing, maintaining
and storing hose for hydraulic systems.
fig. 3
049_090_couplingselection:049_090_couplingselection 3-04-2009 10:14 Pagina 49
Coupling Selection
INTRODUCTION
50
fig. 1 - Fitting visual glossary
A hose fitting or coupling provides a latching system for the

hose to various hydraulic components. Hose fittings must
always be selected on the base of the application and the
hose manufacturers specifications.
Hydraulic hose fittings can be divided into two main cate-
gories based on their method of attachment to the hose. They
can be either reusable or permanently attached. Under
these two categories there are several variations.
fig. 2 - Standard fitting (Crimped skive)

Permanently attached
The most widely used type of hydraulic fitting, is based on a
method of attachment to the hose called permanent. It is
assembled on the hose in a manner which distorts the fitting
by compressing its outer shell (ferrule) onto the hose and can-
not be reused. There are two methods to install the perma-
nent type of fitting: one is called the crimp method and the
other is the swage.
The crimp method uses movable die fingers to generate a
radial force on the ferrule of the coupling to compress to a
controlled size onto the hose: this operation traps the hose
body between the fitting insert and the ferrule. fig. 3 - Interlock
Swaging uses a fixed diameter set of dies and the hose and
fitting are pushed through the centre to compress the ferrule
onto the hose.
The crimping method is the most used.
The result is always a permanent coupling attached to the
hose, that cannot be reused.
Hydraulics fittings are generally permanent fittings and require

crimping equipment to be assembled to a hose. They are avail-
able in either preassembled (“one-piece”) or two-piece con-
figurations. fig 4 - Screw together (Reusable)
51
fig. 5 - One piece configuration
fig. 6 - Two piece configuration
• “One-piece” (fig. 5) couplings are made with the ferrule

permanently attached to the insert (stem).
• “Two-piece” (fig. 6) couplings consist of an insert (stem) and
a separate ferrule.
When using two-piece couplings, it is important to match the
ferrule with its appropriate insert and hose.
There are also two types of ferrules: skive and no-skive. Skive
ferrules require the hose cover to be removed and crimps
directly onto the reinforcement wire, while no-skive ferrules
compress or grip the hose reinforcement through the hose
cover.
For heavy duty applications, large size of wire spiral hoses,

Manuli has engineered a special robust architecture of cou-
pling, called “InterLock” (fig. 3). Internal and external skive
operations are carried out in order to allow the insert and fer-
rule to grip directly onto the steel reinforcement of the hose:
this creates a sort of mechanical lock between the hose struc-
ture and the coupling. This architecture guarantees a particu-
larly reliable connection hose-fitting, important in special appli-
cations impacted by relevant stress or safety aspects.
None of these components, hose, insert or ferrule, are

reusable once they have been part of an assembly.
Reusable
As the name implies, this type of fitting can be reused. When
the hose needs to be replaced, the fittings can be removed
and applied to a new hose.
There are three very common variations of this type of fitting

and they are:
52
• Screw together
• Clamp type
• Push-on
The “screw together” type is usually two pieces, the ferrule and
the insert. The hose is screwed into the ferrule and the insert
is screwed into the ferrule and the hose, resulting in the hose
being trapped between the two steel components (see fig. 4). fig. 7 - Push-on (Push-lock)
The “clamp type” is made up of a nipple or insert which goes

into the hose and two clamp halves which are held securely
around the hose and the insert using bolts and nuts. There is
a locking area provided on the insert into which the clamp
halves fit to prevent the insert from being pulled or blown out
of the hose.
The “push-on type” is primarily used on very low pressure con-

trol or industrial applications. The insert has very large barbs on
the portion that fits into the hose and it is used without clamps
or ferrules. The hose used with this type of fitting is also specif-
ically designed to provide a tighter grip on the fitting as pres-
sure is applied (see fig. 7).
Coupling identification
A hydraulic coupling has two functional ends:
• the termination end (or thread end) for port or adaptor
attachment and sealing properties;
• the hose side end for hose attachment (fig. 1).
Termination end (thread ends and sealing surfaces) are identi-

fied by the reference international specifications (ISO, SAE,
etc.).
In case of replacement, the termination end of a coupling can
be identified by comparing it with the coupling being
replaced or by measuring the port or thread end to which it
will be fitted.
The termination end may be in many different configurations,
thread type, sealing surfaces configurations, with or without
O-Rings, etc.
Hose and thread ends are measured by industry standard
dash sizes. The hose and dash size refers to the inside diame-
ter in 1/16" (except for SAE 100 R5 and SAE 100 R14, which
are based on tubing O.D.).
The termination end depends on the hose type and size to

which it is attached (and the port to connect!). Coupling
design is specified by the hose manufacturer to meet hose per-
formance: Manuli presents the coupling type (insert and fer-
rule) associated on the hose data sheet (catalogue).
HOW TO IDENTIFY FLUID CONNECTORS

Measuring Tools
Proper tool kits are generally available from hose or fittings
53
manufacturers to identify the fluid connectors termination
ends. They are provided of a seat angle gauge, thread pitch
gauge and an I.D./O.D. caliper to make accurate measure-
ments of commonly used connectors, generally in a unique
useful tool offering all the capabilities.
How to measure threads

fig. 1 Threads are designated by diameter (external on the male and
internal on the female), and by the number of threads per
inch (Imperial system), or by the distance between each
thread in millimetres (metric system).
The Imperial system is identified in ‘teeth per inch’ (TPI).

The metric system is identified by prefixing the thread diameter
with an “M” followed by the pitch of the thread.
Examples:
fig. 2 3/8”-19 means thread diameter 3/8” and 19 teeth per inch
M22x1,5 means thread diameter 22mm with a thread pitch of
1,5mm
Use a thread pitch gauge to determine the number of threads

per inch or the distance between threads in metric connec-
tions. Place the gauge on the threads until the fit is accurate.
Match the measurement with the proper charts. Measure also
the thread diameter with an I.D./O.D. caliper. Match the
measurements to the charts (fig. 1-2).
fig. 3
How to measure sealing surface angles
Female connections are usually measured by inserting the
Read “Out” dimension
gauge into the connection and placing it on the sealing sur-
face. If the centerlines of the connection and gauge are paral-
lel, the correct angle has been determined.
Male flare type connectors are usually measured by placing
the gauge on the sealing surface. If the centerlines of the con-
nection and gauge are parallel, the correct angle has been
determined.
fig. 4 1) With the caliper measure the thread diameter at the largest
point of the OD in case it is a male thread, the ID if it is a
Read “In” dimension female thread (fig. 4-5).
2) Using the pitch gauge determine the number of threads

per inch (imperial thread) or the distance between pitches
(metric). Comparison of gauge and couplings threads against
a lighted background will ensure an accurate reading (fig. 3).
3) Match the measurement taken above against those in the

appropriate tables that appear to be similar to the coupling
fig. 5 under consideration.
4) Measure the seat angle: when the centre line of the seat
gauge extends parallel with the projected longitudinal axis of
54
the coupling, then the angles of the gauge and seat match centre Lines
(fig. 6, 7). are parallel:
RIGHT
5) Compare the measurement taken to the coupling standard
tables.
fig. 6 - Right seat angles
centre Lines
at an angle
WRONG
fig. 7 - Wrong seat angles

END-THREAD MEASUREMENT
To identify thread size termination end, measure the exterior

male thread diameter O.D: or the internal female thread diam-
55
eter I.D., then looking to the column mm, you will get the cor-
respondent thread size.
End-Thread Measurement
Male O.D. mm Female I.D. Male O.D. mm Female I.D. Male O.D. mm Female I.D.
- 8,5 3/8"-24 UNF - 19,2 1/2"-14 NPSM 1"-11 GAS 33,2 -

- 8,7 1/8"-28 GAS M20x1,5 20,0 - 1.5/16"-12 UN 33,3 -
- 9,2 1/8"-27 NPSM - 20,3 7/8"-14 UNF 1"-11,5 NPTF 33,8 -
3/8"-24 UNF 9,4 - 13/16"-16 UN 20,5 M22x1,5 - 34,0 M36x2
1/8"-28 GAS 9,6 - 1/2"-14 GAS 20,8 - M36x2 36,0 -
M10x1 10,0 7/16"-20 UNF - 21,1 5/8"-14 GAS - 39,1 1.5/8"-12 UN
1/8"-27 NPTF 10,4 - 1/2"-14 NPTF 21,6 - - 39,4 1.1/4"-11,5 NPSM
- 10,5 M12x1,5 M22x1,5 22,0 - - 39,5 1.1/4"-11 GAS
7/16"-20 UNF 11,0 - 7/8"-14 UNF 22,2 - - 40,0 M42x2
- 11,4 1/2"-20 UNF - 22,5 M24x1,5 1.5/8"-12 UN 41,1 -
- 11,6 1/4"-19 GAS 5/8"-14 GAS 22,8 - 1.1/4"-11 GAS 41,7 -
M12x1,5 12,0 - - 23,8 1"-14 UNS M42x2 42,0 -
- 12,2 1/4"-18 NPSM M24x1,5 24,0 - 1.1/4"-11,5 NPTF 42,4 -
1/2"-20 UNF 12,5 M14x1,5 - 24,5 M26x1,5 - 43,0 M45x2
1/4"-19 GAS 13,0 9/16"-18 UNF - 24,6 3/4"-14 GAS-NPSM M45x2 45,0 -
1/4"-18 NPTF 13,9 - - 24,9 1.1/16"-12 UN - 45,2 1.1/2"-11 GAS
M14x1,5 14,0 - - 25,0 M27x2 - 45,5 1.1/2"-11,5 NPSM
9/16"-18 UNF 14,2 - 1"-14 UNS 25,3 - - 45,7 1.7/8"-12 UN
- 14,5 M16x1,5 M26x1,5 26,0 - - 46,0 M48x2
- 14,6 5/8"-18 UNF 3/4"-14 GAS 26,3 - 1.7/8"-12 UN 47,5 -
- 15,1 3/8"-19 GAS 1.1/16"-12 UN 26,7 - 1.1/2"-11 GAS 47,7 -
- 15,5 3/8"-18 NPSM 3/4"-14 NPTF 26,9 - M48x2 48,0 -
5/8"-18 UNF 15,7 - M27x2 27,0 - 1.1/2"-11,5 NPTF 48,5 -
M16x1,5 16,0 11/16"-16 UN - 27,9 1.3/16"-12 UN - 48,8 2"-12 UN
- 16,5 M18x1,5 - 28,0 M30x2 - 50,0 M52x2
3/8"-19 GAS 16,6 - M30x2 30,0 - 2"-12 UN 50,7 -
3/8"-18 NPTF 17,3 - 1.3/16"-12 UN 30,1 - M52x2 52,0 -
11/16"-16 UN 17,4 3/4"-16 UNF - 30,7 1"-11,5 NPSM - 57,0 2"-11 GAS
M18x1,5 18,0 - - 30,9 1"-11 GAS 2"-11 GAS 59,4 -
- 18,5 M20x1,5 - 31,0 M33x2 2"-11,5 NPTF 60,6 -
- 18,8 1/2"-14 GAS - 31,2 1.5/16"-12 UN - 61,2 2.1/2"-12 UN
3/4"-16 UNF 19,0 13/16"-16 UN M33x2 33,0 - 2.1/2"-12 UN 63,3 -
COUPLINGS SELECTION CRITERIA

Several factors, such as thread end compatibility, pressure
and mechanical resistance, corrosion resistance, vibration,
56
temperature, use of adaptors, fluid compatibility, etc. must be
considered when selecting a coupling for an application or
system/equipment.
Thread end and sealing surface compatibility

Thread ends must be compatible in order to prevent leaking or
failure. Three elements must be considered in particular:
thread interface, seat angles and eventual O-Rings. It is critical
that both the male and female fittings are compatible to
ensure an effective seal. Incorrect sealing will cause leaks,
which can represent a safety and environmental hazard.
Temperature
Metal surfaces can expand and contract under extreme tem-
perature fluctuations. Selecting couplings with O-Rings, will give
a better sealing even with metal components deformations.
It may be necessary to use O-Ring materials that are suitable
for high temperatures and chemically compatible with the
working fluid at the requested temperature. If the application is
at high temperature, it is advisable to avoid brass or aluminium
fittings.
Fluid compatibility
It is common practice to select hoses taking particular care of
the compatibility with the working fluid, it is far less common
to do so for couplings.. Also couplings, however, can also be
affected by fluids, in particular aggressive fluids. Always check
the fluid compatibility chart for coupling and O-Ring materials
and contact Manuli for specific details or doubts.
Corrosion resistance
Most hydraulic fittings are manufactured from carbon steel
and have zinc plating external treatment for corrosion resist-
ance. Even if the high performance of the Manuli couplings
treatment pass 400 hours before red corrosion in the standard
salt spray tests (ASTM B117), other materials such as stainless
steel can be necessary for special applications (marine equip-
ment, mining, etc.).
Working pressure
Working pressure should be a relevant consideration when
selecting a fitting. Some fittings do not seal well at high pres-
sures and can cause leaks. O-Ring type fittings as well as solid
port connectors work well at high pressures. It is important to
make sure that not only the maximum rated working pressure
is higher than the working pressure of the system but also that
the architecture (thread type, sealing surfaces, thicknesses,
shape of the connection, etc.) of the termination end is suit-
able for the intended use.
Vibrations
Hose flexing conditions and/or vibrations at the end connec-
57
tion, can potentially weaken or reduce the connection capa-
bility. It is important to select couplings accordingly: flanges
or other couplings with O-Ring for sealing perform better
under vibration, avoid use of couplings that seal on the
threads.
Couplings thread style and pressure performance

The couplings termination ends are realised according to the
reference international specifications, that define the thread
type, sealing surfaces angles and type, architecture of the ter-
mination end, etc.
Manuli couplings product range presents a wide variety of the
most common termination end types, offering also some
global OEM (Original Equipment Manufacturer) special con-
nections and upon request even personalised solutions.
Among the others we can mention:
BSP (British Standard Pipe) standard connections:

• Male BSPP (Parallel) and BSPT (Tapered)
• BSP 60°
• BSP O-Ring 60°
• BSP flat seat
DIN (Deutsches Institut für Normung) standard connec-

tions:
• DIN standpipe
• DIN Metric 60°
• DIN Multiseal
• DIN Metric 24° (light and heavy series)
SAE (Society of Automotive Engineers) standard connec-

tions:
• JIC (Joint Industrial Council) connections
• ORFS (O-Ring Face Seal) connections
• SAE connections (90° cone)
• NPTF (National Pipe Tapered Fuel) and NPSM (National Pipe
Straight Mechanical) connections
• SAE flanges (3000 and 6000 psi)
• STAPLE LOCK connections
NF (Norme Française) standard connections:

• 24° metric connections
• 24° gaz connections
JIS (Japanese Industrial Standard) standard connections
The following table is a summary (exceeding international

specifications) of hydraulic pressure performance by thread
style and size for coupling termination ends.
The table is intended only as an approximate guide to field

performance of products, figures shown are maximum oper-
58
ating pressures in bar, based upon a 4:1 safety factor relative
to the connection minimum burst pressure. Testing of Manuli
fittings range confirm the data; anyway the robustness
and high quality of the Manuli fittings generally exceed
the mentioned performance. Testing was conducted at the
recommended assembly torque in hardened test blocks.
The pressure rating of the hose assembly, complete of all the
components, including fittings and adapters, must be defined
as the rate of the weakest component.
Selecting a termination end for a given hose, means also a
proper choice of the type, architecture and pressure rate com-
patible with the hose one.
Max. Working pressure (bar)

Hose size / Dash
Coupling termination end type
3/16" 1/4" 5/16" 3/8" 1/2" 5/8" 3/4" 1" 1-1/4" 1-1/2" 2"
-03 -04 -05 -06 -08 -10 -12 -16 -20 -24 -32
Termination end type Ref. Specification DN
5 6 8 10 12 16 19 25 31 38 51
BSP Male BS5200 - ISO WD8434-6 350 500 460 460 430 350 350 280 250 210 210
O-Ring BSP Female BS5200 - ISO WD8434-6 - 500 - 460 430 350 350 280 250 210 210
BSP Female BS5200 - ISO WD8434-6 - 500 460 460 430 350 350 280 160 125 80
Multiseal DIN Female DIN 20066/Febr.'82 250 250 250 250 250 160 - - - - -
Metric 60° DIN Female DIN 20066/Febr.'82 - - - - - - 63 63 63 63 40
Metric Male 24° L Series DIN 20066/Oct. '02 415 400 350 330 275 250 215 165 125 100 -
Metric Female 24° L Series DIN 20066/Oct. '02 415 400 350 330 275 250 215 165 125 100 -
Metric Male 24° Heavy Series DIN 20066/Oct. '02 630 630 630 630 630 450 420 385 350 280 -
Metric Female 24° Heavy Series DIN 20066/Oct. '02 630 630 630 630 630 450 420 385 350 280 -
Millimetric Metric Male NORM. FRANC. E48-064 630 630 630 630 630 420 420 420 250 250 250
Millimetric Metric Female NORM. FRANC. E48-064 630 630 630 630 630 420 420 420 250 250 250
Metric Gaz Male NORM. FRANC. E48-064 630 630 630 630 630 420 420 420 250 250 250
Metric Gaz Female NORM. FRANC. E48-064 630 630 630 630 630 420 420 420 250 250 250
JIS Metric Female JIS B8363 350 350 350 350 350 280 280 280 175 105 105
JIS Gas Female JIS B8363 350 350 350 350 350 280 280 280 175 105 105
JIC 37° SAE Male SAE J514 350 350 350 350 350 350 350 280 210 160 125
JIC 37° SAE Female SAE J514 350 350 350 350 350 350 350 280 210 160 125
JIC 45° SAE Male SAE J514 350 350 350 350 310 240 240 210 170 140 105
JIC 45° SAE Female SAE J514 350 350 350 350 310 240 240 210 170 140 105
NPTF Male SAE J514 350 350 280 280 245 210 210 175 145 145 145
NPSM Female SAE J514 350 350 280 280 245 210 210 175 145 145 145
ORFS Female SAE J1453 420 460 460 460 420 420 420 350 275 210 -
CODE 61 SAE Flanges SAE J518 - - - - 350 - 350 350 280 210 210
CODE 62 SAE Flanges SAE J518 - - - - 420 - 420 420 420 420 420
XTRAFLANGES SAE J518 - - - - - - - 560 560 560 450
WASH CLEANER FEMALE (M24913) - - 420 420 420 - - - - - - -
Additional considerations on termination ends selection

Some useful considerations as support to the termination ends
59
selection, for a proper use in the requested application.
The fittings working pressures suggested by the international

specifications are the most important guideline to select the
right termination end: working pressure of the hose assembly
must be the lowest level between hose and fitting ones. Fitting
working pressure should be selected higher or equal to the
hose one.
But also other considerations are relevant.
For heavy duty applications, in presence of vibrations, high

fatigue mission profiles and/or large size hoses, flanges are
often preferable compared to other termination ends. When
this is not possible, other robust termination ends can be
selected, such as DIN Metric heavy series and ORFS.
The recommendation in favour of safety is to avoid selection of

low-pressure termination ends for hose assemblies dedicated
to the most severe mission profiles. Even thought the market
requires the maximum availability of many different termina-
tion end types (for example medium pressure termination end
for InterLock fittings dedicated to heavy duty wire spiral hoses)
these should not be interpreted as optimum solutions.
In addition, O-Ring type termination ends are always to be pre-

ferred for new projects, as also declared by the international
specifications ISO, SAE, etc. for their better performance com-
pared to the traditional metal to metal sealing types. Standard
O-Ring supplied are generally NBR based, suitable up to max.
temperature of 125°C as from the international specifications;
for eventual special applications different types of O-Rings
could be necessary, with a more appropriate compound, con-
sidering chemical compatibility with service fluid and tempera-
ture resistance.
For any doubt and specific advice, contact Manuli Rubber

Industries specialists.
MANULI PART NUMBERING SYSTEM

M = MF2000 fitting
O = Banjo, Bolt, Flanges, etc.
60
L = Push-Lock
First digit
1 2 3 4 5
The numbers stated in this position (from 0 to 8), refer respec-
tively to the following descriptions:
0 = Swaged Ferrule
1 = Multifit Type Male
2 = Multifit Type Female
3 = Interlock Type Male
4 = Interlock Type Female
5 = Xtralock Type Male
6 = Xtralock Type Female
8 = Flange Clamps or Bolt
Second and third digit
1 2 3 4 5
MULTIFIT INTERLOCK DESCRIPTION
XTRALOCK
00 Blank insert
03 BSP Banjo
05 55 BSP Parallel Thread (60° cone)
06 BSP Parallel Thread (Flat face)
07 57 BSP Male Tapered Thread - JIS BSP Female
08 58 BSP Parallel Thread O-Ring (60° cone)
09 Metric Banjo
10 Metric Thread (60° cone superlight)
11 Male Metric Thread (24° cone light type)
12 62 Male Metric Thread (24° cone heavy type)
13 Metric Thread (Multiseal cone)
15 Female Metric Thread (24° cone O-Ring light type
16 66 Female Metric Thread (24° cone O-Ring heavy type)
17 Metric Thread (French Millimetric)
18 Metric Thread (French gaz)
20 DIN Metric Standpipe L.T.
21 DIN Metric Standpipe H.T.
25 75 JIC Thread (37° cone)
27 JIC Thread double exag. (37° cone)
24 74 ORFS type
26 SAE Thread (45° cone)
28 78 NPTF/NPSM Thread
30 SAE O-Ring Thread
33 83 Code 61 SAE flange 3000 psi
36 86 Code 62 SAE flange 6000 psi
38 JIS (Toyota) Thread
39 89 Supercat flange
40 JIS (Komatsu) Thread
41 NPTF Swivel Male
43 SAE O-Ring Thread Swivel Male
44 ORFS Long Drop Elbow
47 JIC Thread (37° cone) Elbow Long Drop
48 Staple Lock Connection
49 Wash Cleaning Female
85 Xtraflange
When the first digit is 8, it denotes Bolt type or SAE flange

clamps, namely:
SAE Flange 3000 psi = 33 61
SAE Flange 6000 psi = 36
BSP Bolt = 02
Metric Bolt = 08
Xtraflange = 85
Fourth digit
1 2 3 4 5
1 = Straight
2 = 22,5° Swept
3 = 30° Swept
4 = 45° Swept
6 = 60° Swept
7 = 67,5° Swept
8 = Compact type
9 = 90° Swept
Fifth digit
3 = Slip-on Nut
2 = Thrust-wire Nut
1 = Crimped-back Nut - Multifit flange
0 = Male/Ferrule - Interlock/Xtralock flange

OPB = One Piece Braided
OPNS = One Piece No Skive
62
OPS = One Piece Spiral
First digit
1 2 3 4 5
The numbers stated in this position (from 0 to 8), refer
respectively to the following descriptions:
1 = Male
2 = Female
8 = Flange Clamps or Bolt
Second digit
1 2 3 4 5
DESCRIPTION
05 BSP Parallel Thread (60° cone)
06 BSP Parallel Thread (Flat face)
07 BSP Male Tapered Thread - OPS BSP Female
08 BSP Parallel Thread O-Ring (60° cone)
10 Metric Thread (60° cone superlight)
11 Male Metric Thread (24° cone light type)
12 Male Metric Thread (24° cone heavy type)
13 Metric Thread (Multiseal cone)
15 Female Metric Thread (24° cone O-Ring light type
16 Female Metric Thread (24° cone O-Ring heavy type)
20 DIN Metric Standpipe L.T.
21 DIN Metric Standpipe H.T.
25 JIC Thread (37° cone)
27 JIC Thread double exag. (37°) - OPS JIC Thread Range
24 ORFS type
26 SAE Thread (90° cone)
28 NPTF/NPSM Thread
30 SAE O-Ring Thread
33 Code 61 SAE flange 3000 psi
36 Code 62 SAE flange 6000 psi
38 JIS (Toyota) Thread
40 JIS (Komatsu) Thread
41 NPTF Swivel Male - Komatsu flange
44 Long drop ORFS Female
43 SAE O-Ring Boss Swivel Male
46 Super Staple Lock Male
47 JIC Thread (74° cone) Elbow Long Drop
48 Staple Lock Connection
49 Wash Cleaning Female
When the first digit is 8, it denotes SAE flange, clamps namely:

