When it comes to your hydraulic equipment, it’s important to make sure you’re using the right hoses. Each use case is different, requiring different specifications for size and diameter, fluid type, temperature, and other considerations like flexibility.
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As you assemble or repair your equipment, ensuring that you follow hydraulic hose standards is a vital part of keeping your hydraulic machinery working safely.
Depending on where you are, there are several different national and international hydraulic hose standards with varying measurements, tolerances, and parameters.
For example, the European Norm/Standard (EN) and the International Standards Organization (ISO) both set their hydraulic hose standards, which differ from each other.
In North America, the typical hydraulic hose standards are set by the Society of Automotive Engineers or SAE. This organization provides a series of hydraulic hose standards in the 100R series, defined under SAE Standard J517.
The 100R series hydraulic hose standards differentiate the hoses based on their construction and ideal usage conditions, including temperature, pressure, and fluid type. Before we get into the specifics of each hose, let’s take a moment to go over the different parts of a hydraulic hose.
While the specific parameters of every hose are different, they generally define three key aspects of the hose: the tube, the strengthening or reinforcement, and the outer, protective cover.
The tube that runs along the inside of a hydraulic hose is responsible for actually transporting hydraulic fluid. For that reason, it has to be able to withstand constant contact with hydraulic fluid, including both biodegradable and petroleum-based fluids.
Because the hose is the part that comes into contact with the fluid, it also needs to withstand other factors, including extremes in temperature, corrosion, and tension.
While the tube is the part that houses hydraulic fluid, the reinforcement is there to strengthen the line, protecting it from any spikes in pressure that may occur. The higher the pressure in the tube, the more support you’ll want to prevent it from bursting or leaking.
Hydraulic hoses come with either textile or steel reinforcement. Textile reinforcement is a woven fabric designed for low-pressure usages, while steel reinforced hoses have either a braided cover around the hose or individual courses of wire wrapped around the tube.
Wire wraps always come in even-numbered layers, with each successive layer wrapped in the opposite direction of the previous layer.
The protective outer layer is known as the cover, and this is the first layer of protection from exterior damage. Usually made from synthetic rubber or textile braiding, the cover helps prevent abrasion and corrosion damage and can provide insulation to prevent the tube from being damaged by external heat, cold, or UV damage.
When choosing the right hydraulic hose, you should first pay attention to any documentation with your equipment. These should specify which hoses are appropriate for your equipment and your particular usage.
However, the documentation may not have all of the information you need; you may be adapting the equipment to a new use or simply have to address a change in conditions. In that case, this guide will help you determine which hose is right for you.
As you choose a hose, you should know the specifics of your situation, including your maximum pressure, normal and extreme operating temperatures, and the nature of your application, such as if your hoses will be used in a vehicle or as part of a permanent installation.
Under each number, you’ll find information about the reinforcement, as well as the diameter range, the maximum operating pressure (in psi), and the minimum bend radius.
Unless otherwise noted, all hoses contain a tube compatible with both petroleum- and water-based hydraulic fluids, a rubber cover designed to resist oil and weather exposure, and are suited to operate between -40° and 100°C.
SAE 100R1
Reinforcement: Single braid steel.
Diameter Range: 3/16” to 2”
Max. Operating Pressure: 575 to 3,250 psi
Min. Bend Radius: 3.5” to 25”
Usage: General use high-pressure hydraulic hose.
SAE 100R2
Reinforcement: Two braids steel.
Diameter Range: 3/16” to 2”
Max. Operating Pressure: 1,150 to 6,000 psi
Min. Bend Radius: 3.5” to 25”
Usage: Good for outdoor uses like construction and mining, as well as on mobile equipment.
SAE 100R3
Reinforcement: Two braids textile.
Diameter Range: 3/16” to 1-1/4”
Max. Operating Pressure: 375 to 1,500 psi
Min. Bend Radius: 3” to 10”
Usage: General use as a low-pressure hydraulic hose, including antifreeze and hydraulic oil.