SAE Flange 3000 psi = 33
SAE Flange 6000 psi = 36 63
Fourth digit
1 2 3 4 5
1 = Straight
2 = 22.5° Flange angle
3 = 30° Flange angle
4 = 45° Swept
7 = 67.5° Flange angle
8 = Compact type
9 = 90° Swept
Fifth digit
3 = Slip-on Nut
2 = Thrust-wire Nut
1 = Crimped-back Nut/Flange
0 = Male

A = Adaptors
64 First digit
1 2 3 4 5 6
The numbers stated in this position (from 4 to 9)
refer respectively to the ends number
4 = one end
5 = two ends
7 = three ends
9 = four ends
Second digit
1 2 3 4 5 6
The numbers stated in this position (from 0 to 9)
refer respectively to the gender and geometry of the ends
One end
second digit end gender
0 male plug
1 female plug
2 sleeve
3 nut
Two ends 1 2
second digit 1st end gender 2nd end gender geometry
0 male male straight
1 female female straight
2 male female straight
3 male male 45° elbow
4 female female 45° elbow
5 male female 45° elbow
Three ends 1 2
second digit 1st end gender 2nd end gender 3rd end gender 3
0 male male male
1 male male female
2 male female male
3 female female female
4 female female male
5 female male female
6 male 1 male 2 male 1
7 female 1 female 2 female 1
1 2
4 65
Four ends
second digit 1st end gender 2nd end gender 3rd end gender 4th end gender
0 male male male male
1 male 1 male 1 male 1 male 2
3 male male male female
4 male female male female
5 male female female female
6 female female female female
7 female 1 female 1 female 1 female 2
9 male male female female
Third and fourth digit
1 2 3 4 5 6
The numbers stated in these positions indicate the end tail
referred to the second digit
Fifth and sixth digit
1 2 3 4 5 6
The numbers stated in these positions indicate end tail referred
to the third digit
02 BSP Male Tapered Thread long/
BSP Female Tapered Thread
03 BSP Male Parallel Thread O’R (Flat Face) - ISO 1179-3
04 BSP Female fixed
05 BSP Parallel Thread (60° cone)
07 BSP Male Tapered Thread
09 BSP Parallel Thread O’R (Flat Face) adjustable - ISO 1179-3
19 Metric ISO 6149 O’R (Flat Face)
22 JIC Thread (37° cone) long
23 JIC Thread (37° cone) bulkhead
24 ORFS type
25 JIC Thread (37° cone)
27 ORFS type bulkhead
28 NPTF Male - NPSM swivel female
29 ORFS type long
30 SAE O’R boss type
31 SAE O’R boss type adjustable
34 NPTF female fixed
TERMINATION ENDS AND TORQUE VALUES

Here below a summary presentation of the main fittings fami-
lies and torque values for correct installation.
66
SAE STANDARD CONNECTIONS

JIC (37° Flare - SAE J514 / J516 ISO 8434-2)
JIC fittings seal on a flare with a central angle of 74° (37° if we
consider the seal surface inclination compared to the fitting
axis) and are available with thrust wire or slip on nut depend-
ing on the geometry (slip on nut can’t fit on parallel sizes).
X 25 XX JIC Thread 74° cone
Male Female Recommended

Nominal Thread Thread
Torque
Dash Inch Values
Thread O.D.* I.D.* (Nm)
Size Size
Size
mm inch mm inch min Max
-4 1/4 7/16 - 20 11.2 .44 9.9 .39 12 15
-5 5/16 1/2 - 20 12.7 .50 11.4 .45 18 22
-6 3/8 9/16 - 18 14.2 .56 12.9 .51 20 35
-8 1/2 3/4 - 16 19.0 .75 17.0 .67 35 50
-10 5/8 7/8 - 14 22.3 .88 20.3 .80 60 80
-12 3/4 11/16 - 12 26.9 1.06 24.9 .98 80 105
-14 7/8 13/16 - 12 30.0 1.18 27.7 1.09 100 120
-16 1 15/16 - 12 33.3 1.31 31.0 1.22 120 150
-20 11/4 15/8 - 12 41.4 1.63 39.1 1.54 150 180
-24 11/2 17/8 - 12 47.4 1.88 45.5 1.79 180 220
-32 2 21/2 - 12 63.5 2.50 61.2 2.41 250 350
ORFS (SAE J1435 / J516 - ISO 8434-3 / 12151-1)

SAE J1453 specifies this type of sealing, more robust compared
to the JIC design; ORFS guarantees sealing through an O-Ring 67
trapped onto a flat surface. This type of fitting is designed for
very high pressure (even 6000 psi) with no leakage problem at all.
X 24 XX ORFS Type
Male Female
Nominal Thread Thread
Recommended
Dash Inch Torque
Thread O.D. (inch) I.D. (inch) Values
Size Size
Size (Nm)
Fraction Decimal Fraction Decimal
-4 1/4 9/16 - 18 9/16 .56 17/32 .51 15
-6 3/8 11/16 - 16 11/16 .69 5/8 .63 26
-8 1/2 13/16 - 16 13/16 .82 3/4 .75 45
-10 5/8 1 - 14 1 1.00 15/16 .93 65
-12 3/4 13/16 - 12 13/16 1.19 11/8 1.11 92
-16 1 17/16 - 12 17/16 1.44 13/8 1.36 130
-20 11/4 111/16 - 12 111/16 1.69 15/8 1.61 180
-24 11/2 2 - 12 2 2.00 115/16 1.92 215
The solid male O-Ring face seal will mate only swivel female fit-
ting. The O-Ring is on the male (for dimensions see the dedi-
cated section).
SAE J512 90° CONE

The American SAE J512 specifies a central cone angle of 90°
(45° if we consider the seal surface inclination compared to
the fitting axis) rather than the 74° angle of the JIC type. Care
needs to be taken with selection because some of the thread
sizes and pitches are the same as the JIC sizes, however, the
different cone seats are not compatible.
These fittings are dedicated to low pressure applications.
X 26 XX SAE J512 90° cone
Male Female Recommended

Nominal Thread Thread Torque
Dash Inch
Thread O.D.* I.D.* values
Size Size
Size
mm inch mm inch N/m
-2 1/8 5/16 - 24 7.9 .31 6.9 .27 8
-3 3/16 3/8 - 24 9.6 .38 8.6 .34 10
-4 1/4 7/16 - 20 11.2 .44 9.9 .39 12
-5 5/16 1/2 - 20 12.7 .50 11.4 .45 15
-6 3/8 5/8 - 18 15.7 .62 14.2 .56 16
-8 1/2 3/4 - 16 19.0 .75 17.0 .68 30
-10 5/8 7/8 - 14 22.3 .88 20.3 .80 50
-12 3/4 11/16 - 14 26.9 1.06 25.1 .99 60
NPTF/NPSM - SAE J516

The NPTF male has 30° inverted seat and tapered threads. The
68
seal take place by deformation of the thread (NPTF on NPSM
fixed female) or on 30° cone for NPSM swivel female.
NPTF is not interchangeable with BSPT connectors because
the thread angle is 60°.
The torque obtained can vary considerably depending on
thread condition. Proper sealing can occur at values much
over than the maximum values listed.
When the junction is with a female straight thread, reduces
the maximum values by 50%.
If sealant is present reduces the torque by 25-30%.
X 28 XX NPTF/NPSM Thread
Male Female Maximum

Nominal Thread Thread Torque
Dash Inch
Thread O.D. (inch) I.D.(inch) values
Size Size
Size
Fraction Decimal Fraction Decimal N/m
-2 1/8 1/8 - 27 13/32 .41 .38 3/8 20
-4 1/4 1/4 - 18 17/32 .54 .49 1/2 30
-6 3/8 3/8 - 18 11/16 .68 .63 5/8 40
-8 1/2 1/2 - 14 27/32 .84 .77 25/32 55
-12 3/4 3/4 - 14 11/16 1.05 .98 1 70
-16 1 1 - 111/2 15/16 1.32 1.24 11/4 90
-20 11/4 11/4 - 111/2 121/32 1.66 1.58 119/32 100
-24 11/2 11/2 - 111/2 129/32 1.90 1.82 113/16 120
-32 2 2 - 111/2 23/8 2.38 2.30 25/16 150
SAE MALE O-RING BOSS (SAE J516/J514)

The O-RING BOSS male will mate with a SAE J1926 port
69
female. The threads are the same of JIC but sealing is assured
by an O-Ring on the male and a seal part on the female (port).
X 30 XX SAE O'R Threads
Recommended
Nominal Male Female Torque
Dash Inch
Thread Thread Thread values
Size Size
Size
mm inch mm inch N/m
-04 1/4 7/16 - 20 11.2 0.44 9.9 0.39 20
-05 5/16 1/2 - 20 12.6 0.49 11.5 0.45 25
-06 3/8 9/16 - 18 14.1 0.56 12.9 0.51 35
-08 1/2 3/4 - 16 18.9 0.74 17.5 0.69 70
-10 5/8 7/8 - 14 22.1 0.87 20.5 0.81 100
-12 3/4 11/16 - 12 26.9 1.06 24.9 0.98 150
-16 1 15/16 - 12 33.1 1.31 31.3 1.23 250
-20 11/4 15/8 - 12 41.1 1.62 39.2 1.54 300
-24 11/2 17/8 - 12 47.4 1.87 45.6 1.79 350
SAE FLANGES
This connection is commonly used in fluid power-system.
70
Flanges are specified from various standard (SAE J518, DIN
20066, ISO 6162, JIS B8363) but all are interchangeable
except for bolt sizes.
There are two pressure rating called Code 61 or 3000 psi
series and Code 62 or 6000 psi series. The design concept is
the same but the hole spacing, flanged head and thickness
are larger for 6000 series (higher pressure).
Sealing is achieved by means of an O-Ring inserted into the
face of the flange and compressed against a flat surface by use
of bolted clamps (captive flange or split flange halves with
threaded holes to match the port).
The port is an unthreaded hole with four bolt holes in a rec-
tangular pattern around the port.
Code 61 - 3000psi series
C
A D
Nominal Flange Bolt Bolt Max Bolt

Dash Inch
Thread Size OD Spacing C Spacing A WP Torque
Size Size
mm inch mm inch mm inch mm inch psi N/m
-08 1/2 M8x1.25x25 5/16-18x1 1/4 30.2 1.19 38.1 1.50 17.4 0.68 5000 20-25
-12 1/4 M10x1.5x30 3/8-16x11/4 38.1 1.50 47.6 1.88 22.2 0.87 5000 28-40
-16 1 M10x1.5x30 3/8-16x11/4 44.4 1.75 52.4 2.06 26.2 1.03 5000 37-48
-20 11/4 M10x1.5x30 7/16-14x11/2 50.8 2.00 58.7 2.31 30.2 1.19 4000 48-62
-24 11/2 M12x1.75x35 1/2-13x11/2 60.3 2.38 69.8 2.75 35.6 1.40 3000 62-79
-32 2 M12x1.75x35 1/2-13x11/2 71.4 2.81 77.8 3.06 42.8 1.68 3000 73-90
-40 21/2 M12x1.75x40 1/2-13x13/4 84.1 3.31 88.9 3.50 50.8 2 2500 107-124
-48 3 M16x2x50 5/8-11x13/4 101.6 4.00 106.4 4.19 61.8 2.43 2000 186-203
Code 62 - 6000psi series

C
A D
Nominal Flange Bolt Bolt Max Bolt

Dash Inch
Thread Size OD Spacing C Spacing A WP Torque
Size Size
mm inch mm inch mm inch mm inch psi N/m
-08 1/2 M8x1.25x30 5/16-18x11/4 31.7 1.19 40.5 1.59 18.1 0.71 6000 20-25
-12 3/4 M10x1.5x35 3/8-16x11/2 41.3 1.50 50.8 2.00 23.8 0.94 6000 34-45
-16 1 M12x1.75x45 7/16-14x13/4 47.6 1.75 57.1 2.25 27.8 1.09 6000 56-68
-20 11/4 M12x1.75x45 1/2-13x13/4 54.0 2.00 66.7 2.63 31.8 1.25 6000 85-102
-24 11/2 M16x2x55 5/8-11x21/4 63.5 2.38 79.4 3.13 36.5 1.44 6000 158-181
-32 2 M20x2.5x70 3/4-10x23/4 79.4 2.81 96.8 3.81 44.5 1.75 6000 271-294
METRIC COUPLINGS
Metric couplings usually means DIN couplings.
Metric thread forms are identified through a number of speci-
71
fications.
The primary specification is the German DIN 2353 - ISO

8434–1, which relates to the tube diameter, thread type and
cone angle (24°), used also by compression tube fittings.
Fittings are available in two series, light and heavy series to
suite the two types of compression coupling types.
DIN 3861 - ISO 8434-1 spec. specifies male threads in light

and heavy series commonly identified as CEL and CES. The
male has 24° cone seat, straight metric threads and matches
the tube OD of the coupling used with it (metric standpipe or
24° female or multiseal 24° and 60°).
DIN 3865 - ISO 8434-4 / 12151-2 spec. specifies a female cou-

pling with cone angle of 24° and an O-Ring fitted on the cone
seat of the female, commonly identified as DKOL and DKOS.
This connection type gives improved sealing performance to
the coupled unions. There are light and heavy series, identifi-
cation is made measuring both thread size and tube OD.
DIN 3863 spec. specifies a cone with a central angle of 60°

and does not relate to compression coupling thread forms. It
can only be mated to a corresponding 60° union.
DIN 3868 spec. is designed to mate with both 24° and 60°
metric cone seats and for this reason is identified as “multiseal”
female.
Multiseal product is present until Pipe 18 mm (M26x1,5).

Over this, thread of 24° product (Myy x 2) are different from
60° (Myy x 1,5) product, so the multiconnection is not guar-
anteed.
STANDPIPE
X 21 XX Standpipe (Heavy Type)

24° CONE SEAT (DIN 3861 - ISO 8434-1) MALE

O-RING 24° CONE (DIN 3865 - ISO 8434-4) FEMALE
72
X 11 XX Metric Thread (24° Cone Light Type) CEL
X 12 XX Metric Thread (24° Cone Heavy Type) CES
X 15 XX Metric Thread (24° Cone O'R Light Type) DKOL
X 16 XX Metric Thread (24° Cone O'R Heavy Type) DKOS
Pipe/Tube Pipe/Tube Male Female Recommended

O.D. O.D. Metric Thread Thread torque
Light series Heavy series Thread O.D. I.D. values
Size
mm (inch) mm (inch) mm inch mm inch (nm)
6 (.24) M 12 x 1.5 12 .47 10.5 .41 12 - 14
8 (.32) 6 (.24) M 14 x 1.5 14 .55 12.5 .49 20 - 25
10 (.39) 8 (.32) M 16 x 1.5 16 .63 14.5 .57 30 - 35
12 (.47) 10 (.39) M 18 x 1.5 18 .71 16.5 .65 35 - 42
12 (.47) M 20 x 1.5 20 .78 18.5 .73 42 - 50
15 (.59) 14 (.55) M 22 x 1.5 22 .87 20.5 .81 50 - 58
16 (.63) M 24 x 1.5 24 .94 22.5 .89 58 - 65
18 (.71) M 26 x 1.5 26 1.02 24.5 .96 75 - 85
22 (.87) 20 (.78) M 30 x 2.0 30 1.18 28 1.11 100 - 110
28 (1.10) 25 (.98) M 36 x 2.0 36 1.41 34 1.34 110 - 125
30 (1.18) M 42 x 2.0 42 1.65 40 1.57 180 - 200
35 (1.38) M 45 x 2.0 45 1.77 43 1.70 200 - 220
42 (1.65) 38 (1.50) M 52 x 2.0 52 2.04 50 1.97 250 - 280
60° CONE SEAT (DIN 3863)Xxxxxx

METRIC FEMALE “MULTISEAL” (DIN 3868)
73
X 10 XX Metric Thread (60° Cone Superlight)
X 13 XX Metric Thread (Multiseal)
Use with Male Female

Pipe/Tube Metric Thread Thread
O.D. Thread O.D. I.D.
Size
mm inch mm inch mm inch
6 .24 M 12 x 1.5 12 .47 10.5 .41
8 .32 M 14 x 1.5 14 .55 12.5 .49
10 .39 M 16 x 1.5 16 .63 14.5 .57
12 .47 M 18 x 1.5 18 .71 16.5 .65
15 .59 M 22 x 1.5 22 .87 20.5 .81
18 .71 M 26 x 1.5 26 1.02 24.5 .96
22 .87 M 30 x 1.5 30 1.18 28.5 1.12
28 1.10 M 38 x 1.5 38 1.50 36.5 1.44
35 1.38 M 45 x 1.5 45 1.77 43.5 1.71
42 1.65 M 52 x 1.5 52 2.04 50.5 1.99
BSP (BRITISH STANDARD PIPE)

(BS 5200 - ISO 8434-6 - ISO 228, PT & BSPT Tapered -
ISO 7-PT)
74
The BSP threads also known as Whitworth threads (55°) may
be parallel (BSPP) or tapered (BSPT).
The BSPP thread is parallel and the male has a 30° flare seat
which seals with a BSPP female on its 30° cone seat. The
threads holds the connection mechanically.
The BSPT male thread is tapered and usually mates with a port.
The seal takes place by thread deformation, that’s why a
sealant is recommended.
Port connections are also made with BSPP male threads: in this
case a soft metal sealing or an O-Ring (dowty washer or
shaped seal) are used to realise the sealing.
The sealing can also be obtained with the 30° seat and O-Ring
on female couplings (BSP O-Ring female).
X 07 XX Tapered Thread
X 05 XX Parallel Thread (60° Cone)
Male Female
Nominal Suggested
Dash Inch Thread Thread
Thread Torque
Size Size O.D. I.D.
Size (Nm)
mm inch mm inch
-2 1/8 1/8 - 28 10.3 .41 9.4 .37 10
-4 1/4 1/4 - 19 13.7 .54 12.4 .49 15
-6 3/8 3/8 - 19 17.3 .68 15.7 .62 25
-8 1/2 1/2 - 14 21.3 .84 19.3 .76 45
-10 5/8 5/8 - 14 22.9 .90 21.1 .83 51
-12 3/4 3/4 - 14 26.9 1.06 24.9 .98 85
-16 1 1 - 11 33.3 1.31 31.5 1.24 104
-20 11/4 11/4 - 11 42.2 1.66 40.1 1.58 156
-24 11/2 11/2 - 11 48.3 1.90 46.2 1.82 215
-32 2 2 - 11 60.4 2.38 57.9 2.28 300
A flat face sealing version exists (06 codes).

X 06 XX Parallel Thread (Flat Face) 75
The BS 5200 specification relates to an O-Ring version (08

codes).
X 08 XX Parallel Thread O'R (60° Cone)
JAPANESE STYLE FITTINGS - JIS B 8363

30° FLARE (BSP) PARALLEL THREAD (TOYOTA STYLE)
The male and the female have straight threads and 30° seat.
76
The 30° flare is on the female; the thread is conform to JIS
B0202 specification and is the same as BSPP. The cone is invert-
ed if compared to BSP female.
30° FLARE (BSP) PARALLEL THREAD (TOYOTA STYLE)
30° CONE (BSP) PARALLEL THREAD (NISSAN STYLE)

The male and the female have straight threads and 30° seat.
The 30° flare is on the male.
The product is interchangeable with BSP female (except for
some cone dimensions details).
The male cone is on the female as BSP product.
30° CONE (BSP) PARALLEL THREAD (NISSAN STYLE)
30° CONE METRIC PARALLEL THREADS (KOMATSU STYLE)

The Komatsu style is identical to Toyota style except for the
threads that is a metric fine thread compliant to JIS B0207
specification (not interchangeable with Toyota product).
30° CONE METRIC PARALLEL THREADS (KOMATSU STYLE)

NF FRENCH STANDARD CONNECTIONS

They have 24° seat and metric threads.
These terminations are similar to DIN types, but the threads are
77
fine type in all the sizes and the sealing is metal to metal on the
24° cone (No O-Ring).
The male will mate with the 24° female or a tubing sleeve.
GAZ type and MILLIMETRIC type differ from tube OD dimen-
sions (see pipe dimensions).
NF FRENCH STANDARD CONNECTIONS

MILLIMETRIC
Thread Pipe
27x1,5 18
27x1,5 20
30x1,5 22
33x1,5 25
36x1,5 28
39x1,5 30
GAZ
Thread Pipe
20x1,5 13,25
24x1,5 16,75
30x1,5 21,25
36x1,5 26,75
OEM SPECIAL CONNECTIONS

KOMATSU 5/8” FLANGE
5/8” is not a SAE size flange: Komatsu specifies general dimen-
78
sions for it.
KOMATSU 5/8” FLANGE
SUPERCAT FLANGES
Caterpillar flanges have the same flange OD as SAE code 62,
but they have a thicker flange head (14,3mm). Split flanges
code 62 cannot be used.
SUPERCAT FLANGES
STAPLE LOCK CONNECTIONS (SAE J1467 – DIN 20043)

These connections are used on mining equipment worldwide.
The seal is made by an O-Ring and a Backup-Ring on a cylin-
drical surface (installed on the male).
The connections are held together by a staple.
STAPLE LOCK CONNECTIONS (SAE J1467 - DIN 20043)
TORQUE VALUES DETAILS

The correct torques to connect the fitting termination ends on
the ports are generally provided by the specifications or sug-
79
gested by the manufacturer.
Anyway the topic is quite complex if we consider the different
conditions at which the fittings can be at the moment of instal-
lation: they may be wet, or cover of dust of oil or in dry con-
ditions, that’s why the torque applied can have a different
impact on the connection.
Generally it is to be intended a value of torque moment
in dry conditions.
Manuli Rubber Industries recommends to use always a torque

wrench and the torque values reported in the reference tables.
However it is well known that there are common practices in
the market that allow tightening of threaded components
without the use of the proper tools. These practices and pro-
cedures can be very dangerous: the threads are designed to
have a proper seal at the proper torque, undertorquing may
cause leaks and overtorquing may shear or damage threads
and reduce the life of the assembly.
Some of these procedures are well structured have a solid
technical base and are supported by a good statistical analysis
of the connection. These procedures are not broadly valid:
generally they are specific to the material of the components
and to the thread type.
One of these tightening method is reported here as an exam-
ple and is only valid for Manuli Rubber Industries JIC Swivel
Females inserts.
1. Tight the female by

hand on the male adap-
tor
2. Mark the hand tight-

ening relative position
between the female nut
and the adaptor
(optional)
3. Block the counterhex

80 with a wrench and
start to tight the swivel

nut (from hand-tighten-
ing position) avoiding
relative rotation of the
insert
4. Tighten the female by

a wrench on swivel nut
with the number of
round or flats prescribed
in the table
5. Check the position of

the marks if compliant
81
with the flats pre-
crimped
THREAD TYPE TORQUE N° OF TURNS

(dash size) PRESCRIPTION (N° of flat)
(SAE Nm, wet conditions)
1/2 turns
7/16-20 (04) 16 Nm MAX (n° 3 flats)
1/2 turns
9/16-18 (06) 28 Nm MAX (n° 3 flats)
1/2 turns
3/4-16 (08) 53 Nm MAX (n° 3 flats)
1/2 turns
7/8-14 (10) 80 Nm MAX (n° 3 flats)
Recommendations & General Guidelines

• Torque values shall be intended as in dry conditions
• They are valid for plated carbon steel components
• The torque wrench needs to be applied on the swivel nut
female
• Block the counterhex if present or avoid the female rotation
(avoid twisting of the hose)
O-RING RECOMMENDATIONS
Table O-Ring indications
82 O'Ring indications
s
Code 61 and 62 flanges
Flange published on SAE J518 and ISO 6162
Hardness: 90 ShA - d x s (mm)
M 23XX1-XX-08 18,64 x 3,53

M 23XX1-XX-12 24,99 x 3,53
M 23XX1-XX-16 32,92 x 3,53
M 23XX1-XX-20 37,69 x 3,53
M 23XX1-XX-24 47,22 x 3,53
M 23XX1-XX-32 56,74 x 3,53
M 23XX1-XX-40 69,44 x 3,53
M 23XX1-XX-48 85,32 x 3,53
BSP O-Ring female

BSP type published on BS5200
M 208XX-XX-04 6,5 x 1,0

M 208XX-XX-06 8,1 x 1,6
M 208XX-XX-08 12,1 x 1,6
M 208XX-XX-10 13,1 x 1,6
M 208XX-XX-12 17,1 x 1,6
M 208XX-XX-16 22,1 x 1,6
M 208XX-XX-20 29,1 x 1,6
M 208XX-XX-24 35,1 x 1,6
M 208XX-XX-32 48,1 x 1,6
24° DKOL female

DKOL type published on ISO 8434-1
M 215X3 - 03 - 12 4 x 1,5
M 215X3 - 04 - 14 6 x 1,5
M 215X3 - 04 - 16 7,5 x 1,5
M 215X3 - 05 - 16 7,5 x 1,5
M 215X3 - 06 - 18 9 x 1,5
M 215X3 - 08 - 22 12 x 2
M 215X3 - 10 - 26 15 x 2
M 215X3 - 12 - 30 20 x 2
M 215X3 - 16 - 36 26 x 2
M 215X3 - 20 - 45 32 x 2,5
M 215X3 - 24 - 52 38 x 2,5
24° DKOS female

DKOS type published on 8434-1
M 216X3 - 03 - 16 6 x 1,5
M 216X3 - 04 - 16 6 x 1,5
M 216X3 - 04 - 18 7,5 x 1,5
M 216X3 - 05 - 20 9 x 1,5
M 216X3 - 06 - 20 9 x 1,5
M 216X3 - 06 - 22 10 x 2
M 216X3 - 08 - 24 12 x 2
M 216X3 - 10 - 30 16,5 x 2,4
M 216X3 - 12 - 36 20,3 x 2,4
M 216X3 - 16 - 42 25,3 x 2,4
M 216X3 - 20 - 52 33,3 x 2,4
SAE MALE O-Ring BOSS (SAE J514)

O-Rings dimensions for the fittings M13010 and M14310 are
83
published by the SAE J515 specification (O-Ring size specifica-
tions for SAE J1926/2 and SAE J1926/3, ISO 11926-2 and ISO
11926-3).
SAE Male O-Ring Boss (SAE J514)
O-Ring dimensions
Fitting ref. code
ID x section diameter (mm)
M 13010-04-04 8,92 x 1,83

M 13010-06-06 11,89 x 1,98
M 13010-06-08 16,36 x 2,21
M 13010-08-08 16,36 x 2,21
M 13010-08-10 19,18 x 2,46
M 13010-10-12 23,47 x 2,95
O-Ring compound is according to SAE J515 specification.

For petroleum based and water based hydraulic fluids, with
working temperature range -35°C to 125°C:
Hardness: 90 ShA, Compound: NBR based
ORFS MALE (SAE J1453 - ISO 8434-3)

O-Rings dimensions for the fittings M12410 are published by
the SAE J515 and ISO 8434-3.
ORFS Male (SAE J1453)
O-Ring dimensions
Fitting ref. code ID x section diameter (mm)
M 12410-04-04 7,65 x 1,78

M 12410-06-06 9,25 x 1,78
M 12410-06-08 12,42 x 1,78
M 12410-08-08 12,42 x 1,78
M 12410-08-10 15,60 x 1,78
M 12410-10-10 15,60 x 1,78
M 12410-12-12 18,77 x 1,78
M 12410-12-16 23,52 x 1,78
M 12410-16-16 23,52 x 1,78
M 12410-20-20 29,87 x 1,78
M 12410-24-24 37,82 x 1,78
O-Ring compound is according to SAE J515 specification.

For petroleum based and water based hydraulic fluids, with
working temperature range -35°C to 125°C:
Hardness: 90 ShA, Compound: NBR based.
STAPLE LOCK O-Rings and Back-up Rings

STAPLE LOCK CONNECTIONS (SAE J1467 - DIN 20043)
Back-up Ring
Fitting ref. code O-Ring (s x d) mm (s x d x OD) mm
M 14810-04-04 6,0 x 2,0 0,8 x 6,8 x 10,0

M 14810-06-06 10,0 x 2,0 0,8 x 10,8 x 14,0
M 14810-08-08 13,0 x 2,5 0,8 x 14,0 x 18,0
M 14810-12-12 19,0 x 2,5 0,8 x 20,0 x 24,0
M 14810-16-16 25,0 x 2,5 0,8 x 27,0 x 31,0
M 14810-20-20 33,0 x 2,5 0,8 x 34,0 x 38,0
M 14810-24-24 40,0 x 3,0 1,5 x 42,0 x 47,0
M 14810-32-32 50,0 x 3,0 1,5 x 51,0 x 56,0
ADAPTORS
Some couplings connect directly to a port, while others need Caution
adaptors. Connecting directly to the port eliminates the need
84 Some male swivel type couplings have
for an additional connection, but can make installation more internal O-Rings: Fluid compatibility with
difficult. Adaptors can make installation easier, eliminating the the O-Rings must also be considered.
need for coupling orientation but introduce an additional con-
nection or possible leak point.
Adaptors are used in the following situation:

1. To avoid fitting orientation. If an elbow fitting is required on
both ends of a hose assembly, use it on one end only; use
a straight fitting and an elbow adaptor on the other. This
makes installation easier and eliminates the need for orien-
tation of the fittings while assembling at the swaging
machine.
2. When jump-size fittings are not available, make the jump

with an adaptor.
3. To ease port connection and hose installation.
4. To obtain a different thread configuration, when using

adaptors, the preferred method is to install the adaptor first,
the hose assembly next.
The adaptor is an interface for connecting a number of ports

without direct compatibility. Adaptors can be classified into
PRODUCT GROUPS (JIC, ORFS, BSP, etc.) depending on the
end configuration type as fittings.
The Manuli MF4000™ (*) range is manufactured from a solid
piece of steel: straight ones from cold drawn bars and 45°,
90°, Tee and Cross geometry forged and then machined. This
process eliminates the potential leak of points that are typical
of brazed fittings.
Standard O-Rings supplied with MF4000™ adaptors range are
made in NBR 90±5 ShA and they are suitable for petroleum-
base and nonflammable water-base hydraulic fluids.
MF4000™ products are zink plated so to provide corrosion
protection responding to SAE and ISO standards and to com-
ply with ASTM-B177, ISO 9227 salt spray test method.
(*) The MF4000TM range is Manuli Rubber Industries complete

offer of adaptors.
PORT DIMENSIONS
UNF-UN Thread Port Dimensions (SAE J475 - J1926)

85
The thread ends of a SAE OR connection, have UN/UNF straight
threads. The O-ring is fitted on the male end and the female port
has an angular sealing surface.
When the male is threaded the O-ring is sandwiched between the
male shoulder and the female surface. Sealing comes from the O-
ring being energised and compressed by the resistance and hold-
ing power for service pressure.
Adjustable adaptors can be assembled following the procedure
described at the end of section.
UNF-UN Thread Port Dimensions (SAE J475 - J1926)

F
Y
A
X
B
C
Y
D E
45°± 5°
H
K
T
DETAIL X
T T
Thread 7/16"-20 1/2"-20 9/16"-18 3/4"-16 7/8"-14 1"1/16-12 1"3/16-12 1"5/16-12 1"5/8-12 1"7/8-12
Dimensions (mm)
T Nom. 11.11 12.7 14.29 19.05 22.23 26.99 30.16 33.34 41.27 47.62
C Max. 1.5 1.5 1.5 2.4 2.4 2.4 2.4 3 3 3
D Min. 12 12 13 17 17 20 20 20 20 20
E Min. 14 14 16 20 20 24 24 24 24 24
K Min. 5 6 7.5 12.5 12.5 16 18 21 27 33
A Min. 21 23 25 34 34 41 45 49 58 65
B Min. 15 16 18 26 26 32 35 38 48 54
F ± 0.05 12.45 14.05 15.70 24 24 29.20 32.40 35.55 43.55 49.90
G ± 0.2 2.5 2.6 2.7 2.7 2.7 3.5 3.5 3.5 3.5 3.5
Y ± 1° 12° 12° 12° 15° 15° 15° 15° 15° 15° 15°
H Ref. 9.5 9.5 10.5 12 13.5 15.5 15.5 15.5 15.5 15.5
O' ring 8.92 x 1.83 10.52 x 1.83 11.9 x 1.98 16.36 x 2.21 19.18 x 2.46 23.47 x 2.95 26.59 x 2.95 29.74 x 2.95 37.47 x 3.00 43.47 x 3.00
Assembly 21 26 37 74 105 180 225 285 305 390
torque (Nm)
• If the face of the port is on a machined surface, dimensions

A and B do not need to be considered as long as the flat sur-
face rugosity, requirements are respected (Ra max 3.2 μm)
and damage of the OR is avoided during assembly.
• C is the maximum recommended spotface depth to allow
sufficient wrench grip for proper tightening of the fitting or
locknut.
• Spot faced surface (dimension B) must be squared (0.2 mm)
to thread in port.
• F diameter must be concentric (0.1 mm) to thread in port.
• Surface on length G needs Ra 3.2 μm max in order to avoid
damage OR during installation.
BSPP Thread Port Dimensions

(Retaining RING seat type, ISO 1179-3)
86
ISO 1179 ports are designed for different sealing methods on the
top flat face of the port. For all non-adjustable adaptors the assem-
bly procedure is the same as for SAE OR except for different sealing
methods.
Adjustable adaptors can be assembled following the procedure
described at the end of section.
BSPP Thread Port Dimensions (Retaining RING seat type) (ISO 1179-3)
±5° A
45°
C
B
D E
H H
K
T T T
Thread 1/8"-28 1/4"-19 3/8"-19 1/2"-14 3/4"-14 1"-11 1"1/4-11 1"1/2-11

Dimensions (mm)
T Nom. 9.73 13.16 16.66 20.96 26.44 33.25 41.91 47.80

C Max. 1 1.5 2 2.5 2.5 2.5 2.5 2.5
D Min. 8 12 12 14 16 18 20 22
E Min. 13 18.5 18.5 22 24 27 29 31
A Min. 17 21 24.5 30 37 46 54 61
B +0.2/-0 9.8 13.2 16.7 21 27.1 33.3 42 47.9
H Ref. 6.5 9 9.5 11.5 13.5 15 16 16
O' ring 7.97 x 1.88 10.80 x 2.62 13.95 x 2.62 17.86 x 2.62 23.47 x 2.62 29.70 x 3.53 37.70 x 3.53 44 x 3.53
Assembly 20 35 70 100 190 300 330 400
torque (Nm)
• If the face of the port is on a machined surface, dimensions A

and B do not need to be considered as long as the flat surface
rugosity requirements are respected (Ra max. 3.2 μm) and
damage of O-Ring is avoided during assembly.
• C is the maximum recommended spotface depth to allow
sufficient wrench grip for proper tightening of the fitting or
locknut.
• Spot faced surface (dimension B) must be squared (0.2 mm)
to thread in port.
BSPP Thread Port Dimensions
87
Sealing achieved by matching female parallel thread (port) and
male tapered (fitting).
BSPT - BSPP Thread Port Dimensions (ISO 7-Thread)
±5°
45° U
S V
N
Thread 1/8"-28 1/4"-19 3/8"-19 1/2"-14 3/4"-14 1"-11 1"1/4-11 1"1/2-11

Dimensions (mm)
V Min. 5.5 8.5 8.5 10.5 13 14.5 17 17

U 9.72 13.15 16.66 20.95 26.44 33.24 41.91 47.8
N 4 6 6.4 8.2 9.5 10.4 12.7 12.7
S - Working 6.5 9.7 10.1 13.2 14.5 16.8 19.1 19.1
Thread
Metric Thread Port Dimensions (Retaining RING seat type - ISO

6149)
88
ISO 6149 male and port ends are similar in design to SAE male and
port ends so the assembly procedures are similar as well.
Metric Thread Port Dimensions (Retaining RING seat type) (ISO 6149)
±5° A
45°
C
B
D E
H
H
K
T
T
T
Thread 10x1 12x1.5 14x1.5 16x1.5 18x1.5 20x1.5 22x1.5 26x1.5 27x2 33x2 42x2 48x2
Dimensions (mm)
T Nom. 10 12 14 16 18 20 22 26 27 33 42 48
C Max. 1 1.5 1.5 1.5 2 2 2.5 2.5 2.5 2.5 2.5 2.5
D Min. 8 12 12 12 12 14 14 16 16 18 20 22
E Min. 13.5 18.5 18.5 18.5 18.5 20.5 20.5 22.5 24 26 28 30
A Min. 16 20 21.5 24 27 30 32 36 37 45 55 62
B 10 12 14 16 18 20 22 26 27 33 42 48
H Ref. 8 9 9 10.5 12 12 12.5 12.5 14.5 14.5 15 17.5
O' ring 8.1 x 1.6 9.3 x 2.2 11.3 x 2.2 13.3 x 2.2 15.3 x 2.2 17.3 x 2.2 19.3 x 2.2 23.6 x 2.9 23.6 x 2.9 29.6 x 2.9 38.6 x 2.9 44.6 x 2.9
Assembly 20 35 45 55 70 80 100 170 170 310 330 410
torque (Nm)
Sealing with O-Ring and retaining washer.

• If face of port is on machined surface, dimensions A and C need
not apply as long as the surface requirements (Ra min 3.2 ) are
able to avoid damage to the OR during installation.
• C is maximum recommended spotface depth to permit sufficient
wrench grip for proper tightening of the fitting or locknut.
• Spot faced surface (dimension B) must be squared (0.2 mm) to
thread in port.
• F diameter must be concentric (0.1 mm) to thread in port.
NPTF Thread Port Dimensions
89
Sealing achieved by matching female tapered thread and male
tapered thread (deformation at the crests).
NPTF Thread Port Dimensions (SAE J476)
45° U
V
S
N
Thread 1/8"-27 1/4"-18 3/8"-18 1/2"-14 3/4"-14 1"-11,5 1"1/4-11,5 1"1/2-11,5

Dimensions (mm)
V Min. 7.9 11.4 11.7 15.4 15.9 19.0 19.5 19.5

U ref. 10.2 13.5 17 21.2 26.5 33.1 41.9 48
N 4.1 5.8 6.1 8.1 8.6 10.2 10.7 10.7
P 9.5 12.5 15.9 19.8 25.1 31.5 40.2 46.3
S - Working 7.6 11.6 11.8 15.4 15.7 19.6 20.2 20.6
Thread
SAE, ISO and BSP Adjustable End Assembly SAE J1926/3 schemes
90
1. Inspect both ends (male and port) to make sure that there
are no damages, scratches foreign particles, burrs or nicks.
2. Install O-Ring on the male, if it is not pre-installed. Make sure
that the O-Ring is not damaged in the process.
3. Lubricate the O-Ring with suitable lubricant: it could be the
same system oil or it must be compatible with the O-Ring
elastomer and with the system fluid.
4. Back off the lock nut as far as possible and push as far as
possible the back-up washer as well (fig. 1). fig. 1 - Locknut Backed Off
5. Screw the fitting into the port until the back-up washer con-
tacts the face of the port (fig. 2).
6. To align the tube end of the Adaptor with the hose assembly,
unscrew by the required amount. Do not unscrew more
than one full turn (fig. 3).
7. Tighten the locknut to the appropriate torque value (from
the appropriate tables) with a torque wrench while holding
the fitting in the right position with a second wrench (fig. 4).
8. Inspect the connection to make sure that the back-up wash-
er is in the correct position and is flat on the port thus ensur- fig. 2 - Fitting installed hand tight
ing that the O-Ring is properly seated (fig. 5).
fig. 3 - Fitting backed-off for alignment
fig. 4 - Fitting locknut tightened to appropri-

ate torque
Locknut
Back-up
washer
O-Ring
fig. 5 - Final assembly of adjustable stud end

091_102_Mining:091_102_Mining 31-03-2009 10:38 Pagina 91
Mining
INTRODUCTION
The Manuli Mining product range includes a comprehensive
program of hose inserts, staple-lock adaptors and ball valves.
92
These products are used in:
• hydraulic equipment and long walls installations (for coal
and soft rock mining)
• undreground and open pit mines (soft-rock and hard-rock
mines)
• high pressure and heavy duty hydraulic lines, medium pres-
fig. 1 - Long wall mining
sure line, return lines.
Mining processes Minerals Pillar Entry Ways or “Rooms”
1. SOFT ROCK Mining

a. LONG WALL Mining
b. ROOM and PILLAR Mining
a. LONG WALL Mining

This method operates through a series of hydraulical roof
Black areas are blocks of minerals
supports used to prop up the ceiling of a mine (see fig.1). Colored areas are mined where minerals hase been removed
A shearing machine is used to cut the coal/rock under- fig. 2 - Room and Pillar Mining
ground.
b. ROOM and PILLAR Mining

Is a method whereby pillars of coal/rock are used to support
the roof of the mine. Compared to the Long wall process, this
method is used on a lower volume production. Normally,
continous mining machines are required.
2. HARD ROCK Mining

Known for applying drilling machines, explosives, and the
roof bolters (to pin and make safe the roof of a mine - see fig. 3 - Roof bolter
fig.3) and the crushers (to break up lumps of minerals into
manageable pieces).
3. OPEN PIT Mining

It is characterized by drilling operations of rocks with explo-
sives and removal of materials using large excavators, dump
trucks (see fig.5).
MINING PRODUCT RANGE

fig. 4 - Crusher
Hoses
The hose features normally required, for an application in such
environment, are:
• High abrasion resistance (from coal dust and machine
movement)
• High ozone resistance
• High ageing resistance (to temperatures)
• Anti-staticity, to prevent electrical static created by moving
machine parts and frictions by coal dust
• Flame retardant characteristic
• Low toxicity of smokes in case of fire fig. 5 - Open pit Mining
The Manuli hoses specifically suggested for Mining applica-

tions (as detailed under “Processes” refer to previous page) are:
93
• ROCKMASTER® family • SHIELDMASTER®MINE family
• ETERNITY/2™ • DIAMONDSPIR™
ROCKMASTER® specifically (approval for SHIELDMASTER®MINE

is on progress) has been approved by mining safety Institutes
all over the world, such as:
• MSHA (USA),
• FRAS (Australia),
• Polish Safety B (Poland),
• MA (China),
• DGMS (India).
The technical key-features of the two main hose families, are

shown in the table here below:
Manuli mining hoses
HOSE FAMILIES
FEATURES ROCKMASTER® SHIELDMASTER®MINE

Weight loss negligible with 2000 cycles
Weight loss lower than 0,05 g with (method ISO 6945).
ABRASION Resistance 25 N weight and 2000 cycles Resistance up to 2 million abrasion cycles (1000
(method ISO 6945) times better than specifications requirements)
More than 300 hours of dynamic Higher performance is due to the exter-
OZONE Resistance ozone test ISO 10960 method nal plastic material applied
ELECTRICAL ANTISTATICY property Resistance lower than 1MOhm Resistance lower than 1MOhm
Excellent: more than 1 Million impulse Excellent: more than 1 Million impulse test
test cycles for wire spiral structures. cycles for wire spiral structures.
FATIGUE Resistance Heavy duty hoses tested with flexing Heavy duty hoses tested with flexing
impulse tests impulse tests
ETERNITY/2™
High-Performance wire braided hose.
Compact structure, also provided with Rockmaster® mining
cover compound, for applications with high fatigue profiles in
restricted spaces on modern mining equipment.
DIAMONDSPIR™
®
fig. 6 - Shieldmaster Mine High-Performance wire spiral hose, provided with Rockmaster®
mining cover compound for heavy duty applications.
Manuli Mining hoses meet and exceed the requirements of main

international specifications for mining (high temperature resistance,
abrasion resistance, low electrical resistance, low toxicity), by:
• BC174 (UK Coal), ISO 6805, MDG41 (Australia).
fig. 7 - Diamondspir™
STAPLE-LOCK system
The staple-lock is a fitting designed to be easily connected and
94
disconnected without need of spanners. Sealing is assured by
o’ring and back-up ring.
The staple-pin locates in the grove on the male to secure the

connection.
It’s also removed by levering with a screwdriver to disconnect
connection.
The staple-lock system is in compliance with SAE J1467 and

DIN 20043.
Fittings
High performance long wall mining fittings range consists of
the following families:
• STAPLE-LOCK
• SUPER STAPLE-LOCK
• FLUSH-FIT
Manuli fittings for mining are specifically indicated for soft-rock
mining.
All of them are defined in the:

• two pieces (MF2000) range: (Multifit, Interlock, Xtralock)
• one piece (MF3000) range: (OPB, OPNS, OPS).
All the fittings have these common characteristics:
• “Drab olive” zinc plating treatment:

- it ensures corrosion resistance higher than 450 hours before
red corrosion (tested according to ASTM B117 (ISO 9227)
method – higher than international specifications require- Manuli mining fittings
ments, e.g. SAE J516 with 72 hours before red corrosion.
• High mechanical robustness and fatigue resistance:

- safety factor burst/working pressure is higher than 4:1.
• Highly robust staples have a smaller connection “footprint”

and “high” fatigue resistance:
- the staple design permits quick and easy connection in
constrained environments.
• Excellent hydraulic sealing, leak free solutions.

Adaptors
Manuli adaptors for mining are specifically designed for the
95
soft-rock mining process.
STAPLE-LOCK adaptors
The staple-lock design permits an easy connection in confined
spaces. These are important to both maintain and to support
underground equipment (see fig. 1).
Available with male and female staple ends as well as thread-

ed options.
fig. 1 - Staple-lock adaptor These types of adaptors need to have a high corrosive protec-
tion surface finish to meet the requirements of a difficult envi-
ronment. For this reason, staple adaptor in stainless steel are
also available.
The standard staple-lock adaptors meet and exceed all interna-

tional standards, including DIN 20043, SAE J1467 and NCB 638.
Super STAPLE-LOCK adaptors

The Super Staple-lock has been developed to satisfy high flow,
high pressure system demands, necessary to achieve faster
more cost effective mining production (see fig. 2). Use for
large bore, high pressure, wire- spiral Rockmaster® and
Shieldmaster®, along with Diamondspir™ DN63 (2 ½”) at 350
fig. 2 - Super staple-lock adaptor bar (5000 psi), Super Staple-lock.
SPECIAL adaptors
Special adaptors are available to accommodate sudden
changes in direction and piping configuration, multi-piping
take off ports for pressure supply and return lines (see fig. 3).
FLUSH-FIT adaptors
Increased performance concept of which locks the male and
female inserts together with a staple-pin. In this case, the instal-
lation of hydraulic hoses side by side or coiled, do not run the
risk of damage during movement as a result of machinery
fig. 3 - Special mining adaptors operation. This means that the staple-Lock pin is hidden inside
the body of the adaptor but can still be quickly removed due
to the creation of a gap to initiate staple extraction (see fig. 4).
Their main features are:

• Increased strength and performance, compared to standard
staple
• “Snag free profile” provided by flush-fit design
• Smaller connection “footprint’”
fig. 4 - Flush-fit adaptors

Mining BALL VALVES

Manuli ball valves are specifically designed for the soft-rock
96
mining process.
Designed to meet a variety of mining needs: from isolating
sections of pipelines, to flow control.
The design concept of valves is always the same, meantime

the material can change to suit the pressure, environment or
medium to be controlled.
The products are available in:

• Staple-lock and Super Staple-lock versions (from DN6 (1/4”)
to DN63 (2 ½”))
• swivel female available also (together with fixed ones)
• 2-ways; 3-ways and 4-ways designs utilizing staple or thread-
ed connections
• provided with different handle styles (the lockable handle to
be used with a padlock).
Manuli ball valves
MDG41 COMPLIANCE
Particularly important in the mining field, has become the
MDG41 (MECHANICAL DESIGN GUIDELINE), published by the
NSW (New South Wales) Department of Primary Industry
(from Australia) and recognized in other states as well.
It refers to the fluid power systems at all mines which operate
above 5 Mpa (720 psi) or 60 degrees Celsius.
The objective of the guide is to minimize risks and exposure to
hazards by people wherever fluid power systems are in use (sim-
ply, to reduce the amount of fluid injection and burn injuries).
This guide should be used in conjunction with OH&S
Regulation 2001.
It affects mine operators and contractors.
The hose assembly, to be compliant with MDG41:
1. must be fit for purpose (meets the required working pres-

sure)
2. must be FRAS, if being used in an underground coal mine
components must not be mixed (the hose coupling and
hose
3. must be made by the same manufacturer
4. must be made to the manufacturers exact specifications
5. it must be pressure tested (twice RMWP)
6. a permanent label must be fitted showing:
- date of manufacture
- who made it
- serial or traceability number
- assembly length (normally the overall length)
- end fitting type (DN10 staple male for example)
7. the supplier should keep records of all hose assemblies
8. pressure test certificate (on request)

9. burst suppression sleeve where applicable
97
10. sleeve securing options, such as glue lined heat shrink.
First digit
The numbers, stated in this position,
refer respectively to the following descriptions:
1 = Multifit Male Type

2 = Multifit Female Type
3 = Interlock Crimped
5 = Xtralock Male Type

description
46 Super Staple-lock Connection
48 Staple-lock Connection
59 Flush-fit Connection
Fourth digit
1 = Straight
Fifth digit
0 = Male/Flush-fit Female
0 1 2 3 4 5 - 6 7 Ferrules
Male/Flush-fit
Size
0 1 2 3 4 5 - 6 7
digit “0”
M Ferrule MF2000
0 1 2 3 4 5 - 6 7
digit “1”
0 Always
0 1 2 3 4 5 - 6 7
digit “2”-“3”
01 Ferrule M00100 MF2000-ferrule R1 reusable
08 Ferrule M00800 MF2000
09 Ferrule M00900 MF2000
13 Ferrule Interlock 4-6 spirals
14 Ferrule Interlock 4 spirals
18 Ferrule Xtralock 6 spirali
34 Ferrule 3400 MF2000
digit “4” 0 1 2 3 4 5 - 6 7
0 Ferrule release 00
digit “5” 0 1 2 3 4 5 - 6 7
0 Always

98 First digit
The numbers stated in this position, refer respectively to the fol-
lowing descriptions:
1 = Multifit Male Type 2 = Multifit Female Type

description
46 Super Staple-lock Male
59 Flush-fit Female
Fourth digit
1 = Straight
Fifth digit
First digit
The numbers stated in this position, refer respectively to the fol-
lowing descriptions:
1 = Multifit Male Type 2 = Multifit Female Type

description
46 Super Staple-lock Male
59 Flush-fit Female
Fourth digit
1 = Straight
Fifth digit
MINING ADAPTORS PART NUMBERING SYSTEM

digit “0” 0 1 2 3 4 5 6 - 7 8 - 9 10
A Adaptors
digit “1” 0 1 2 3 4 5 6 - 7 8 - 9 10
The numbers stated in this position refer to the ends number.
4 One End 7 Three Ends

5 Two Ends 9 Four Ends
digit “2” 0 1 2 3 4 5 6 - 7 8 - 9 10
The numbers stated in this position refer to the gender and
99
geometry of the ends.
One End/Accessories
0 Male plug
1 Female plug
TWO ENDS
1st end 2nd end geometry

0 male male straight
1 female female straight
2 male female straight
1 2 THREE ENDS
3 1st end 2nd end 3rd end

0 male male male
1 male male female
2 male female male
3 female female female
4 female female male
5 female male female
1 2
1st end 2nd end 3rd end
3 Y female female female
FOUR ENDS
1st end 2nd end 3rd end 4th end

0 male male male male
3 male male male female
4 male female male female
5 male female female female
3 6 female female female female
1 2 7 female 1 female 1 female 1 female 2
4 9 male male female female
Digit “3”-“4” 0 1 2 3 4 5 6 - 7 8 - 9 10
The numbers stated in these positions indicate the first end
100
type (see table “Termination Ends Type and Priority”).
When male and female ends are present, the male is always
the first end. When all the ends are male or female, one end
takes priority respect to the other one following the tables
“Termination Ends Type and Priority”.
Digit “5”-“6” 0 1 2 3 4 5 6 - 7 8 - 9 10
The numbers stated in these positions indicate the second end.
Digit “7”-“8” 0 1 2 3 4 5 6 - 7 8 - 9 10
and “9”-“10”
When the ends are part of the same family, the first size is the small-
est. The size sequence is the same of the ends sequence (the first size
indicates the first end, the second size indicates the second end).
Special adaptors (3-ways and 4-ways)

When two ends are part of the same family, the family is indi-
cated only one time. When three or four ends are part of the
same family, the family is repeated twice.
When all the ends are part of different families, all the families
and all the relative sizes are indicated.
Special suffix
The special suffix allows the identification of special features L LONG BODY
not included in the standard coding.
The special suffix must be placed at the end of the code. X L EXTRA LONG BODY
Termination Ends Type and Priority

03 BSP Banjo (Female) / BSP Male Parallel Thread O’R Flat Face
(ISO 1179-3)
04 BSP Fixed Female GAS DIN 3852-2 “form X” - ISO 1179-1
05 BSP Parallel Thread (60° cone BS5200)
06 BSP Male Parallel Thread Flat face
28 NPTF Male SAE J476a
30 Male O-ring Boss (Non-Adjustable Light) SAE J1926-3
31 Male O-ring Boss (Adjustable Light) SAE J1926-3
44 BSP Male Parallel Thread Flat face for bonded washer
46 Super Staple Male / Super Staple Fixed Female
48 Staple Male / Staple Fixed Female
59 Flushfit Female / Flush-fit Fixed Female
64 BSP Male Front Seal
72 Female Swivel Super Staple-lock Connection
82 Female Swivel Staple-lock Connection
MINING STAPLES PART NUMBERING SYSTEM

101
digit “0” 0 1 2 3 4 5 6 7 - 8 9
J Accessories
digit “1” 0 1 2 3 4 5 6 7 - 8 9
L Staples
digit “2”-“3” 0 1 2 3 4 5 6 7 - 8 9
These digits identify the Termination End of the family to whom
staples are referred.
See “Termination Ends Type and Priority”.
digit “4” 0 1 2 3 4 5 6 7 - 8 9
This digit specifies the material used.
0 Standard
1 Stainless
digit “5” 0 1 2 3 4 5 6 7 - 8 9
This digit specifies the surface.
0 Standard
1 Zinc Plated
2 Spring Steel Black Phospate
digit “6” 0 1 2 3 4 5 6 7 - 8 9
The number stated in this position indicate the section’s shape.
S Standard T Flat top

F Flat D Form “D”
digit “7” 0 1 2 3 4 5 6 7 - 8 9
The number stated in this position indicate the length.
S Standard
L Long
0 1 2 3 4 5 6 7 - 8 9
digit “8”-“9”
The number stated in this position indicate the nominal bore
dash size.
MINING BALL VALVES PART NUMBERING SYSTEM

0 1 2 3 4 5 6 7 - 8 9 - 10 11
digit “0”-“1”
AV means always Valves
0 1 2 3 4 5 6 7 - 8 9 - 10 11
digit “2”-“3”-“4”
These digits identify the series.
I.e.: M (Mining) S (Staple-lock) 1 (Design 1)
MS Mining Valves Series Staple Lock 1 MS1 Cubic Shaped; Female-Compact Female
102 MS Mining Valves Series Staple Lock 2 MS2 Hexagonal Shaped; Female-Compact Female
MS Mining Valves Series Staple Lock 3 MS3 Cylindrical Shaped; Female
MS Mining Valves Series Staple Lock 4 MS4 Cubic Shaped; Male-Compact Female
MS Mining Valves Series Staple Lock 5 MS5 Hexagonal Shaped; Male-Compact Female
MS Mining Valves Series Staple Lock 6 MS6 Cylindrical Shaped; Male-Female
MH Mining Valves Series Super Staple Lock 1 MH1 Cubic Shaped; Female
MH Mining Valves Series Super Staple Lock 2 MH2 Cylindrical Shaped; Female
MH Mining Valves Series Super Staple Lock 3 MH3 Cubic Shaped; Male-Female
MH Mining Valves Series Super Staple Lock 4 MH4 Cylindrical Shaped; Male-Female
digit “5” 0 1 2 3 4 5 6 7 - 8 9 - 10 11
Gender
M Male - Male
F Female - Female
B Male - Female
digit “6” 0 1 2 3 4 5 6 7 - 8 9 - 10 11
This digit identify the handle type.
1 Single Handle
L Single Long Handle
X Single Extra Long Handle
P Single Pad Lock Handle
2 Double Handle
3 Hexagon Handle
5 Safety Handle
6 Safety Pad Lock Handle
digit “7” 0 1 2 3 4 5 6 7 - 8 9 - 10 11
This digit identify the handle color.
N Natural
R Red
W White
G Green
B Blue
O Orange
digit “8”-“9”
0 1 2 3 4 5 6 7 - 8 9 - 10 11
and “10”-“11”
The numbers stated in these positions indicate the ends’ size.

When male and female ends are present, the male is always
the first end.
When all the ends are male or female, one end takes priority
respect to the other one following the tables “Priority of the
Ends”.
When ends are part of the same family, the first size is the
smallest.
When ends have the same size, the second size is omitted.
103_116_Qsafe:103_116_Qsafe 3-04-2009 10:25 Pagina 103
Quick Couplings
INTRODUCTION
A quick-coupling is a mechanical device, made up of both a
male and female part, used when frequently connecting and
104
disconnecting two or more lines of a hydraulic or pneumatic
system. This device also guarantees the sealing in both con-
nected and disconnected conditions.
The Manuli quick-couplings range - range - has been
specifically developed and engineered for hydraulic systems.
fig. 1 - Example of hydraulic circuit
APPLICATIONS
The common hydraulic applications for Q.Safe are: tools for
agriculture and construction equipment, braking systems of
agriculture trailers, diagnosis devices of hydraulic circuits, sys-
tems for industrial applications (steel mills industry and plas-
tic/rubber machinery industry).
fig. 2 - Agriculture fig. 3 - Earth movement fig. 4 - Steel mills
If two or more parts of a

hydraulic circuit have to be con-
nected or disconnected several
times during the operation, the
use of quick-couplings will
reduce both set-up time and
cost. In addition the loss of oil
from the circuit is drastically
reduced. fig. 5 – Connections of quick-cou-
plings
STRUCTURE OF A QUICK-COUPLING
A quick-coupling is always made by two different parts con-
necting to each-other: the female part (coupler) and the male
105
part (nipple).
Both the coupler and the nipple are equipped with a shut-off
valve that guarantees hydraulic sealing in uncoupled condi-
tion, usually through a gasket.
When connecting the two parts, both the shut-off valves
move back allowing the flow. In coupled condition the
hydraulic sealing between coupler and nipple is guaranteed
by an O-ring placed in a dedicated groove of the coupler
together with a back-up ring to increase the resistance against
O-ring extrusion.
fig. 6 – Quick-release coupling structure
A quick-coupling can be primarily distinguished according to

the type of locking system between coupler and nipple and
the type of shut-off valve.
fig. 7 – Examples of Locking systems

Main types of locking systems

Q.Safe range currently comprises of two different types of lock-
106
ing systems:
1) Latching ball system
The connection between the two parts is provided by a num-
ber of balls held by the sleeve of the coupler and the external
groove of the nipple.
a. Uncoupled condition
b. Connection: pulling back the sleeve the latching balls can

fall in the nipple groove
c. Coupled condition: the latching balls are held in the nip-

ple groove by the sleeve which returns in initial position
2) Screw-on latching system

The connection occurs by screwing a sleeve, machined with
female thread, to a mating male thread machined on the
other part.
a. Uncoupled condition
b. Connection: when the two halves start to engage, sealing

between male and female is guaranteed by an O-ring
c. Coupled condition
The main types of shut-off valve

Q.Safe range currently comprises of three different types of
107
shut-off valve system.
1) Poppet valve: the sealing occurs through a prominent valve
placed inside the nipple and the coupler.
When the quick-coupling is disconnected the sealing is guar-
anteed by a moulded shaped seal.
fig. 8 – Poppet valve quick-coupling
shaped seal In order to increase the resistance against seal wash-out in

gland case of high flow, the Q.Safe poppet valve is made by three
different parts:
• the body of poppet valve
• the gland
• shaped seal
poppet valve
fig. 9 – Components of a poppet valve
2) Ball valve: the sealing occurs through a ball valve placed

inside the nipple and the coupler.
When the quick-coupling is disconnected the sealing is guar-
anteed by a metal-to metal sealing.
Ball valve was the first type of shut-off system introduced in
the market, but in comparison to the poppet valve it is less
convenient mainly due to the following reasons:
fig. 10 – Ball valve quick-coupling • higher pressure drop of the quick-coupling
• lower burst pressure of the quick-coupling and then lower
working pressure.
3) Flush valve: this type of shut-off system avoids the loss of fluid
during the operation of connection and disconnection.
Because of the complicated architecture, the manufacturing
costs of flat face quick-coupling are quite high. However,
when dust reduction and environment protection are the
main concerns, flush valve solution is the most effective one.
fig. 11 – Flush-valve (or “Flat-face”) quick-
coupling The sealing is guaranteed by a moulded shaped seal. In
order to prevent the seal wash-out in case of high flow and
to increase the resistance against wear due to dirt and and
dust inclusion, Q.Safe flush valve is made in Polyurethane
with a special shape.
PRODUCT RANGE
The Q.Safe range consists of the following product families:
108
fig. 1 – MQS-A series: ISO-A fig. 2 – MQS-B series: ISO-B

MQS-N series: Standard
fig. 3 – MQS-AF series: Push-pull fig. 4 – MQS-F series: Flat Face
fig. 5 – MQS-SG, -SC, -ST series: fig. 6 – MQS-VB, -VS series:

Screw to connect Braking Circuit Valve
fig. 7 – MQS-CV series: fig. 8 – Accessories & Service Kits

Check valves
Depending on the typical applications, main international

standards and engineering specifications, Q.Safe range can
be divided as shown in the following tables.
Poppet and ball valves quick-couplings for agriculture and

industrial applications
109
Shut-off Connection Locking
Series Description Female ref Male ref Specifications
valve Disconnection system
Q008 Q002 Poppet
MQS-A ISO A
Q009 Q003 Ball Pull back Latching
ISO 7241-A
the sleeve balls
ISO A
MQS-AP Q010 Q006 Poppet
under pressure
MQS-AF PUSH-PULL Q013 –
Poppet Latching
PUSH-PULL Push-pull ISO 7241-A
MQS-AFP Q015 – balls
under pressure
Q032 Q029 Poppet Pull back Latching
MQS-N STANDARD balls
–
Q033 Q030 Ball the sleeve
Pull back Latching
MQS-B ISO B Q024 Q021 Poppet balls
ISO 7241-B
the sleeve
1) MQS-A, MQS-AP, MQS-AF and MQS-AFP families undertake

to ISO 7241-A standard that defines the main performances
and the geometry of connection area of nipple and coupler.
ISO 7241-A standard was introduced to guarantee the
worldwide interchangeability of quick-release couplings.
• MQS-A (ISO A ) nipple and coupler connection occurs
pulling back the coupler sleeve and pushing the nipple into
the coupler. The disconnection occurs pulling back the cou-
pler sleeve and pulling out the nipple.
fig. 9 – Example of Push-Pull coupler
• MQS-AF refers to push-pull coupler, widely used in low and
medium tractors.
When bulkhead mounted on the outside sleeve, the connec-
tion occurs just pushing the MQS-A nipple into the push-pull
coupler. The disconnection occurs just by pulling out the nipple.
An important feature of a push-pull coupler is the breakway

function that allows the automatic disconnection to prevent
damage of the quick-release coupling or the hose in case of
accident (i.e. a towed implement becomes unhitched). This
fig. 10 – Example of breakaway function
when Push-Pull is wall-mounted feature is ruled by ISO 5675 standard.
• MQS-AP and MQS-AFP are recommended in case of con-

nection under pressure (i.e. residual pressure due to thermal
expansion).
The connection is allowed through to a micro-valve placed
on the top of poppet valve capable to spill oil from the cir-
cuit and then reducing the pressure.
fig. 11 – Micro valve of MQS-AFP

2) MQS-N quick-coupling refers to the oldest series introduced

in the market, still very common in agriculture applications.
110
The ½” inch size of this series is completely interchangeable
with ½” inch size of MQS-A series. Therefore Q.Safe range
does not include MQS-N ½” size.
3) MQS-B quick-couplings are very similar to MQS-A series, but

undertaking to ISO 7241-B standard that defines the main
performances and the geometry of connection area of nip-
ple and coupler.
MQS-B is the reference series for industrial applications.
Beside carbon steel version, brass and stainless steel versions
are very common as well.
Screw-on quick-couplings for heavy duty applications

SCREW for
MQS-SG Q052 Q051 Poppet –
German market
Screw-on
SCREW for
MQS-SC hydraulic cylinders Q056 Q055 Ball Screw-on latching –
system
MQS-ST SCREW Q058 Q057 Poppet –

for trucks
In case of severe working conditions with pressure impulses,

latching balls system can suffer in terms of reliability and dura-
bility because of BRINELLING.
In these working conditions screw-on quick-couplings are the
most effective solution due to the large surface contact
between male and female part. Therefore the mechanical
stress can be reduced.
In addition screw-on quick-coupling allow the connection
under pressure.
There is no international standard referring to the performanc-
es and the interchangeability of any screw-on quick-coupling
type.
1) MQS-SG series was originally introduced into the German mar-

ket, but now is used worldwide. This has helped to resolve
some issues related to pressure impulses and vibrations on
heavy duty applications.
fig. 12 – MQS- SG series (Screw fig. 13 - Application on hydraulic

for German Market) hammer
2) MQS-SC quick-coupling is specifically designed for very high

pressure applications in steady conditions like hydraulic
111
cylinders
fig. 14 – MQS- SC series (Screw for fig. 15 - Application on hydraulic

Hydraulic Cylinders) cylinders
3) MQS-ST series is commonly used in truck trailer applications.

Usually the sleeve of coupler is wing-shaped which enables
easier connection to the male and female.
fig. 16 - MQS – ST series (Screw for fig. 17 – Application on trucks

Trucks)
Flat-face quick-couplings

Push the male Latching ISO 16028
MQS-F FLAT FACE Q041 Q039 Flat HTMA (3/8” only)
Pull back the sleeve balls
MQS-F was originally designed for construction equipment appli-

cations in the North American market. Later ISO 16028 standards
was introduced to define the main performances and the geom-
etry of connection area of the nipple and the coupler.
Main features of flat-face couplings are:
• no fluid loss during disconnection
• reduced air inclusion during connection
• easy cleaining of mating surfaces
fig. 18 – MQS – F series (Flat-face) fig. 19 – Flat-face application on

earth moving machines
An optimized internal design of MQS-F quick-release coupling

guarantees to reduce the flow distorsion, therefore minimaz-
112
ing the pressure drops.
Braking circuit valves

BRAKING Latching
MQS-VB Q048 Q047 Flat Pull back the sleeve ISO 5676
CIRCUIT VALVE balls
Screw-on
AGRICULTURE latching –
MQS-VS Q050 Q049 Flat Screw-on
VALVE
system
1) MQS-VB series undertakes to ISO 5676 and it’s specifically

designed to connect the braking circuit of the trailer to the
hydraulic system of the tractor.
2) MQS-VS valve has the same function of MQS-VB but with
screw-on locking system.
fig. 20 – Braking circuit valve fig. 21 – Agriculture valve
fig. 22 – Tractor and trailer

Q.Safe Part Numbering System
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13 113
DIGIT “0”
Q Quick-release coupling
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
DIGIT “1”
0 Hydraulic
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
DIGIT “2” – “3”

Quick-release coupling
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
Series Description
02 Male according to ISO 7241-1 standards, series A - Poppet valve
03 Male according to ISO 7241-1 standards, series A - Ball valve
06 Male according to ISO 7241-1 standards, series A - Connectable under pressure
08 Female according to ISO 7241-1 standards, series A - One-way release, poppet valve
09 Female according to ISO 7241-1 standards, series A - One-way release, ball valve
10 Female according to ISO 7241-1 standards, series A - One-way release, connectable
under pressure
13 Female according to ISO 7241-1 standards, series A - Two-ways release, poppet valve
15 Female according to ISO 7241-1 standards, series A - Two-ways release, connectable
under pressure
29 Male interchangeable with series 4000 - Poppet valve
30 Male interchangeable with series 4000 - Ball valve
32 Female interchangeable with series 4000 - One-way release, poppet valve
33 Female interchangeable with series 4000 - One-way release, ball valve
39 Flat-Face male according to ISO 16028
41 Flat face female according to ISO 16028 - With safety sleeve
47 Male for hydraulic braking circuit according to ISO 5676
48 Female for hydraulic braking circuit according to ISO 5676
49 Screw-type male for hydraulic braking circuit
50 Screw-type female for hydraulic braking circuit
51 Screw-type male for German market
52 Screw-type female for German market
55 Screw-type male for hydraulic cylinder
56 Screw-type female for hydraulic cylinder
57 Screw-type male for truck
58 Screw-type female for truck
DIGIT “4”
114 0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates the material

1 steel
2 AISI 316
3 AISI 303
4 Brass
5 Aluminum
DIGIT “5”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates the sealing material

0 no seal
1 NBR
2 HNBR
3 FKM (viton, FPM)
4 CR (neoprene)
5 EPDM
6 FFPM (Kalrez)
7 PTFE
8 VMQ (silicone rubber)
9 AU (polyurethane)
DIGIT “6” – “7”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates the termination end type
Series Description
04 BSP male bulkhead / Fixed female BSP DIN 3852-2 “form X” - ISO 1179-1
05 BSP parallel thread (60° cone BS5200)
11 Male metric thread (24° cone light type DIN 3861)
12 Male metric thread (24° cone heavy type DIN 3861)
14 Metric male DIN 3852-11 “form E” / Metric fixed female DIN 3852-1 “form X” and “form Y”
19 Metric male (adjustable + non-adjustable heavy) ISO 6149-2 / Metric fixed female ISO 6149-1
23 JIC thread (37° cone) bulkhead
28 NPTF male SAE J476A / NPSM swivel female
30 Male O-Ring boss (non-adjustable light) SAE J1926-3 / Female port SAE J1926-1
34 NPTF fixed female SAE J476A
37 Flange (A/C and refri application) / Metric male 60° cone superlight DIN 3863 bulkhead
77 Male bulkhead DIN (24° cone light type)
82 Male bulkhead BSP
87 Male bulkhead DIN (24° cone heavy type)
DIGIT “8”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13 115
It indicates the thread gender

0 male
1 female
DIGIT “9”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates a customized version
DIGIT “10” – “11”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates the quick coupling size
DIGIT “12” – “13”
0 1 2 3 4 5 6 7 8 9 - 10 11 - 12 13
It indicates the thread size

117_124_Refrigeration:117_124_Refrigeration 2-04-2009 17:17 Pagina 117
Refrigeration
REFRIGERATION APPLICATIONS
Refrigeration line in Manuli concerns with Air Conditioning
and Mobile refrigeration.
118
A/C Air conditioning + Mobile refrigeration
|
\/
Manuli REFRIGERATION product range.
They are both systems that exchange heat with the environ-
ment cooling or freezing the environment itself.
Manuli Refrigeration market

Manuli Refrigeration market consists of:
A/C big buses A/C small & medium buses
Trucks mobile refrigeration A/C Off-high way
Air Conditioning (A/C) and Refrigeration system cycle

The basic refrigeration cycle makes use of the boiling and con-
densing of a working fluid, the refrigerant, to move heat from
one place to another.
Fig. 1 provides a schematic diagram of the components of a
typical one-stage vapor-compression refrigeration system.
Starting at the compressor (which is basically a pump that rais-
es the pressure, so it will move the refrigerant through the sys-
tem), the refrigerant is compressed and sent out of the com-
pressor as a high temperature, high pressure, superheated gas
(it is said to be on the ‘high side’ of the system). The refriger-
ant travels to the condenser, that changes the refrigerant from
a high temperature gas to a warm temperature liquid: as it
condenses, it gives up heat to the outside air. As the refriger-
ant leaves the condenser, it is cooler, but still under pressure
provided by the compressor. It then reaches the expansion
valve (Thermal Expansion Valve, TXV, or throttling valve). The
expansion valve meters the proper amount of refrigerant into
the evaporator and allows the high-pressure refrigerant to
flash through becoming a lower pressure, cooled mix of liquid
and gas (saturated gas). This saturated gas enters the evapo-
rator where it is changed to a cool dry gas: as it evaporates, it

absorbs heat from the warm, moist “room air” blown across
the evaporator, changing its state from liquid to vapor. The
cool dry gas, then, re-enters the compressor to be pressurized
again and to re-start the cycle. 119
So, in summary, during the refrigeration cycle, refrigerant cir-
culates through the system changing temperature, pressure
and physical state (liquid & vapor). This allows heat to be
absorbed from air entering the passenger compartment and
carried to the condenser where it is released. The compressor
provides the pumping action necessary to move the refriger-
ant and together with the expansion valve create the pressure
changes. Flexible hoses are integral part of the system: their
duty is to transfer thermal power conveying the refrigerant
from one side to the other side of the system.
In fig. 1 are also indicated the average working conditions
with the two most common used refrigerants for air-condition-
ing and transport refrigeration applications, respectively R134a
and R404A. The main difference between the two applications
is the temperature of the cabin to refrigerate, that has to be
sensibly lower in transport refrigeration: different temperatures
can be obviously obtained by means of different refrigerants,
due to their different thermodynamic properties.
Anyhow, the real observed working conditions depend on a lot
of factors, among which above all the refrigerant type and the
system dimensioning type. For the example refrigerants maxi-
mum extreme peak values of discharge temperature and pres-
sure (superheated gas) are in the range of 140°C and 35bar.
fig. 1 - Main components and processes - General indication [Referential Refrigerants: R134a (A/C);
R404A (Refrigeration)].
The temperature in the cabin to refrigerate is lower in transport

refrigeration application than in air conditioning application.
Different temperature can be obtained with different refriger-

ants (see fig. 2). Transport refrigeration is higher demanding
120
system than air conditioning.
fig. 2 - Difference between A/C and Refrigeration system
For refrigeration application are recommended hoses with

thermoplastic inner layer, like type D and type E (see hoses
classification in the next paragraph).
HOSES AND FITTINGS

The components of the system are connected by HOSES and
FITTINGS assembled.
fig. 3 - Main structure of refrigeration hose
To clarify further:
fig. 4 - Detailed structure of refrigeration hose

Hoses
Different possible types of hoses, according to specification:
121
• SAE J2064 types A Elastomeric, textile reinforced
• SAE J2064 types B Elastomeric, wire reinforced
• SAE J2064 types C Barrier, textile reinforced
• SAE J2064 types D Thermoplastic, textile reinforced, elastomeric cover
• SAE J2064 types E Veneer, textile reinforced
• SAE J2064 types F Veneer, Barrier, Thermoplastic Liner
The following details explain the hose structure.
SAE J2064 types A Elastomeric, textile reinforced

The hose is made using a suitable seamless synthetic elas-
tomeric tube. The reinforcement does consist of textile yarn,
cord, or fabric adhered to the tube and cover. The outer cover
has a heat and ozone resistant synthetic elastomer.
SAE J2064 types B Elastomeric, wire reinforced

The hose is built with a suitable seamless synthetic elastomer-
ic tube. The reinforcement consists of steel wire adhered to
the elastomeric tube. The cover consists of a heat-resistant
textile yarn impregnated with a synthetic elastomeric cement.
SAE J2064 types C Barrier, textile reinforced

The hose has a suitable thermoplastic barrier between elastomeric
layers. The reinforcement consists of suitable textile yarn, cord, or
fabric adhered to the tube and cover. The outer cover has a heat
and ozone resistant synthetic elastomer.
SAE J2064 types D Thermoplastic, textile reinforced, elas-

tomeric cover
The hose has a suitable thermoplastic tube. The reinforcement
consists of suitable textile yarn, cord, or fabric adhered to the
tube and cover. The outer cover has a heat and ozone resist-
ant synthetic elastomer.
SAE J2064 types E Veneer, textile reinforced

The hose has a suitable thermoplastic veneer lining the inside
diameter with an elastomeric tube outer layer. The reinforce-
ment consists of suitable textile yarn, cord, or fabric adhered to
the tube and cover. The outer cover has a heat and ozone
resistant synthetic elastomer.
SAE J2064 types F Veneer, Barrier, Thermoplastic Liner

The hose has a suitable thermoplastic veneer liner with a ther-
moplastic barrier between elastomeric layer. The reinforcement
consists of suitable textile yarn, cord, or fabric adhered to the
tube and cover. The cover has a heat and ozone resistant syn-
thetic elastomer.
Fittings
Shown here below, the most common termination ends used
122
in Refrigeration.
fig. 1 - 45° SAE female fig. 2 - O-ring female fig. 3 - 24° DIN flare O-ring ogival
female
fig. 4 - O-ring female - Rotalock fig. 5 - Short drop O-ring female fig. 6 - ORFS (flat seat) female
(size 11)
fig. 7 - Flange fig. 8 - SAE male 45° cone fig. 9 - O-ring male seat
fig. 10 - O-ring male fig. 11 - Termination end for

expansion valve
REFRIGERANTS AND LUBRICANTS

The liquid circulating in the system is an emulsion of refriger-
ant and lubricant:
• the refrigerant is related to thermodynamic process;
• the lubricant is to lubricate the mechanical components of
the system.
The international market is now ready for new environmental-
ly friendly solutions.
The most common current refrigerants and lubricants are
shown the in the following tables.
A/C fluid Remarks Lubricant

123
the most common
gas for automotive
R134a PAG/POE
applications and
off-highway machine.
Refrigeration
Remarks Lubricant
fluid
fluid for industrial
R404A applications, buses and PAG/POE
mobile refrigeration.
fluid for industrial

R407C applications, buses and PAG/POE
mobile refrigeration.
PAG = POLYALKYLENE GLYCOL

POE = POLYOL ESTER
SPECIFICATIONS
Specifications may be sudivided into International standards
and OEM’s specifications, as follows:
The SAE J2064 represents the basic standard requirements for
A/C fluids hose assemblies.
Specifications from A/C systems manufactures and OEMs

include tests and requirements similar to SAE J2064, some-
times additional specifications are requested.
The customers’ homologation process generally requires field
tests.
Specification SAE J2064

Application: Automotive field and involves tests using R134a +
PAG (lubricant) -30° ÷ 125°C
Tests on assembly hose
SAE J2064 is neither for design, nor for dimensions.
It prescribes some tests, describes how to perform them and
the performance results.
If the hose assemblies pass the tests it is according to SAE
J2064.
Tests according to SAE

In the following table, the main tests listed according to the
124
international specification (SAE J 2064).
Test Meaning
indication of the loss of refrigerant

1 Permeation test
through the hose wall.
indication of the loss of refrigerant

through the coupling fitting-hose. It is
2 Coupling integrity test
also a very good indication of product
reliability
indication of the performance of the

3 Aging test
hose under aging conditions
indication of the performance of the

4 Cold test
hose under cold conditions.
indication about the reduction of the

5 Vacuum flattening external diameter of the hose in inter-
nal vacuum conditions
indication of the % change in length of

6 Length change
the hose under pressure
7 Bursting strength indication of the burst pressure
8 Proof test indication of the sealing
indication about particles extracted

9 Extraction test from the hose internal surface by
refrigerant/lubricant mixture
indication of the ozone resistance of

10 Ozone test
the cover
indication of the contamination degree

11 Cleanliness test
inside the hose
Moisture ingression indication of the ingression of moisture

12
class through the hose wall
125_134_hoseassembly:125_134_hoseassembly 3-04-2009 10:42 Pagina 125
Hose assembly
HOSE ASSEMBLY DATA

How to describe hydraulic hose assemblies?
When you have to build or order a hydraulic hose assembly,
126
the following information must be clear:
Assembly drawing - www.manuli-hydraulics.com
EQUATOR / 2
Cut hose lenght (mm)
Assembly overall lenght (mm)
• Hose description from catalogue (hose type and size) FLUID CONNECTORS
• First and second coupling termination end style and dash PRODUCT RANGE
size
• Offset angle or orientation of couplings if both couplings
contain elbow ends
• Assembly overall length
• Quantity of assemblies required.
In order to support assemblers and OEMs in this activity,
Manuli offers a complete set of tools for assembling drawing
on the web (visit: www.manuli-hydraulics.com).
Hose cutting
1. To determine the “cut hose length”, from the “overall assem-
bly length” deduct the cut-off length “A” of both end fittings.
Consult the fitting catalogue for “A” dimensions; ENGLISH / ESPAÑOL
2. Cut the hose square, using a proper sharp blade disk with
fine-tooth;
Assembly instructions
3. Clean hoses with compressed air
Hose assembly instructions

Follow the procedure and recommendations reported on the
current edition of the Manuli assembly instructions document,
yearly updated for assembly fabrication.
In addition, a dedicated training presentation on assembly
process is available on www.manuli-hydraulics.com Caution
Caution: follow safety procedures. the selection of hose and proper fittings
should always be determined consider-
Orientation of offset elbows fittings ing the working pressure of the applica-
Fitting orientation is necessary when a hose assembly requires tion, including any surge or pressure
peak. The hose will guarantee normal
two elbow couplings at both the extremities: in this case fittings service life before replacement if correctly
must be oriented to each other to ensure proper installation used at a pressure level within its rated
with minimal stress due to hose twisting. working pressure.
Fitting orientation is measured from the centreline of the first

coupling held in a vertical position and looking at the assem-
127
bly towards the second end by measuring the angle in a
counter clockwise direction (or clockwise depending on the
customer drawing).
The orientation angle tolerance should be within:

± 3 degrees for assembly lengths up to 610mm,
± 5 degrees for assembly lengths over 610mm.
Backing off to get desired angle should be avoided after
having crimped the fittings.
Try to avoid the use of double elbow hose assemblies: twisting
of the hose during installation may occur. In fact the relative
location of the natural curvature in the hose may induce a
twist during pressure cycling and the twisted hose may reduce
the life of the assembly.
Safety recommendations
For safety reasons and to underline the relevance of the hose
fitting compatibility study, carried out by Manuli with severe
qualification programs, to highlight the need to avoid the “mix
and match” of hose and fittings from different manufacturers,
it is recommended to read the par. 6 of the SAE J1273 specifi-
cation, well describing these subjects.
Hose-fitting compatibility is a very delicate aspect of the assem-

bly design, where the proper study and testing of the hose-fit-
ting area is the critical part of the whole project: that’s why it is
absolutely necessary to use the original components with the
recommended assembly prescriptions.
There is also a relevant aspect of industrial liability to consider,
in fact it is responsibility of the assembler to check properly the
compatibility of hose and fittings for the assemblies produced
and released to the end user.
For the proper procedure to carry out assembly operation,
please refer to the Manuli Assembly instructions document
updated yearly.
Refer to SAE J1273 par. 6 for further details on hose assembly fabrication.
J1273
for Hydraulic Hose
Assemblies
CLEANING, INSPECTION, TESTING

Additional operations for assemblies preparation
128
• Cleaning
Assemblies can be cleaned by blowing out with clean com-
pressed air.
Assemblies may be rinsed out with dedicated fluids if the
tube stock is compatible, otherwise hot water at 55°C to
65°C max. See Manuli Rubber Industries catalogue for spe-
cial cleaning equipment.
fig. 1 - Cleaning machine
• Inspection
Examine hose assembly internally for cut or bulged tube,
obstructions, or other abnormalities. Check that the cou-
pling is correctly swaged, that the ferrule neck is exactly
inside the fitting latch area, fitting is aligned with the hose.
Check for proper gap between nut and socket: nuts should
swivel freely.
Check the branding of the hose to be sure that the assem-
bly is not twisted. Cap the ends of the hose with plastic cov-
ers to keep clean. fig. 2 - Proof pressure test
• Proof pressure test

The hose assembly can be requested to be hydrostatically
tested. The procedure for proof pressure testing is clearly
specified in International Standard ISO 1402. The test is gen-
erally carried out at twice the recommended working pres-
sure of the hose.
Test pressure should be held for at least 30 seconds as
requested (proof pressure test is not a destructive test).
When test pressure is reached, visually inspect hose assem-
bly for:
• eventual leaks or signs of weakness
• possible movements or abnormalities of the coupling in
relation to the hose.
Any of these defects are cause for rejection.
Warning: testing should be conducted in

approved test stands with adequate guards to
protect the operators (see also the equipment
manual for proper use of the test bench).
HOSE ASSEMBLY INSTALLATION TIPS
Proper hose installation is essential for satisfactory performance.

If hose length is excessive, the appearance of the installation
129
will be unsatisfactory, the configuration can create problems
due to contacts with external bodies.
If hose assemblies are too short to allow adequate flexing and
deformation in length due to pressure, hose service life will be
reduced.
The diagrams supplied in the previous chapter show proper
hose routing which provide maximum performance and
safety conditions. These are examples suggesting general
guidelines studying new hose installations .
Let’s focus here on the assembly installation tips:

Before installing hydraulic hose assemblies, review the safety
precautions included in this manual as well as the sys-
tem/equipment user manual. Installation varies based on cou-
pling configurations, use of adaptors and routing.
The following sequence of operations is a general procedure

for the correct installation of hose assemblies, in conformity
with safety and technical requirements.
a. clean the surrounding area where connections are to be
made. Make sure no dirt or contamination gets into
hydraulic openings;
b. install adaptors into ports (if used);
c. lay the hose assembly into operating position to verify
length and correct routing;
d. screw one end of hose assembly onto port (or adaptor). If
the hose assembly uses an elbow fitting, always install it first
to ensure proper positioning;
e. screw other end of the assembly without twisting the hose.
Use a spanner on the backup hex of the fitting while tight-
ening;
f. properly torque both ends at the recommended torque
values;
g. run the hydraulic system to circulate oil under low pressure
and reinspect for leaks and potentially damaging contacts.
Circulation also purges air (bleed) from the system that can
cause sluggish performance and possible damage to
pumps and other components.
Tips for coupling installation

Let’s consider the three main cases of male fittings, flanges and
swivel female connections.
1) Male fitting to port connections

Male fitting to port connections can be made using three
types of configurations:
• solid male;
• swivel male;
• block-style adaptors with locknuts.
Solid male fittings are installed by rotating the entire hose

assembly as you screw the male into the port, since hose rota-
130
tion is necessary, never use two solid males on the same
assembly. If an O-ring is used, lubricate it with a light oil before
installation: a dry O-ring will stick and pull away from the seal-
ing area resulting in a poor seal. Once hand-tightened, use a
wrench on the hex to properly torque the fitting. PTFE tape
can be used on tapered threads to ease installation and seal
better.
fig. 1 - Flanges installation tip
Swivel males installation does not require hose rotation.
Simply screw the male into the port and use a spanner to
torque properly. Since the hose does not rotate, you can easily
orientate the hose curvature to assist in routing.
Be aware that male swivels have internal O-Rings that must be
compatible with the fluid used.
Block-style adaptors generally use locknuts to orientate fitting.

Rotate the block and thread fitting into port. When nearly
tight, hold block in position needed and tighten locknut
against port.
2) Flanges (figure 1)
Are installed using split flange clamps or one piece clamps.
For proper flange fitting installation:

• put a small amount of oil on the O-Ring and place it in the
fitting groove. Oil will prevent the O-Ring from falling out;
• place fitting over port;
• install clamp over flange head and screw in bolts by hand;
• use wrench to tighten using crossing pattern sequence;
• tighten to correct torque figure.
3) Female swivel connections

Female swivel connections are made by rotating the swivel nut
over the solid male threads on the port. Never use a swivel
female with a swivel male. Once hand tightened and use a
wrench to hold the backup hex (if present) while tightening
the swivel nut to proper torque. This will prevent insert rotation
and hose twist.
Bent tube and block-style fittings must be held in position by
hand while tightening.
HOSE PROTECTION
Many accessories and additional components are sometimes
used with hose assemblies in order to protect them from abra-
131
sions, extreme temperatures and irradiation, for safety reasons,
for fire protection, etc.
Let’s see the most common types of protection the selection
criteria and the methods used to solve routing and protection
problems.
Bundling (fig. 1).

fig. 1 - Bundling When installing hose assemblies, various bundling techniques
can improve space utilisation, appearance and hose life. Here
are some tips:
• Group and bundle similarly constructed and sized hose
together using clamp blocks, nylon straps or nylon sleeving
or plastic spring guards;
• Always consider mechanical movement when bundling.
Allow sufficient slack without pulling on a fitting or another
hose. Bundles (like individual hoses) should bend in one
plane only;
fig. 2 - Sleeving • Avoid to bundle high-pressure hoses with low-pressure
hoses: under pressure, they can work against each other;
• Bundling rubber hose with thermoplastic or PTFE hose
should be avoided.
Sleeving
There are numerous sleeving types used today. The most com-
mon is nylon (fig. 2), which is typically used for one or more
of the following applications:
• to protect hose from abrasion;
• for use in bundling;
fig. 3 - Spring guard
• to protect equipment and operators from injury due to hose
failure (fluid jet dispersion).
Spring guard
There are many type of spring guards: flat armour, plated wire,
plastic, etc. They can be used to bundle hoses or provide sta-
bility and/or protection against abrasion. Tightly wound plate
wire guards can also be used as bend restrictors to ease stress
on the hose (fig. 3).
fig. 4 - Bend restrictor Bend restrictors

Bend restrictors typically are PVC or steel sleeves which are
installed near the coupling during hose assembly. They reduce
bending stress in the hose near the coupling to prevent dam-
age (fig. 4).
Clamps
Clamps are used to fix the assemblies to the system/equipment
and avoid potential contacts with high temperature surfaces,
reduce vibration and risk of unintended movements (fig. 5).
fig. 5 - Clamps A wide range of clamp types and quality is available on the
market: with rubber hoses, the use of special clamps with

internal soft rubber rings in contact with the hose cover is
132
advisable. These clamps considerably reduce the risk of abrasion
on the hose cover, even in presence of vibrations, dust, etc.
Manuli Rubber Industries has experience with some of the top

quality level of clamps (fig. 6); contact Manuli Rubber Industries
for detailed recommendations.
Some useful tips for the installation of clamps and assemblies
are the following:
• choose clamp bore close to the hose OD, without crimping it:
- the hose should “breath” under pressure;
- the hose should adjust its configuration.
• for safety reasons, position the clamps to reduce the possi-
bility of “whiplash” in case of fitting blow-off;
• “soft” rubber insert between clamps structures is always
advisable to reduce vibrations transmission and cover wear
(the rubber insert has to be “sacrificial”).
Safety restraint systems (whipcheck and guards/shields)

Restraint systems such as whipchecks and protection shields
are used to fulfil the safety requirements of the hydraulic
systems and equipment, in particular when there is risk of injury
to operators and personnel working near the equipment.
Restraint systems are used:
• in hydraulics applications when there are safety aspects

involved in a potential failure of the assembly, mainly blow-
off of the fitting: we recommend STOPFLEX type;
• always with compressed air and with gas applications in

general (e.g. EQUATOR hose with compressed air), due to
the hazard connected with the potential “whiplash” of the
hose disconnected from the fitting, we recommended
WHIPCHECK type, double connection rings.
When the equipment-designers identify an hazardous condi-

tion where the risk can be contained using restraint systems or
shields, different International Specification can be followed as
reference.
• For example, refer to - International Standard ISO 3457

(earth-moving machinery - guards and shields - definitions
and specifications) – Point 4.9: “Where hoses are used oper-
ating to a pressure of at least 50 bar and/or at temperature of
at least 50°C, and are located within 0,5 m of the operator,
deflecting shield should be provided to protect the operator
from thesudden hose failure.
The shield should be sufficiently sturdy to stop or divert fluids
away from the operator.”
• ISO 4413 "Hydraulic fluid power - General rules relating to

systems" point 9.5.3 Protection against failure (of hose
133
assemblies) reports: "If the failure of a hose assembly consti-
tutes a whiplash hazard, the hose assembly shall be
restrained or shielded. If the failure of a hose assembly con-
stitutes a fluid ejection or fire hazard, it shall be shielded." The
need of restraint systems or shields on the hose assemblies
depends on the evaluation of the impact on safety of each
assembly in the equipment by the equipment designers.
fig. 6 - Clamp with rubber ring
• EN 982 "Safety of machinery - Safety requirements for fluid
power systems and their components - Hydraulics" is the
“armonized” safety specification in Europe. Point 5.3.4.3.2
Failure (of flexible hose assemblies) states: "If the failure of a
flexible hose assembly constitutes a whiplash hazard, it shall
be restrained or shielded. If the failure of a flexible hose
assembly constitutes a fluid ejection hazard, it shall be
shielded."
fig. 7 - Whipcheck double eys • EN 982 describes also the safety requirements for flexible
hose assemblies in the chapter 5.3.4.3:“Flexible hose assem-
blies shall fulfil all performance requirements specified in the
appropriate European and/or international standard(s)”. This
means that hose assemblies on a machines must meet the
SAE, ISO and EN requirements and must have a record for
qualifications and production control tests, to be complying
with the European Machinery Directive 98/37/CE.
• Similar requirement and recommendations are reported by

fig. 8 - Protective shields the SAE J1273 specification, par. 4.2 Whipping hose (safety
considerations): "If a pressurised hose assembly blows apart,
the fittings can be thrown off at high speed and the loose
hose can flail or whip with great force. When this risk exists,
consider guards and restraints to protect against injury." Also
in this case the requirement of the restraint systems for hose
assemblies would be subjected to the system designer risk
evaluation.
The restraint system with steel ferrule crimped on the

hose are not recommended, due to the risk to involve
hose deformation, cover bubbles, etc. since the hose
body must be free to “breath” under pressure. Manuli
recommends the use of restraint systems with internal
rubber ring in contact with the hose cover or steel
cords (e.g. STOPFLEX).
EUROPEAN LEGISLATION ON SAFETY AND CONCLUSION

Safety is of maximum importance when designing hydraulic
circuits, especially when considering the high pressure lines.
134
In Europe the reference legislation is the European Machinery
Directive 98/37/CE, that requires at the point 1.5.3. “Where
machinery is powered by an energy other than electricity (e.g.
hydraulic, pneumatic or thermal energy, etc.), it must be so
designed, constructed and equipped as to avoid all potential
hazards associated with these types of energy.”
The European standard EN 982 - “Safety of machinery - safety

requirements for fluid power systems and their components -
hydraulics,” lists possible hazards associated with the use of
hydraulic power in a machine:
• mechanical hazards (e.g. coupling blow-off, whipping
hose, hose burst, pinhole in hose);
• thermal hazards (e.g. fluid high temperature) can heat
metal parts such as couplings and adaptors, causing severe
burns when touched by someone;
• unintended movements caused by electromagnetic fields;
• hazards resulting from contact with, or inhalation of, harmful
fluids, gases, mists, fumes and dusts;
• fire or explosion hazards;
• hazards caused by failure of energy supply, breaking down
of machinery parts and other functional disorders (e.g.
falling or ejecting of moving parts or pieces held by the
machinery, unexpected start, etc.).
135_146_maintenance:135_146_maintenance 31-03-2009 10:47 Pagina 135
Maintenance
MAINTENANCE
A proper preventive maintenance program for fluid connec-
tors used in hydraulic system/equipment is the key success
136
factor to guarantee a reliable equipment in service and avoid
potential injury to personnel.
That’s why in this section we suggest criteria to implement a

correct preventive maintenance program and to identify prob-
lems and defects on fluid connectors in field, proposing the
necessary corrective actions.
The SAE J1273 par. 8 “Maintenance inspection” is suggested as

one of the main guideline existing in the sector.
Refer to SAE J1273 par. 8 specification for further details on maintenance

inspection. J1273
for Hydraulic Hose
Assemblies
PERIODIC INSPECTIONS
Prior to conducting any inspection of your hydraulic system, it
is important to know how the equipment sounds, looks and
137
feels during normal operation. Any noticeable difference in its
daily operation may indicate a problem. Take time to check it
out thoroughly.
Frequency of inspection
Because this varies by type of equipment, refer to the machine
or equipment reference manual for recommendations.
Always follow the manufacturers inspection recom-

mendations. If they are not available, a good rule is:
• for mobile equipment: every 400-600 service hours or

three months, whichever occurs first
• for stationary equipment: every 800-1000 service hours

or every three months whichever occurs first.
In addition, the following factors influence how often you

need to inspect your hoses:
• critical nature of the equipment;
• operating temperatures;
• operating and safety procedures;
• environmental factors;
• type of usage (rugged, high vibrations, infrequent or long
lasting operating time, etc).
Of course the direct experience with each specific equip-

ment/machine is often the best guide to understand when to
conduct inspections. The past history of each machine type
and model is a source of information to fix the inspection fre-
quency.
If we consider a rugged and high pressure hose application

operating 24 hours a day, seven days a week, it will require
more frequent inspections than a hose used in a mild environ-
ment at ambient temperature that is only pressurised a few
times a day.
Specific functional problems, such as high heat sources, con-

stant high temperature of the fluid being conveyed, localised
abrasions and/or severe hose configurations, for example with
very reduced bend radius near the couplings, etc. may need
more frequent inspections to avoid or detect potentially dam-
aging situations.
Inspection methodology
The use of a proper preventive maintenance checklist can help
to carry out inspections, aimed at maintaining
machines/equipment efficient and in conditions of maximum
safety.
Follow as a general guideline the next 3 steps:
138
Step 1
Place the equipment/machine and components in a safe and
neutral position, being sure that the components are not
under stress, holding a load or in mid-cycle position (this could
cause the equipment to be unstable or to move).
Before starting the maintenance operations on the equipment
drop eventual loads, retract cylinders, etc.
Turn off equipment or machine power putting it in conditions
that it cannot be restarted accidentally by an inattentive oper-
ator. Consider the use of lock out tags to prevent accidental
operation of the equipment.
Step 2
Remove external protection panels and visually inspect hose
and fittings for damages or leaks.
In particular look for:
Leakages: leaking can occur in the hose body, at the hose-

coupling interface and/or on the fitting end. Signs of leakage
can be simple oil humidity near the fittings, visible puddles of
fluid in or around the equipment, low level of fluid in reservoir
or greasy/dirty hoses. In this case, it is important carefully look
around to locate the leak. If leaks are detected on the hose
assembly, it is necessary to replace it.
Warning: never check for leaks by running the

hands over hose or hydraulic connections, on the
contrary clean the area, determining where the
leak originates. Visual inspection of the other
hydraulic components, like valves, pumps, cylin-
ders, etc., for leaks and damages is also advisable.
Hose cover and other abnormalities: if the cover is dam-

aged, the reinforcement could be deteriorated as well. Visual
inspection of the cover for signs of abrasion, blisters, cracks,
nicks, cuts and/or hardened conditions, is a first check to be
done. Also the whole system around needs to be checked in
order to find eventual direct causes of the damages (for exam-
ple abrasions or heat sources).
If the hose is particularly hot, the operating temperature may

be excessive: the systems has to be checked for unefficiencies
If the hose wire reinforcement is clearly visible in some parts, it

is necessary to replace the hose: for other criteria of hose 139
replacement, refer to the following list of abnormalities:
• leaks at hose fitting or in hose

• damaged, cut or abraded cover
• exposed reinforcement
• kinked, crushed, flattened, or twisted hose
• hard, stiff. heat cracked, or charred hose
• blistered, soft, degraded, or loose cover
• cracked, damaged, or badly corroded fittings
• fitting slippage on hose
• leaking ports
• damaged or missing hose clamps, guards or shield
• excessive dirt and debris around hose
• other signs of significant deterioration.
If any of these conditions exist, evaluate the hose assem-

blies for correction or replacement.
Hose configurations (routings): proper hose routing is criti-

cal in preventing early hose failure.
It is recommended to carry out a rough analysis to check that
hoses do not rub against each other or against metal parts,
that the bend radii of the configurations are not lower than
the minimum recommended in all the possible configurations,
that twisting or kinking are not present, that there is enough
slack to allow for length deformation under pressure, etc.
Also check that hoses are not located close to a high heat
source for potential cover cracks or hardening.
Step 3
Reinstall the external protection panels and restart the sys-
tem/equipment.
Control the whole system behaviour under normal working
conditions, check for smell of burning oil, signs of excessive
heat, vibrations, strange noises, etc.
If any step in the inspection indicates a potential or a clear

problem, it is recommended to check it out and repair imme-
diately.
It is also necessary to keep a detailed logbook of inspections
and maintenance activities, complete with service informa-
tion. This can be used also to identify and prevent recurrent
problems of the system/equipment type, fix the frequency of
inspection, list the necessary component substitution recom-
mendations, etc.
HOSE ASSEMBLY TROUBLESHOOTING GUIDE

The following list of troubleshooting is a useful guideline to Caution
recognise the hose field problems and identify faults, causes
140 Before attempting to replace or inspect a
and correct solutions. It is also a useful training session with hydraulic hose assembly on an applica-
prevention targets, based on the field experience. tion first ensure that the machine is
Even if not exhaustive, this list highlights the main problems of turned off and all moving parts are
common use, installation, maintenance of hose assemblies, secured and lowered to the ground.
Ensure that the assembly is depressurised
fittings, adapters, etc. before attempting to un-install. The
assembly and internal fluid may be hot,
When selecting a component for a new application, the therefore, allow to cool down before
knowledge of potential failure modes is a suitable guideline to handling. Wear personal protection
equipment. Never place a hand or other
drive the selection of hose and fittings and to develop the body part near a high pressure fluid jet. A
proper assembly solution considering the functional parame- through risk assessment should be carried
ters of the application/equipment. out prior to working on machinery and
sites.
When replacing a failed hydraulic hose assembly it is impor-
tant to understand why the assembly being replaced failed.
This is to ensure that the replacement assembly is “fit for pur-
pose” and that premature failure can be avoided.
Failure of assemblies can be avoided by implementing regular

inspection and monitoring deterioration. Hydraulic hose
assemblies can then be replaced before a failure occurs.
Failure of hose assemblies can cause danger to personnel,
possible machine damage, a fire hazard and environmental
pollution.
We will now take a look at the faults that can be identified as

a reason for failure or increase the risk of failure, the causes of
these effects and remedies to prevent future failure resulting in
extended hose assembly service life.
We can categorise failure faults, as follows:
• visible faults on the external hose & connectors:

- hose has burst – critical failure!
- hose cover shows signs if deterioration
- fluid spray from hose cover (pin hole) – critical failure!
- connectors become detached – critical failure!
- leakage from connectors
- weapage at the rear of the ferrule
• non-visible faults from within the hose & connectors:

- internal tube material fault
- internal tube deterioration.
Hose has burst

The reason for this occurrence may have been one of the
141
following:
• The peak pressure of the hydraulic system is too high for
the hose type utilised this is generally due to poor know-
ledge of the application or of an application function but
also to component faults (fig.1).
• The hose has been bent past its minimum bend radius,
damaging the wires, weakening the assembly and resulting
fig. 1 in a pressure burst failure at the centre of the hose bend.
• The hose cover has been abraded by external causes, the
reinforcement is corroded in the location of the burst:
external protections for the hose can be necessary or special
cover materials are recommended (fig. 2).
• A hose burst close to the connector may be due to coni-
cal stress caused by wire fatigue. This can be the result of
starting the bend too close to the connector (fig. 3) or a very
flexible hose that has been allowed to whip, creating the
“elephant ear effect” (fig. 4). A hose bend restrictor can be
fig. 2 used. The hose assembly has been damaged causing an
instant failure or a failure due to a damage induced weaken-
ing of the hose assembly (fig. 5).
• High-frequency, intense pressure spikes fatigued bold
reinforcement: it is advisable to check the severity of pressure
spikes. The selection of robust hose types (e.g. with wire
spiral architecture instead of wire braided reinforcement).
Replace hose assembly with properly crimped assembly.
• Pressure exceeded strength of the hose and/or the hose
bold is twisted during attachment to ports and movement
opened gaps in reinforcement. In this case it is necessary to
fig. 3
check pressure rating output of the system, eventually use a
hose with a higher pressure rating, and improve the routing,
maybe with swivel couplings, studying the flexing configura-
tions so that the hose remains always in the same plane (it is not
recommended to bend the hose in more than one plane).
Hose cover shows signs of deterioration

Hose cover deterioration will involve a reinforcement decay
due to corrosion, etc. and could eventually lead to a critical
assembly failure. The cause of deterioration may be one of the
fig. 4 following:
• Hose cover abrasion, as a result of hose assemblies rub-

bing against each other or as a result of contact with sharp
edges or rough machine components, will expose the hose
reinforcement allowing wire corrosion to take place. Severe
abrasion may have damaged the reinforcement, weakening
the hose. With synthetic fibre reinforced hose types the abra-
sion weakens the hose’s ability to withstand the internal pres-
sure. All instances will eventually lead to a critical hose failure
fig. 5 (fig. 6-7).
• Cracks may be observed on the hose cover. This may be

due to natural ageing or as a result of accelerated ageing
142
due to ozone attack or use of the assembly at extreme range
of temperature (fig. 8).
• A hardening of the hose cover may be the result of an
incorrectly specified hose type for the application system
temperatures, internal or external. Excess temperature may
have been generated by high friction of the fluid inside the
system (e.g. closed circuits) or by external heat sources (e.g.
engine compartment). fig. 6
• A soft hose cover may be a result of an incorrectly cured rub-
ber by the manufacturer or the effects of an incompatible fluid
coming into constant contact with the cover.
• A cracked and peeled hose cover may indicate an extreme
abrasion contact, maybe in combination with a flexing of
the hose close to the connector, during application causing
fatigue. Another symptom can be fluid weeping from the
same area of the hose cover (fig. 9).
• Blisters observed on the hose cover may be a conse-
quence of fluid leakage from inside the hose assembly or fig. 7
fluid being driven through the hose cover.
This may be due to a manufacturing fault or the effects of an
incompatible fluid (fig. 10).
• The aging and the effects of environmental conditions such
as heat, cold, ozone and sunlight, cause loss of performance
properties and failure. The production date of the hose has
to be checked: hoses older than 5 to 7 years are due for
replacement to meet the application conditions.
Hose cover is cracked radially but the cover material is not

fig. 8
hard or brittle
The hose has been exposed to extreme cold temperatures that
caused radial cracks of the cover during the flexing move-
ments. It is necessary to select a hose with characteristics that
meet these conditions or to insulate the assembly with a suit-
able protection.
Cracks in hose liner and cover result in leakage while tube and
cover are still soft and flexible at room temperature: this is the
evidence that flexing of hose during periods of extreme cold
when liner and cover were brittle caused the failure. fig. 9
In this case it is important to check the minimum internal and
external temperatures, in particular at the time of equipment
start-up. Use a hose that remains flexible below the applica-
tions lowest operating temperature.
fig. 10
Fluid spray from hose cover

Danger! Do not attempt to put your hands near the spray. This
143
could result in serious injury!
Fluid venting from the hose cover may be the result of wire
reinforcement breakage due to hose damage or maybe as a
consequence of a hose tube manufacturing fault (fig. 11).
It may also be the result of a hose tube failure due to the use
of incompatible fluid, extreme temperatures or hose-tube
fatigue.
fig. 11 Incorrect assembly operation could be another cause of this
type of failure.
Connector has become detached (blow-off)

The possible causes of such a severe failure can be:
• Connector and hose are mix-matched between two differ-
ent manufacturers, therefore there is not the correct level of
connector retention on the hose (fig. 12).
• The internal pressure, may be over the rated one, lateral
stretch, axial twist or a combination of all the stress/strain
fig. 12 resulted in a critical assembly failure.
• Connector has been incorrectly installed onto the hose
and/or not swaged/crimped according to the manufacturer
procedures (fig. 13).
• A connector may be damaged due to incompatible inserts
and ferrules being used resulting in a material fracture.
• A ferrule may crack resulting in a hose assembly failure. This
may be due to incorrect swaging assembly equipment or to
a material fault (fig. 14).
Leakage is observed from connectors

fig. 13
Connector leakage can be linked to the following causes:
• The connector may have become loose due to incorrect
tightening or as a result of machinery vibration. The fluid
may be seen leaking from the end of the connector or
behind the nut (fig. 15).
• The sealing surface of the connector and/or the mating sur-
face may be incorrectly manufactured, old and/or corroded
or damaged (fig. 16).
• Where an O-Ring is specified, it may have been damaged or
aged after a long period in service or simply was fallen out
fig. 14 of the insert or mating surface allowing leakage (fig. 17).
• The connector nut, thread or clamp bolt thread may have
been damaged misaligning the components while tighten-
ing.
Leakage between the insert and the top of the ferrule

(hose-fitting area)
• This may be the result of incorrectly matched or assembled
hose and connectors, hose deterioration due to extreme
temperatures, too high working pressure for the selected
fig. 15 hose type (presence of uncontrolled pressure peaks), vibra-
tions, hose stretch or twist (severe routing with reduced

bend radius near the fittings or twist), chemical incompatibil-
144
ity with the service fluid (fig. 18-19).
• This may also be caused by insufficient hose insertion during
assembly and/or undercrimping. Also excessive vibration
and flexing movements may weaken the interface and
reduce the assembly ability to prevent fluid leakage.
Whether it has been undercrimped or the insert and ferrule
have been improperly assembled, the hose assembly must
be replaced with one properly assembled. fig. 16
Hose leaks without bursting

High fluid velocity or aggressive fluid erodes hose tube (inter-
nal layer). Fluid velocity may be too high or a jet stream of fluid
through an orifice may impact the tube in a concentrated
area. Contamination particles can add to the erosion. In this
case it is necessary to consider a larger diameter hose to han-
dle the flow rate at a lower velocity. Make sure that hoses
come straight away from any port that has an orifice. Fluid
should be clean, check fluid and filters. fig. 17
Hose tube failure

Tube is swollen and badly deteriorated, it could also be partially
washed out. The fluid used may not be compatible with the
hose tube; the effect of very high temperature of the fluid can be
a concomitant cause too. In this case it is necessary to check the
Manuli fluid chart on the catalogue, verifying also details regard-
ing the maximum temperature recommended. For further spe-
cific assistance contact Manuli Rubber Industries (fig. 20).
fig. 18
Reinforcement failure: hose is flattened out in several areas
and appears twisted.
Hose was installed in a twisted position and when pressurised
tries to return to a neutral position causing the reinforcement to
tear apart. The twist of the hose can reduce the hose service
life. The cause is an incorrect installation problem: using the
hose branding as visual indication of proper installation it is pos-
sible to realise a correct routing and installation of the assembly
(eventually using also live swivel adaptors if necessary).
Leakage on a tapered male termination end fig. 19

Thread has been re-used without proper installation proce-
dure. The use of a proper sealant, like a PTFE tape or other
sealant material on the threads is necessary.
The reuse of tapered fittings is not recom-

mended, the use of a new fitting is
advised.
fig. 20
Fitting seal area leakage: SAE screw threads with 37 or 45

degree flare seals
145
The flare seat may be severely deformed and/or cracked. This
condition is due to over-tightening. The solution can be to
replace fittings and refer to the installation guide, following the
recommended torques. The female flare or the male seat may
have been damaged in transit or storage: in this case consider
all flare fittings should be inspected for scratches or nicks prior
to installation. Replace the fitting with a new one if damaged.
Remark: the 37 degree and 45 degree flare fitting

are not interchangeable with each others. The
degree of angle is different and will not produce
an adequate seal.
Fitting seal area leakage: O-Ring seal types

New fittings with O-Ring seal can leak at start up due to
improper installation. The O-Ring must be lightly lubricated
prior to threading onto the fitting: this reduces axial friction
during insertion which causes the O-ring to move out of the
seal area and to be sheared. Do not exceed with the oil, risk-
ing to lubricate also the threading requiring excessive torque
at the installation.
Fittings with O-Rings can leak after considerable service time

due aging of the rubber. O-Ring must be replaced after a
fixed service period (depending on the application).
In case of further leaks check system pressure and relief valve

condition and setting. In case the O-Ring seal is swollen or par-
tially eroded, this phenomenon can be caused by fluid incom-
patibility: it is necessary to replace the O-Ring with a material
recommended for the fluid being used.
O-Ring material can be found hard, brittle and cracked by

exposure, resulting in a leak. In this case it is necessary to veri-
fy the presence of high fluid temperatures or vicinity to high
heat sources. Eventually replace the O-Ring with a suitable
material compatible with the system temperature (see photo
of a typical aged O-Ring: fig. 17)
Bolts on flange head fitting not correctly tightened cause the

O-ring to extrude out of the fitting: bolts must be tightened
correctly at the proper recommended torque values, following
the correct procedure of installation.
Wrong size O-Ring installed: check fitting manufacturers
specifications for proper O-Ring size and material (refer to the
coupling section of this technical manual).
Description of leaks: SAE J1176 (and ISO/TR 11340) Note

In order to describe, register and communicate the gravity of
146 Manuli specialist assistance may be
the leak it is useful to refer to SAE J1176 specification. required to determine the cause of the
SAE J1176 establishes a guide for defining the degree of exter- failure. Consult your nearest dealer or
nal leakage with 6 classifications for dusty (class 0D to class 5D contact Manuli Rubber Industries for
from no moisture to recurring fluid with a measurable stream advice.
of droplets) and 6 for dust-free conditions (class 0 to class 5
from no moisture to recurring fluid with a stream of droplets).
The choice of classifications is intended to be by visual mean
and describes the state at the observation.
Pump cavitation: suction hose is flattened out or kinked in

one or more areas
If the hose selected for a suction application does not have the
characteristics to be suitable for vacuum resistance or routing is
not correct, exceeding the minimum bend radius, then the hose
can be partially collapsing and then fluid flow can be seriously
restricted. A more robust structure is necessary, Manuli offers a
wide range of hoses suitable for vacuum resistance applications.
It is necessary to replace the assembly and re-route it, using even-
tually elbow fittings to reduce the hose bend.
Conclusions
The procedure in case of different faults and causes is as follows:
• should material or assembly manufacture faults be
suspected then the assembly should be returned with all
application details to the manufacturer for analysis and
reporting;
• should the fault be the result of incorrect hose or con-
nector selection then refer to the hose selection part of
this manual to carry out a correct hose and fittings selec-
tion after having evaluated the application;
• should the fault be considered the result of incorrect
installation then refer to the criteria recommended in
the hose assembly routing section in this manual;
• should it be suspected the fault could be the result of a
faulty application then consult with the machine user
or manufacturer.
Considering the vast array of faults which can be identified as

the cause for an assembly failure or can increase for failure it
can now be understood why simply replacing a hydraulic
hose assembly with a similar type and installing it without
investigating the reason for failure may only result in a short
service life of the replacement assembly and/or a potential risk
of injury to personnel.
"FAILURE RECOGNITION & PREVENTION" IS THE ONLY

SAFE SOLUTION FOR REPLACING HYDRAULIC HOSE
ASSEMBLIES.
147_168_appendix:147_168_appendix 31-03-2009 17:59 Pagina 147
Appendix
SYSTEM OF UNITS AND CONVERSIONS

The following tables show the most common units of measu-
rements and conversion charts used in the hydraulic sector.
148
Hose size identification numbers

Nominal hose I.D. SAE ISO R5 hose
inches dash size Metric size dash size
fraction decimal
3/16 .1875 -3 5 -4
1/4 .250 -4 6.3 -5
5/16 .3125 -5 8 -6
3/8 .375 -6 10 -
13/32 .40625 - - -8
1/2 .500 -8 12.5 -10
5/8 .625 -10 16 -12
3/4 .750 -12 19 -
7/8 .875 - - -16
1 1.000 -16 25 -
1 1/8 1.125 - - -20
1 1/4 1.250 -20 31.5 -
1 3/8 1.375 - - -24
1 1/2 1.500 -24 38 -
1 13/16 1.8125 - - -32
2 2.000 -32 51 -
2 1/2 2.500 -40 63 -
3 3.000 -48 76 -
3 1/2 3.500 -56 89 -
4 4.000 -64 102 -
Decimal and Millimeter Equivalents of Fractions

Inches Inches Inches
Fraction Decimals Millimeters Fraction Decimals Millimeters Fraction Decimals Millimeters
1/64 .015625 .397 23/64 .359375 9.128 11/16 .6875 17.463
1/32 .03125 .794 3/8 .375 9.525 45/64 .703125 17.859
3/64 .046875 1.191 25/64 .390625 9.922 23/32 .71875 18.256
1/16 .0625 1.588 13/32 .40625 10.319 47/64 .734375 18.653
5/64 .078125 1.984 27/64 .421875 10.716 3/4 .750 19.050
3/32 .09375 2.381 7/16 .4375 11.113 49/64 .765625 19.447
7/64 .109375 2.778 29/64 .453125 11.509 25/32 .78125 19.844
1/8 .125 3.175 15/32 .46875 11.906 51/64 .796875 20.241
9/64 .140625 3.572 31/64 .484375 12.303 13/16 .8125 20.638
5/32 .15625 3.969 1/2 .500 12.700 53/64 .828125 21.034
11/64 .171875 4.366 33/64 .515625 13.097 27/32 .84375 21.431
3/16 .1875 4.763 17/32 .53125 13.494 55/64 .859375 21.828
13/64 .203125 5.159 35/64 .546875 13.891 7/8 .875 22.225
7/32 .21875 5.556 9/16 .5625 14.288 57/64 .890625 22.622
15/64 .234375 5.953 37/64 .578125 14.684 29/32 .90625 23.019
1/4 .250 6.350 19/32 .59375 15.081 59/64 .921875 23.416
17/64 .265625 6.747 39/64 .609375 15.478 15/16 .9375 23.813
9/32 .28125 7.144 5/8 .625 15.875 61/64 .953125 24.209
19/64 .296875 7.541 41/64 640625 16.272 31/32 .96875 24.606
5/16 .3125 7.938 21/32 .65625 16.669 63/64 .984375 25.003
Pressure Conversions
Metric to PSI PSI to Metric 149
( 1 kPa = .145 psi ) ( 1 psi = 6.89 kPa )
Kilo Pascals Mega Pascals Bar Pounds per Pounds per Kilo Pascals Mega Pascals Bar
(kPa) (MPa) (Bar) Square Inch Square Inch (kPa) (MPa) (Bar)
(psi) (psi)
100 0.1 1 14.5 10 68.9 0.07 0.7

200 0.2 2 29.0 20 137.9 0.14 1.4
300 0.3 3 43.5 30 206.8 0.21 2.1
400 0.4 4 58.0 40 275.8 0.28 2.8
500 0.5 5 72.5 50 344.7 0.34 3.4
600 0.6 6 87.0 60 413.7 0.41 4.1
700 0.7 7 101.5 70 482.6 0.48 4.8
800 0.8 8 116.0 80 551.6 0.55 5.5
900 0.9 9 130.5 90 620.5 0.62 6.2
1,000 1.0 10 145.0 100 689 0.7 6.9
2,000 2.0 20 290.1 200 1,379 1.4 13.8
3,000 3.0 30 435.1 300 2,068 2.1 20.7
4,000 4.0 40 580.2 400 2,758 2.8 27.6
5,000 5.0 50 725.2 500 3,447 3.4 34.5
6,000 6.0 60 870.2 600 4,137 4.1 41.4
7,000 7.0 70 1,015.3 700 4,826 4.8 48.3
8,000 8.0 80 1,160.3 800 5,516 5.5 55.2
9,000 9.0 90 1,305.3 900 6,205 6.2 62.1
10,000 10 100 1,450 1,000 6,895 6.9 68.9
20,000 20 200 2,901 2,000 13,790 13.8 137.9
30,000 30 300 4,351 3,000 20,684 20.7 206.8
40,000 40 400 5,802 4,000 27,579 27.6 275.8
50,000 50 500 7,252 5,000 34,474 34.5 344.7
60,000 60 600 8,702 6,000 41,369 41.4 413.7
70,000 70 700 10,153 7,000 48,263 48.3 482.6
80,000 80 800 11,603 8,000 55,158 55.2 551.6
90,000 90 900 13,053 9,000 62,053 62.1 620.5
100,000 100 1000 14,504 10,000 68,948 68.9 689
200,000 200 2000 29,008 20,000 137,895 137.9 1,379
300,000 300 3000 43,511 30,000 206,843 206.8 2.068
40,000 275,790 275.8 2,758
Physical quantities, units and conversions

150 Quantity Unit SI / Imperial Conversion
mass Kilogram kg 1kg = 2,2046 lb

pound (UK) lb 1lb = 0,4535 kg
force Newton N (1N = 1kg m/s2) 1N = 0,2248 lbf
pound force (UK) lbf 1lbf = 4,4482 N
power Watt W (1W = 1kg m2/s3) 1W = 0,7375 ft lbf/s
foot pound force ft lbf/s 1ft lbf/s = 1,356 W
per second
lenght Meter m 1m = 3,2808 ft
Millimeter mm 1mm = 0,03937 in
foot (UK) ft 1ft = 0,3048 m
inch (UK) In 1in = 25,4 mm
area square meter m2 1m2= 1550 in2
square centimeter cm2 1cm2 = 0,1550 in2
square inch (UK) in2 1in2 = 6,45 cm2
volume cubic meter m3 1m3 = 1000 liter
cubic centimeter cm3 1cm3 = 0,0610 in3
cubic inch (UK) in3 1in3 = 16,387 cm3
gallon (UK) Gal 1gal = 4,5460 liter
gallon (US) Gal 1gal = 3,785 liter
pressure Bar bar (1bar = 105N/m2) 1bar = 14,5035 psi
mega-pascal MPa (1MPa = 10bar) 1MPa = 145,035 psi
kilo-pascal KPa (1KPa = 0,01bar) 1KPa = 0,1450 psi
pound-force lbf=psi 1psi = 0,0689 bar
per square inch
flow rate liters per second l/s (l/s = 0,001m3/s) 1l/min = 0,2199 gallons (UK) per minute
liters per minute l/m (l/min = 0,001m3/min) 1l/min = 0,2642 gallons (US) per minute
gallons per minute (UK) gal/min 1gal/min = 4,546 l/min
gallons per minute (US) gal/min 1gal/min = 3,785 l/min
viscosity Centistokes cSt (cSt = mm2/s)
Units and conversions

Unit from to multiply by
Lenght 1 inch in m 0,0254

1 meter m in 39,370
1 foot ft m 0,3048
1 meter m ft 3,281
Area 1 inch2 in2 mm2 645,16
1 meter2 m2 in2 1550
Volume 1 gallon (UK) gal l 4,546
1 liter l gal (UK) 0,22
1 gallon (US) gal l 3,78
1 liter l gal (US) 0,264
Weight 1 pound lb kg 0,454
1 kilogram kg lb 2,205
Pressure 1 pound/inch2 psi bar 0,06895
1 bar bar psi 14,5
1 pound/inch2 psi MPa 0,006895
1 mega pascal MPa psi 145,035
1 kilo Pascal kPa bar 0,01
1 bar bar kPa 100
1 mega Pascal MPa bar 10
1 bar bar MPa 0,1
Velocity 1 foot/second ft/s m/s 0,3048
1 meter/second m/s ft/s 3,281
Flow 1 gallon/minute (UK) gal/min. l/min. 4,546
1 liter/minute l/min. gal/min. (UK) 0,22
1 gallon/minute (US) gal/min. l/min. 3,78
1 liter/minute l/min. gal/min. (US) 0,264
Temperature degree Fahrenheit °F °C 5/9 (°F-32)
degree Celsius °C °F °C.(9/5)+32
Torque 1 pound/inch lb/in Nm 0,113
1 Newton/meter Nm lb/in 8,85
1 pound/foot lb/ft Nm 1,356
1 Newton/foot Nm lb/ft 0,7374
Temperature Conversion Chart

°C Temp °F °C Temp °F °C Temp °F 151
FAHR. CENT.
210 -79.0 -110 -166 9.9 50 122.0 115 240 464

100 -73.0 -100 -148 10.4 51 123.8 121 250 482
200 -68.0 -90 -130 11.1 52 125.6 127 260 500
-62.0 -80 -112 11.5 53 127.4 132 270 518
190 90 -57.0 -70 -94 12.1 54 129.2 138 280 536
180 -55.0 -67 -88.6 12.6 55 131.0 143 290 554
80 -51.0 -60 -76 13.2 56 132.8 149 300 572
170 -50.0 -58 -72.4 13.7 57 134.6 154 310 590
-46.0 -50 -58 14.3 58 136.4 160 320 608
160 70 -40.0 -40 -40 14.8 59 138.2 165 330 626
150 -34.0 -30 -22 15.6 60 140.0 171 340 644
-30.0 -22 -7.6 16.1 61 141.0 177 350 662
140 60 -29.0 -20 -4 16.6 62 143.6 182 360 680
130 -23.0 -10 14 17.1 63 145.4 188 370 698
-20.0 -4 24.8 17.7 64 147.2 193 380 716
120 50 -17.7 0 32.0 18.2 65 149.0 199 390 734
-17.2 1 33.8 18.8 66 150.8 204 400 752
110 -16.6 2 35.6 19.3 67 152.6 210 410 770
40 -16.1 3 37.4 19.9 68 154.4 215 420 788
100
-15.5 4 39.2 20.4 69 156.2 221 430 806
90 30 -15.0 5 41.0 21.0 70 158.0 226 440 824
-14.4 6 42.8 21.5 71 159.8 232 450 842
80 -13.9 7 44.6 22.2 72 161.6 238 460 860
70 -13.3 8 46.4 22.7 73 163.4 243 470 878
20 -12.7 9 48.2 23.3 74 165.2 249 480 896
60 -12.2 10 50.0 23.8 75 167.0 254 490 914
50 -11.6 11 51.8 24.4 76 168.8 260 500 932
10 -11.1 12 53.6 25.0 77 170.6 265 510 950
40 -10.5 13 55.4 25.5 78 172.4 271 520 968
-10.0 14 57.2 26.2 79 174.2 276 530 986
30 0 -9.4 15 59.0 26.8 80 176.0 282 540 1004
20 -8.8 16 60.8 27.3 81 177.8 288 550 1022
10 -8.3 17 62.6 27.7 82 179.6 293 560 1040
10 -7.7 18 64.4 28.2 83 181.4 299 570 1058
-7.2 19 66.2 28.8 84 183.2 304 580 1076
0 20 -6.6 20 68.0 29.3 85 185.0 310 590 1094
10 -6.1 21 69.8 29.9 86 186.8 315 600 1112
-5.5 22 71.6 30.4 87 188.6 321 610 1130
20 30 -5.0 23 73.4 31.0 88 190.4 326 620 1148
30 -4.4 24 75.2 31.5 89 192.2 332 630 1166
-3.9 25 77.0 32.1 90 194.0 338 640 1184
40 40 -3.3 26 78.8 32.6 91 195.8 343 650 1202
-2.8 27 80.6 33.3 92 197.6 349 660 1220
50 -2.2 28 82.4 33.8 93 199.4 354 670 1238
50 -1.6 29 84.2 34.4 94 201.2 360 680 1256
-1.1 30 86.0 34.9 95 203.0 365 690 1274
-0.6 31 87.8 35.5 96 204.8 371 700 1292
-0 32 89.6 36.1 97 206.8 376 710 1310
-0.5 33 91.4 36.6 98 208.4 382 720 1328
-1.1 34 93.2 37.1 99 210.2 387 730 1346
-1.6 35 95.0 38. 100 212 393 740 1364
Temperature -2.2 36 96.8 43 110 203 399 750 1382
-2.7 37 98.6 49 120 248 404 760 1400
Fahrenheit in Centigrades: -3.3 38 100.4 54 130 266 410 770 1418
If degree °F are higher than zero; -3.8 39 102.2 60 140 284 415 780 1436
°C = (+ °F - 32) x 5/9 -4.4 40 104.0 65 150 302 421 790 1454
-4.9 41 105.8 71 160 320 426 800 1472
If degree °F are lower than zero; -5.5 42 107.6 76 170 338 432 810 1490
°C = (- °F - 32) x 5/9 -6.0 43 109.4 83 180 356 438 820 1508
-6.6 44 111.2 88 190 374 443 830 1526
Centigrades in Fahrenheit: -7.1 45 113.0 93 200 392 449 840 1544
If degree °C are higher than zero; -7.7 46 114.8 99 210 410 454 850 1562
-8.2 47 116.6 100 212 413 460 860 1580
°F = °C x 9/5 + 32 = °C x 1,8 + 32 -8.8 48 118.4 104 220 428 465 870 1598
If degree °C are lower than zero; -9.3 49 120.2 110 230 446 471 880 1616
°F = - °C x 9/5 + 32 = - °C x 1,8 + 32
GLOSSARY
The following is a glossary of terms commonly used in the hose and fittings industry for the hydraulic
sector. However, such words and expressions should not be intended as only with the precise meaning
152
exposed in all the circumstances.
abrasion: a wearing away by friction.

abrasion tester: a machine for determining the quantity of material worn away by friction under
speci-fied conditions.
accelerated life test: a method designed to approximate in a short time the deteriorating effects
obtained under normal service conditions.
accelerator: a compounding ingredient used with a curing agent to increase the rate of vulcanisation.
acid resistant: having the capability to withstand the action of identified acids within specified limits of
concentration and temperature.
activator: a compounding ingredient used to increase the effectiveness of an accelerator.
adapter: the accessory part which can complete the connection between a hose fitting and another
fluid system component. Often, a tube fitting connected to a hose
alloy: metal made of the fusion of two or more metals.
annealing: thermal treatment process which consist of heating a metallurgical product at a sufficient
temperature to recover some or all of its structural and physical-chemical balance and then gradually
cooling it.
assembly rather than a tube assembly.
adhesion: the strength of bond between cured rubber surfaces or between a cured rubber surface
and a non-rubber surface.
adhesion failure: the separation of two bonded surfaces at an interface by a force less than specified
in a test method or the separation of two adjoining surfaces owing to service conditions.
adhesive: a material which, when applied, will cause two surfaces to adhere.
adhesive coating: a layer applied to any product surface to increase its adherence to an adjoining
surface.
aftercure: a continuation of the process of vulcanisation after the cure has been carried to the desired
degree and the source of heat removed.
afterglow: in fire resistance testing, the red glow persisting after extinction of the flame.
aging: changes in physical properties over a period of time.
air cure: vulcanisation without the application of heat. See also: hot air cure.
air oven aging: a means of accelerating a change in the physical properties of rubber compounds by
exposing them to the action of air at an elevated temperature at atmospheric pressure.
ambient temperature: the temperature of the atmosphere or medium surrounding an object under
consideration.
angle of lay: the angle developed at the intersection of a structural element and a line parallel to its
lineal axis.
antioxidant: a compounding ingredient used to retard deterioration caused by oxygen.
anti-ozonant: a compounding ingredient used to retard deterioration caused by ozone.
anti-static: having the capability of furnishing a path for a flow of static electricity.
armored hose: a hose with a protective covering, applied as a braid or helix, to protect from physical
abuse.
assembly: hose assembly.
autoclave: a pressure vessel used for vulcanising rubber products by means of steam under pressure.
banbury mixer: a specific type of internal mixer used to incorporate fillers and other ingredients into 153
rubber or plastic.
band: a thin strip of metal used as a boltless clamp.
bank: an accumulation of material at the opening between the rolls of a mill or calender.
batch: the product of one mixing operation.
bench marks (tensile test): marks of known separation applied to a specimen used to measure strain
(elongation of specimen).
bench test: modified service test in which the service conditions are approximated in the laboratory.
bend: the curvature of a hose from a straight line.
bending force: an amount of stress required to induce bending around a specified radius and hence,
a measure of stiffness.
bend radius: the radius of a bent section of hose measured to the innermost surface of the curved
portion.
bleeding: surface exudation. See also: bloom.
blister: a raised area on the surface or a separation between layers usually creating a void or air-filled
space in a vulcanised article.
bloom: a discolouration or change in appearance of the surface of a rubber product caused by the
migration of a liquid or solid to the surface.
body wire: a round or flat wire helix embedded in the hose wall to increase strength or to resist collapse.
bolt hole circle: a circle on the flange face around which the centre of the bolt holes are distributed.
bore: an internal cylindrical passageway, as of a tube, hose or pipe; the internal diameter of a tube,
hose or pipe.
braid: a continuous sleeve or reinforcement of interwoven single or multiple strands of yarn or wire.
braid angle: the angle developed at the intersection of a braid strand and a line parallel to the axis of
a hose.
braid smash: a defect in a braided reinforcement caused by one or more of the ends of reinforcing
material breaking during the braiding operation.
braided hose: hose in which the reinforcing structure presents braided configuration.
braided ply: a layer of braided reinforcement.
braider: a machine which interweaves strands of yarn or wire to make a hose reinforcement.
brand: a mark or symbol identifying or describing a product and/or manufacturer, either embossed,
inlaid or printed.
breaker ply: an open mesh fabric used to anchor a hose tube or cover to its reinforcement and to
spread impact.
buckled ply: a deformation in a ply which distorts its normal plane.
buffing: grinding a surface to obtain dimensional conformance or surface uniformity.
burst: a rupture caused by internal pressure.
burst pressure: the pressure at which rupture occurs.
calender: a machine equipped with three or more heavy, internally heated or cooled rolls revolving
in opposite directions, which is used for continuously sheeting or plying up rubber compounds, or fric-
tioning or coating fabric with rubber compound.
capped end: a hose end covered to protect its internal elements.
carcass: the fabric, cord and/or metal reinforcing section of a hose as distinguished from the hose tube
or cover.
cement: unvulcanised raw or compounded rubber in a suitable solvent used as an adhesive or sealant.
cemented end: a hose end sealed with the application of a liquid coating.
circular woven jacket: a textile reinforcing member produced on a circular loom for such types of
hose as fire hose.
154
clamp: in hose, a metal fitting or band used around the outside of a hose end to bind the hose to a
coupling, fitting or nipple.
cold flexibility: the relative ease of bending following exposure to specified low temperature conditions.
compound: the mixture of rubber or plastic and other materials which are combined to give the
desired properties when used in the manufacture of a product.
compound ingredient: a material added to a rubber to form a mix.
compression set: the deformation which remains in rubber after it has been subjected to and released
from a specific compressive stress for a definite period of time at a prescribed temperature.
conditioning: the exposure of a specimen under specified conditions, e.g. temperature, humidity, for
a specified period of time before testing.
concentricity: the uniformity of hose wall thickness as measured in a plane normal to the axis of the
hose.
conductive: a rubber having qualities of conducting or transmitting heat or electricity (generally
applied to rubber products capable of conducting static electricity).
copolymer: a polymer formed from two or more types of monomers.
corrugated cover: a longitudinally ribbed or grooved exterior.
corrugated hose: hose with a carcass fluted radially or helically to enhance its flexibility or reduce its
weight.
coupling: a frequently used alternative term for fitting.
cover: the outer component usually intended to protect the carcass of a product.
cover wear: the loss of material during use due to abrasion, cutting or gouging.
cracking: a sharp break or fissure in the surface. Generally caused by strain and environmental conditions.
crazing: a surface effect on rubber articles characterised by multitudinous minute cracks.
creep: the deformation, in either cured or uncured rubber under stress, which occurs with lapse of
time after the immediate deformation.
Crimped-back nut: the method used to realise the mechanical connection of the nut on the fitting by
means of a crimping operation of the neck of the nut.
crimping: the act of forming a hose fitting with a surrounding series of die segments to compress the
hose within the fitting.
crosshead extruder: an extruder so constructed that the axis of the emerging extruded product is at
right angles to the axis of the extruder screw.
cross-link: chemical bond bridging one polymer chain to another.
cross wrap: the overlapping layer or layers of narrow tensioned wrapper fabric spiralled circumferen-
tially over the outside of a hose to obtain external pressure during vulcanisation.
cure: the act of vulcanisation.
cure time: the time required to produce vulcanisation at a given temperature.
cut resistant: having that characteristic of withstanding the cutting action of sharp objects.
date code: any combination of numbers, letters, symbols or other methods used by a manufacturer
to identify the time of manufacture of a product.
denier: a yam sizing system for continuous filament synthetic fibres.
design factor: a ratio used to establish the working pressure of the hose based on the burst strength
of the hose.
dry: the absence of tack; no adhering properties.
durometer: an instrument for measuring the hardness of rubber and plastic compounds.
durometer hardness: a numerical value which indicates the resistance to indentation of the blunt
indentor of the durometer.
E
155
eccentricity: in hose, the condition resulting from the inside and outside diameters not having a com-
mon centre.
eccentric wall: in hose or tubing, a wall of varying thickness.
elastic limit: the limiting extent to which a body may be deformed and yet return to its original shape
after removal of the deforming force.
elastomer: a macromolecular material which, in the vulcanised state at room temperature, can be
stretched repeatedly to at least twice its original length and which, upon release of the stress, will
immediately return to approximately its original length.
elongation: the increase in length expressed numerically as a fraction or percentage of the initial
length.
end: a single strand or one of several parallel strands of a reinforcing material on a single package such
as a braider spool.
endurance test: a service or laboratory test, conducted up to product failure, usually under normal use
conditions.
extruded: forced through the shaping die of an extruder. The extrusion may be solid or hollow cross
section.
extruder (extrusion): a machine, generally with a driven screw, for continuous forming of rubber or
plastic trough a die. It is widely used for the production of hoses.
fabric: a planar structure produced by interlaced yams, fibres or filaments.

fabric impression: a pattern in the rubber surface formed by contact with fabric during vulcanisation
(wrapped).
fatigue: the weakening or deterioration of a material occurring when a repetitious or continuous
application of stress causes strain.
ferrule: a collar placed over a hose end to affix the fitting to the hose. The ferrule may be crimped or
swaged, forcing the hose in against the insert.
filler: any compounding material, usually in powder form, added to rubber in a substantial volume to
improve quality or lower cost;
fitting: a device attached to the end of the hose to facilitate connection.
flange-fitting: a circular ring, at the end of a hose for joining to another circular ring, generally by
bolting.
flat spots: flat areas on the surface of cured hose caused by deformation during vulcanisation.
flex cracking: a surface cracking, induced by repeated bending and straightening.
flexible mandrel: a long, round, smooth rod capable of being coiled in a small diameter. It is used for
support during manufacture of certain types of hose.
flex life: the relative ability of a rubber article to withstand cyclical bending stresses.
flex life test: a laboratory method used to determine the life of a rubber product when subjected to
dynamic bending stresses.
flow rate: a volume of fluid per unit of time passing a given cross-section of a flow passage in a given
direction.
foreign material: any extraneous matter such as wood, paper, metal. sand, dirt or pigment that
should not normally be present in the tube or cover of a hose.
formula: a list of ingredients and their amount, used in the preparation of a compound.
free hose length: the lineal measurement of hose between fittings or couplings.
friction: a rubber adhesive compound impregnating a fabric, usually applied by means of a calendar
(also used to intend the resistance to motion due to the contact of surfaces).
G
156
grab test: a tensile test for woven fabric using specimens considerably wider than the jaws holding
the ends of the test specimen.
grain: the unidirectional orientation of rubber or filler particles resulting in anisotropy of rubber com-
pounds.
ground finish: a surface produced by grinding or buffing,
gum compound: a rubber compound containing only those ingredients necessary for vulcanisation.
Small amounts of other ingredients may be added for processability, colouring, and improving resist-
ance to aging.
hardening: an increase in resistance to indentation.

hardness: resistance to indentation.
heat resistance: the property or ability to resist the deteriorating effects of elevated temperatures.
helical cord: in hose, a reinforcement formed by a cord or cords wound spirally around the body of
a hose.
helix: in hose, a shape formed by spiralling a wire or other reinforcement around the cylindrical body
of a hose.
hold test: a hydrostatic pressure test in which the hose is subjected to a specified internal pressure for
a specified period of time.
hose: a flexible conduit consisting of a tube, reinforcement, and usually an outer cover.
hose assembly: a length of hose with a coupling attached to one or each end.
hose clamp: a collar, band or wire used to hold hose on to a fitting.
hose duck: a woven fabric made from plied yams with approximately equal strength in warp and
filling directions.
hot air cure: vulcanisation by using heated air, with or without pressure.
hysteresis: a loss of energy due to successive deformation and relaxation. It is measured by the area
between the deformation and relaxation stress-strain curves.
hysteresis loop: in general, the area between stress-strain curves of increasing and reducing stress, a
measure of hysteresis.
ID: the abbreviation for inside diameter.

identification yarn: a yarn of single or multiple colours, usually embedded in the hose wall, used to
identify the manufacturer.
impregnation: the act of filling the interstices of an article with a rubber compound. Generally applies
to the treatment of textile fabrics and cords.
impression: a design formed during vulcanisation in the surface of a hose by a method of transfer,
such as fabric impression or molded impression.
impulse: an application of force in a manner to produce sudden strain or motion, such as hydraulic
pressure applied in a hose.
indentation: the extent of deformation by the indentor point of any one of a number of standard
hardness testing instruments (sometimes used to intend a recess in the surface of a hose).
inhibitor: an ingredient used to suppress a chemical reaction or a growing activity such as mildew.
insert: optional term for nipple of a fitting (coupling).
inspection block: a description on a drawing of the dimensional inspection to which a hose will be
subjected.
instantaneous modules: the slope of a stress-strain curve at a single point, employed when modules
varies from point to point.
157
interstice: a small opening, such as between fibres in a cord or threads in a woven or braided fabric.
jacket: a seamless tubular braided or woven ply generally on the outside of a hose.
kinking: a temporary or permanent distortion of the hose induced by bending beyond the minimum
bend radius.
knit fabric: a flat or tubular structure made from one or more yams or filaments whose direction is
generally transverse to the fabric axis but whose successive passes are united by a series of interlocking
loops.
knit ply: a layer of textile reinforcement in which the yarns are applied in an interlocking looped con-
figuration in a continuous tubular structure.
knitter: a machine for forming a fabric by the action of needles engaging threads in such a manner
as to cause a sequence of interlaced loops.
laminated cover: a cover formed to desired thickness from thinner layers vulcanised together.
lap: a part that extends over itself or like part, usually by a desired and predetermined amount.
lap seam: a seam made by placing the edge of one piece of material extending flat over the edge of
the second piece of material.
lay: the amount of advance of any point in a strand for one complete turn.
layer: a single thickness of rubber or fabric between adjacent parts.
latch area: are of the fitting to provide mechanical connection with the ferrule.
lead cure finish: a type of exterior surface of hose, smooth or longitudinally corrugated, obtained by
the lead pipe method of vulcanisation (old method).
leakage: a crack or hole in the tube which allows fluid to escape, or a hose assembly which allows
fluid to escape at the fittings or couplings.
life test: a laboratory procedure used to determine the resistance of a hose to a specific set of destruc-
tive forces or conditions.
light resistance: the ability to retard the deleterious action of light.
lined hose: term generally referring to fire hose having a seamless woven jacket or jackets and a tube.
liner: a separator, usually cloth, plastic film or paper, used to prevent adjacent layers of material from
sticking together. Also used as synonym of internal tube of a hose.
lining: internal tube layer.
livering: a gelling in cement giving a liver-like consistency.
loose cover: a separation of the cover from the carcass or reinforcements.
loose ply: a separation between adjacent plies.
loose tube: a tube separated from the carcass.
lot: a specified quantity of hose from which a sample is taken for inspection.
low temperature flexibility: the ability of a hose to be flexed, bent or bowed at low temperatures
without loss of serviceability.
low temperature flexing: the act of bending or bowing a hose under conditions of cold environ-
ment.
LPG: the abbreviation for liquefied petroleum gas.
M
158
mandrel: a form, generally of elongated round section, used for size and to support hose during
fabrication and/or vulcanisation. It may be rigid for flexible.
mandrel built: a hose fabricated and/or vulcanised on a mandrel.
mandrel wrapped: a tubing, built up by wrapping a thick unvulcanised sheet around a mandrel.
manufacturer's identification: a code symbol used on the hose to indicate the manufacturer.
mass flow rate: the mass of fluid per unit of time passing a given cross-section of a flow passage in a
given direction.
masterbatch: a preliminary mixture of rubber and one or more compound ingredients for such pur-
poses as more thorough dispersion or better processing, and which will later become part of the final
compound in a subsequent mixing operation.
migration: in a rubber compound, the movement of more or less rubber soluble materials from a
point of high concentration to one of low or zero concentration. Migration is applied to the movement
of accelerators, antioxidants, anti-ozonants, sulphur, softeners and organic colours. It is a form of diffusion.
migration stain: a discolouration of a surface by a hose which is adjacent to but not touching the dis-
coloured surface.
mildew inhibited: containing material to prevent or retard the propagation of a fungus growth.
mildew resistance: withstanding the action of mildew and its deteriorating effect.
mill: a machine with two horizontal rolls revolving in opposite directions used for the mastication or
mixing of rubber.
minimum burst pressure: the lowest pressure at which rupture occurs under prescribed conditions.
modules: in the physical testing of rubber, the load necessary to produce a stated percentage of elon-
gation, compression or shear.
moisture absorption: the assimilation of water by a rubber or textile product.
moisture regain: the re absorption of water by textile.
monomer: a low molecular weight substance consisting of molecules capable of reacting with like or
unlike molecules to form a polymer.
Mooney scorch: a measure of the incipient curing characteristics of a rubber compound using the
Mooney viscometer.
Mooney viscosity: a measure of the plasticity of a rubber or rubber compound determined in a
Mooney shearing disc viscometer.
MPa: MegaPascal a measure of pressure, 1 MPa equal to 145 psi
MSHA: Mine Safety and Health Administration
necking down: a localised decrease in the cross-sectional area of a hose resulting from tension.
nerve: a measure of toughness or recovery from deformation in unvulcanised rubbers or compounds.
nip: the clearance between rolls of a mixing mill or calender.
nipple: the internal member or portion of a hose fitting (insert).
nominal: a dimensional value assigned for the purpose of convenient designation; existing in name
only.
nozzle end: an end of hose in which both the inside and outside diameters are reduced.
OD: the abbreviation for outside diameter.

off gauge: not conforming to a specified thickness.
oil proof: not affected by exposure to oil.
oil swell: the change in volume of a rubber article resulting from contact with oil.
open seam: a seam whose edges do not meet, creating a void.

open steam cure: a method of vulcanising in which steam comes in direct contact with the product
159
being cured.
operating pressure: like working pressure or maximum working pressure.
optimum cure: the state of vulcanisation at which a desired combination of characteristics is attained.
overcure: a state of vulcanisation beyond the optimum cure.
oxidation: the reaction of oxygen on a rubber product, usually evidenced by a change in the appear-
ance or in physical properties.
oxygen bomb aging: a means of accelerating a change in the physical properties of rubber com-
pounds by exposing them to the action of oxygen at an elevated temperature and pressure.
ozone cracking: the surface cracks, checks or crazing caused by exposure to atmosphere containing
ozone.
ozone resistance: the ability to withstand the deteriorating effects of ozone (generally cracking).
peptizer: a compounding ingredient used in small proportions to accelerate by chemical action the
softening of rubber under the influence of mechanical action, heat, or both.
permanent fitting: the type of fitting which, once installed, may not be removed for use in another
hose.
permanent set: the amount by which an elastic material fails to return to its original form after defor-
mation.
pick: an individual filling yarn of a fabric or woven jacket.
pin-hole: very small hole, present on the tube surface of a hose as defect.
pin-pricking: the small holes made by means of pins on the hose cover for gas applications.
pitch: the distance from one point on a helix to the corresponding point on the next turn of the helix,
measured parallel to the axis.
pitted tube: surface depressions on the inner tube of a hose.
pitting: superficial fatigue effect on metallic surfaces creating surface depressions, corrosion.
plain ends: the uncapped or otherwise unprotected, straight ends of a hose.
plasticity: a measure of the resistance to shear of an unvulcanised elastomer; it is also used to indicate
a property of vulcanised rubber to retain a shape or form imposed to it by a deforming force.
plasticizer: a compounding ingredient which can change the hardness, flexibility, or plasticity of an
elastomer.
plastometer: an instrument for measuring the viscosity of raw or unvulcanised rubber.
plied yarn: a yarn made by twisting together in one operation two or more single yarns.
ply: a layer or rubberised fabric or a layer of reinforcement.
ply adhesion: the force required to separate two adjoining reinforcing members of a hose.
ply separation: a loss of adhesion between plies.
pock marks: uneven blister-like elevations, depressions or pimpled appearance.
polymer: a macromolecular material formed by the chemical combination of monomers having either
the same or different chemical composition.
porous tube: the physical condition of a hose tube due to the presence of pores or a hose tube that
has low resistance to permeation.
pre-cure: see semi-cure and scorch.
pressure, burst: the pressure at which rupture occurs.
pressure, operating: working pressure.
pressure, proof: a specified pressure which exceeds the manufacturer's recommended working pres-
sure applied to a hose to indicate its reliability at normal working pressure. Proof pressure is usually
twice the working pressure.
pressure, service: generally to intend working pressure.
pressure, working: the maximum pressure to which a hose will be subjected, including the momen-
tary surges in pressure which can occur during service, it is often abbreviated as WP.
160
pricker mark: a perforation of the cover of a hose performed before or after vulcanisation.
processability: the relative ease with which raw or compounded rubber can be handled in or on
rubber processing machinery.
proof pressure test: a non-destructive pressure test applied to a hose to determine its reliability at nor-
mal working pressures by applying pressures which exceed the manufacturer's rated working pressure.
Proof pressure is usually twice the working pressure.
psi: the abbreviation for pounds per square inch.
pulled-down tube: loose tube.
pure gum: a rubber compound containing only those ingredients necessary for vulcanisation; par-
ticularly applicable to natural rubber.
qualification test: the examination of samples from a typical production run of hose to determine
adherence to a given specification; performed for approval as a supplier.
quality conformance inspection or test: the examination of samples from a production run of hose
to determine adherence to given specifications, for acceptance of that production run.
rag-wrap: for wrapped cure.

recovery: the degree to which a hose returns to its normal dimensions or shape after being distorted.
reinforcement: the strengthening members, consisting of either fabric, cord, and/or metal of a hose
(sometimes intended as the non-rubber elements of a hose).
reinforcing agent: an ingredient (not basic to the vulcanisation process) used in a rubber compound
to increase its resistance to mechanical forces.
resin: a compounding material, solid or liquid in form, used to modify the processing and/or vulcani-
sed characteristics of a compound.
retarder: a compounding ingredient used to reduce the tendency of a rubber compound to vulcani-
se prematurely.
reusable coupling: reusable fitting.
reusable fitting: the type of fitting which, by design, may be removed and reused.
reversion: the softening of vulcanised rubber when it is exposed to an elevated temperature; a dete-
rioration in physical properties; (extreme reversion may result in tackiness.).
rise test: a determination of the distance a fire hose, under a specified internal pressure, lifts from the
surface on which is rests.
roll ratio: the ratio of the surface speeds of two adjacent mill or calender rolls.
rubber: a material, elastomer based, that is capable of recovering from large deformations quite
quickly.
rubber cement: generally adhesive cement, rubber based.
safety factor: design factor.

sampling: a process of selecting a portion of a quantity of a hose for testing or inspection, selected
without regard to quality.
scorch: premature vulcanisation of a rubber compound.
screw-together reusable fitting: a type of hose fitting whose socket and nipple are threaded together
in combination with the hose.
161
seam: a line formed by the joining of the edges of a material to form a single ply or layer.
seaming strip: a strip of material laid over a seam to act as a binder.
self cure: vulcanisation without the application of heat.
semi-cure: a preliminary but incomplete cure applied to a tube or hose in the process of manufacture to
cause the tube or hose to acquire a degree of stiffness or to maintain some desired shape, service pressure.
service test: or field test, a test in which the product is used under actual service conditions.
set: the amount of strain remaining after complete release of a load producing a deformation.
shank: that portion of a fitting, which is inserted into the bore of a hose.
shear modules: the ratio of the shear stress to the resulting shear strain (the latter expressed as a frac-
tion of the original thickness of the rubber measure, at right angles to the force); shear modules may
be either static or dynamic.
shelf storage life: the period of time prior to use during which a product retains its intended perform-
ance capability.
shell: sometimes as alternative to the term ferrule.
shock load: a stress created by a sudden force.
simulated service test: test of field simulation.
sink: a collapsed blister or bubble leaving a depression in a product.
skim coat: a layer of rubber material laid on a fabric but not forced into the eave.
skimmed fabric: a fabric coated with rubber on a calendar; the skim coat may or may not be applied
over a friction coat.
skive: the removal of a short length of cover to permit the attachment of a fitting directly over the hose
reinforcement.
slip-on nut: method to block the nut on the fitting by means of a plastic slip.
smooth bore hose: a wire reinforced hose in which the wire is not exposed on the inner surface of
the tube.
smooth cover: a cover having an even and uninterrupted smooth surface.
socket: the external member or portion of a hose fitting, commonly used in describing screw-together
reusable fittings.
soft end: a hose end in which the rigid reinforcement of the body, usually wire, is omitted.
spacing: the space between adjacent turns of helically wound wire.
specification: a document setting pertinent details of a product, such as performance, chemical com-
position, physical properties and dimensions, prepared for use in, or to form the basis for, an agree-
ment between negotiating parties.
specific gravity: the ratio of the weight of a given substance to the weight of an equal volume of
water at a specified temperature.
specimen: an appropriately shaped and prepared sample, ready for use in a test procedure.
spider mark: a cleavage or weak spot caused by the failure of a compound to reunite after passing a
spoke of the spider of an extrusion machine.
spiral: a method of applying reinforcement in which there is no interlacing between individual strands
of the reinforcement.
spiral lay: the manner in which a spiral reinforcement is applied with respect to angularity and lead
or pitch as in a hose or cylindrical article.
splice: a joint or junction made by lapping or butting, and held together through vulcanisation or
mechanical means.
spread: a thin coat of material in solvent form applied on a fabric surface by means of knife, bar or
doctor blade.
spread fabric: a fabric the surface of which is coated with a rubber solution and dried.
spring guard: a steel or plastic helically wound protection applied externally to the hose to protect
from abrasion or make bunches of hoses.
standard: a document or an object for physical comparison, for defining product characteristics,
products or processes, prepared by a consensus of a properly constituted group of those substantially
162
affected and having the qualifications to prepare the standard for use.
staple: a steel fork used for special fittings connection.
static bonding: use of a grounded conductive material to eliminate static electrical charges.
static conductive: having the capability of furnishing a path for a flow of static electricity.
static wire: a wire incorporated in a hose to conduct static electricity.
stock: an uncured rubber compound of a definite composition from which a given article is manufac-
tured.
straight end: a hose end with an inside diameter the same as that of the main body of the hose.
straight wrap: in a curing process, a wrap of lightweight fabric in which the warp threads of the
fabric are parallel to the axis of the hose.
stress relaxation: the decrease in stress after a given time at constant strain.
stress-strain: the relationship of force and deformation of a unit area of a body during compression,
extension or shear.
stretch: an increase in dimension, an elongation.
strike through: in coated or frictioned fabric, a penetration of rubber compound through the fabric;
in woven fire hose, the penetration of the rubber backing through the jacket.
strip test: in fabric testing, tensile strength test made on a strip of fabric ravelled down to a specified
number of threads or width of fabric.
sulphur free: the sulphur in a rubber compound extractable by sodium sulphite after the normal vul-
canisation process.
sulphur total: all the sulphur present in a rubber compound, including inorganic sulphides and
sulphates.
sun checking: the surface cracks, checks, or crazing caused by exposure to direct or indirect sunlight.
surge: a rapid and transient rise in pressure.
swaging: the act of forming a hose fitting by passing it into a die, generally split, which is sized to yield
the desired finished fitting diameter.
swelling: an increase in volume or linear dimension of a material specimen immersed in liquid or
exposed to a vapour.
tack: the ability to adhere to itself.

tack rubber: a property of a rubber and rubber compounds that causes two layers of compounds that
have been pressed together to adhere firmly at the area of contact.
tear resistance: the property of a rubber tube or cover of a hose to resist tearing forces.
teeth: the tension filaments which appear between two adhering plies of rubber as they are pulled apart.
tensile strength: the maximum tensile stress applied while stretching a specimen to rupture.
tensile stress: a stress applied to stretch a test piece (specimen).
termination end: the end part of the fitting, connection and sealing type of a fitting.
test pressure: pressure used to perform a test (e.g. impulse test, proof test).
tex: a yarn size system defined as the weight in grams of 1000 meters of yarn.
thermoplastics: range of resins being easily softened under heat.
thin cover: a cover, the thickness of which is less than specified; a wire braid hydraulic hose specifically
made with a thin cover to eliminate the need for skiving when attaching couplings.
thin tube: a lining the thickness of which is less than specified (compact).
thrust wire nut: method of mechanical connection of the nut on the fitting by means of a circular wire.
tight braid: an unevenness in a braid reinforcement caused by one or more ends of the reinforcement
being applied at a greater tension than the remaining ends; a localised necking down of the braided
reinforcement caused by a stop in the braiding operation.
tolerance: the upper and lower limits between which a dimension must be held; the total range of
variation, usually bilateral, permitted for a size, position or other required quantity.
163
trapped air: air trapped during cure, which usually causes a loose ply or cover, a surface mark, depres-
sion or void.
tube: the innermost continuous all-rubber or plastic element of a hose.
tubing: a non-reinforced, flexible, homogeneous conduit, generally of circular cross-section.
twist: the turns about the axis, length of hose, of a fibre, etc; twist is usually expressed as turns per
length unit.
ultimate strength: tensile strength.

undercure: a less than optimal state of vulcanisation, which may be evidenced by tackiness or inferior
physical properties.
viscosity: the resistance of a material to flow under stress.

void: the absence of material or an area devoid of materials where not intended.
volume change: a change in linear dimensions of a specimen immersed in a liquid or exposed to a
vapour.
vulcanisation: an irreversible process during which a rubber compound, through a change in its
chemical structure (e.g. cross-linking), becomes less plastic and more resistant to swelling by organic
liquids, and which confers, improves or extends elastic properties over a great range of temperature.
volumetric expansion: the volume increase of hose when subjected to internal pressure. It is gener-
ally reported in cubic centimetres per unit length of hose.
warp: the lengthwise yarns in a woven fabric or in a woven hose jacket; also the deviation from a
straight line of a hose while subjected to internal pressure.
water resistant: having the ability to withstand the deteriorating effect of water.
wavy tube: a tube or lining with an inner surface having surface ripples formed by the pattern of the
reinforcement.
weathering: the surface deterioration of a hose cover during outdoor exposure, as shown by cracking
or crazing.
weft: a term used for filling.
weftless cord fabric: a cord fabric either without filling yarns or with a few small filling yarns widely
spaced.
wire braid: see braid.
wire loop: in braided hose, a loop in the wire reinforcement caused by uneven tensions during
bobbin winding or braiding.
wire reinforced: a hose containing wires to give added strength, increased dimensional stability, or
crush resistance.
wire throw-out: in braided hose, a broken end or ends in the wire reinforcement protruding from the
surface of the braid;
wire wound: having a single wire or a plurality of wires spiralled in one or more layers as a protective
or reinforcing member.
wire woven: woven with the wire reinforcement applied helically by means of a circular loom.
working pressure: the maximum pressure to which a hose will be subjected, including the momen-
tary surges in pressure which can occur an during service; frequently abbreviated as WP.
164
woven fabric: a flat structure composed of two series of interlacing yarns or filaments, one parallel to
the axis of the fabric and the other transverse.
WP: the abbreviation for working pressure.
wrapped cure: a vulcanising process using a tensioned wrapper (usually of fabric) to apply external
pressure.
wrapper marks: the impressions left on the surface of a hose by a material used during vulcanisation.
yarn: a generic term for continuous strands of textile fibres or filaments in a form suitable for knitting,
weaving, or otherwise interwining to form a textile fabric.
Zinc-plating: traditional external treatment for corrosion resistance of steel components, applied to
couplings, adaptors, etc. with electrochemical methods.
TYPE APPROVALS
Some applications have strict requirements that are not coded
in the Norms and Standrads.
165
The requirements are coded by independent certification
bodies that have therefore specific acceptance criteria.
Type Approvals are the certifications of appropriate characteris-
tics. In particular FRAS, MSHA, LOBA and WUG are specific to
mine applications, others are third party certifications for stan-
dard hydraulic end/or marine applications.
ABS American Bureau of Shipping

BV Bureau Veritas
BWB Bundesamt für Wehrtechnik und Beschaffung
DNV Det Norske Veritas
DGMS Directorate General of Mine Safety (India)
FRAS Fire Resistant and Anti-Static (Australian Dept.
Mineral Resources)
GL Germanischer Lloyd
MADI-CERT GOST-R accreditation (Russian Federation and CIS)
HBL Houillers du Bassin de Lorraine
INDIA MoD Government of India - Ministry of Defence
KRS Korean Register of Shipping
LOBA Landesoberbergsamt Nordrhein - Westfalen
LR Lloyd’s Register of Shipping
MAKNII State Makeyevka Research Institute of Work
Safety in Mining Industry (Ukraine)
MSHA Mine Safety and Health Administration
RINA Registro Italiano Navale
Polish Safety Certification type “B” for mining
MED Marine Equipment Directive (European Directive)
For further details, please refer to the

Manuli Fluid Connectors Catalogue.
Manuli Rubber Inustries assumes no responsibility or liability for any loss or damage,
whether direct or indirect, consequential or incidental, which might arise from incorrect data
or incorrect interpretation of the data reported in the present Technical Manual,
or in any similar documentation.
Trademarks, service marks and any product identification are
Manuli Rubber Industries’ property at all times.
Printed in Italy, April 2009
© copyright by Manuli Rubber Industries S.p.A.
www.manuli-hydraulics.com - info@manulirubber.com
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MRI 030974
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Piazza della Repubblica, 14/16 200 Middle Road #08-03 Prime Centre
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cop manuale:cop manuale 17-03-2009 12:13 Pagina 1

MANULI SONATRA S.A.

MANULI HYDRAULICS GmbH

MANULI HYDRAULICS RUS 000

6. QUICK COUPLINGS 103

8. HOSE ASSEMBLY 125

10. APPENDIX 147

Catalogue describes the complete product range, while the

Your system/equipment applications study will drive you in

Preventive maintenance is especially important, in fact the

A preventive maintenance programme will enhance also the

Combining the proper Manuli high quality products with a

• regularly scheduled inspections;

Additional technical information on components and acces-

Be aware of the dangers connected with hydraulic pres-

Due to the serious criticalities of hydraulic applications it is impor-

• operating personnel must receive training on the use of

HYDRAULIC SYSTEMS AND FLUIDS

Unfortunately this first transformation is often unsatisfactory for

Many applications would hardly accept a rigid pipeline; often

at high speed, the systems have also a lot of vibrations; a

Flexible hoses will be widely described in this manual; basically

• Single effect cylinders consist in a tube in which a piston is

The cylinder bears two oil inlets at each end.

Other types of actuators, for example hydraulic motors, are

maximum number of cycles of this pump is about 200 (the

Basically bio-oils can be divided in four families depending on

2. Rape-seed oil base - These oils have cheap raw materials

3. Synthetic-ester base - Long life and a very wide tempera-

Also water is still used in certain applications but mainly where

While water cleaning applications utilise pressures from 100 to

Kinematic viscosity is measured in centiStoke (cSt): 1cSt=10-6 m2/s.

γ is the specific weight

The applications we are interested in, using hydraulic hoses,

Just to give an idea about the importance of the three terms

z can be at maximum 4m (hose completely vertical)

Q = 50 l/1’ = 0,000833 m3/s

Q = v . πd2/4 --> v = 4Q/πd2 v = 6,58 m/s

g = 9,81 m/s2 --> v2/2g = 2,21 m

It can be noticed how pressure energy takes part for 99,39 %

BASICS OF HOSES AND ASSEMBLIES

The hose is the flexible part of the assembly; its structure

To connect the hose to the outer system and prevent leakage,

The interface between hoses and fittings is a very important

Polyammide Resistant to wide range of fluids

The pressure resistance of the hose must be higher than the

Free steam vulcanisation is also used: the hose is directly vul-

Coverless type is usually only used for stainIess steel braided

HIGH PRESSURE HYDRAULICS: MAIN APPLICATIONS

Underground and open pit mining

Industrial and maintenance services

Applications with continuous long term aging conditions, where

RUBBER HOSE STRUCTURE

HYDRAULIC HOSE INTERNATIONAL STANDARDS

* 100R1A, 100R1AT, 100R2A, 100R2AT

The norms specify mainly:

In an effort to consolidate all norms, ISO standards are designed

Manuli Rubber Industries has a wide range of products that

Manuli Product Range 23

EN and SAE standards do not cover all the requirements in the

HOSE SELECTION CRITERIA

The most important target in this activity is the safety.

An effective way to remember the hose selection criteria is to

Hose Size (Dash numbers)