SAE 100R4
Reinforcement: Single or more braid textile with spiral wire.
Diameter Range: 3/4″ to 4”
Max. Operating Pressure: 35 to 300 psi
Min. Bend Radius: 5” to 24”
Usage: Typically used as suction and return hoses for hydraulic systems.
SAE 100R5
Reinforcement: Two braids textile with steel braid between. Braids have mildew-resistant compounds to resist wear.
Diameter Range: 3/16” to 3-1/16”
Max. Operating Pressure: 35 to 300 psi
Min. Bend Radius: 3” to 33”
Usage: Meant for medium-pressure applications, used in many automotive situations, including air brakes and power steering systems.
SAE 100R6
Reinforcement: Single braid or spiral textile.
Diameter Range: 3/16” to 3/4″
Max. Operating Pressure: 300 to 500 psi
Min. Bend Radius: 2” to 6”
Usage: General use as a low-pressure hydraulic hose.
SAE 100R7
Tube: Thermoplastic.
Temperature: -40° to 93°C
Cover: Thermoplastic.
Reinforcement: Synthetic fiber.
Diameter Range: 1/8” to 1”
Max. Operating Pressure: 1,000 to 3,000 psi
Min. Bend Radius: 1” to 12”
Usage: Medium-pressure, non-conductive settings where steel reinforcement is not allowed.
SAE 100R8
Tube: Thermoplastic.
Temperature: -40° to 93°C
Cover: Thermoplastic.
Reinforcement: Synthetic fiber.
Diameter Range: 1/8” to 1”
Max. Operating Pressure: 2,000 to 6,000 psi
Min. Bend Radius: 1” to 12”
Usage: High-pressure, non-conductive settings where steel reinforcement is not allowed.
SAE 100R12
Temperature: -40° to 121°C
Reinforcement: Four steel wire spirals.
Diameter Range: 3/8” to 2”
Max. Operating Pressure: 2,500 to 4,000 psi
Min. Bend Radius: 5” to 25”
Usage: High-pressure applications in heavy-duty service settings.
SAE 100R13
Temperature: -40° to 121°C
Reinforcement: Multiple steel wire spirals.
Diameter Range: 3/4″ to 2”
Max. Operating Pressure: 5,000 psi
Min. Bend Radius: 9.5” to 25”
Usage: High-pressure applications, where there is a high likelihood of pressure spikes, like forklifts or construction machinery.
SAE 100R14
Tube: PTFE (Type B hose has conductive inner layer)
Temperature: -54° to 204°C
Reinforcement: Single braid steel.
Diameter Range: 3/16” to 1-1/4”
Max. Operating Pressure: 600 to 1,500 psi
Min. Bend Radius: 1-1/2” to 16”
Usage: High-pressure applications handling superheated fluids.
SAE 100R15
Temperature: -40° to 121°C
Reinforcement: Multiple steel wire spirals.
Diameter Range: 3/8” to 1-1/2”
Max. Operating Pressure: 6,000 psi
Min. Bend Radius: 6” to 21”
Usage: For petroleum-based fluids only. High-pressure applications with steady working pressure, including logging, agriculture, and oilfield equipment.
SAE 100R16
Reinforcement: One or two braids steel.
Diameter Range: 1/4″ to 1-1/4”
Max. Operating Pressure: 1,800 to 5,800 psi
Min. Bend Radius: 2” to 8”
Usage: High-pressure applications, where hose needs to be especially flexible.
SAE 100R17
Reinforcement: One or two braids steel.
Diameter Range: 3/16” to 1”
Max. Operating Pressure: 3,000 psi
Min. Bend Radius: 2” to 6”
Usage: High-pressure applications, rated for general industrial purposes.
SAE 100R18
Tube: Thermoplastic.
Temperature: -40° to 93°C
Cover: Thermoplastic.
Reinforcement: Synthetic fiber
Diameter Range: 1/8” to 1”
Max. Operating Pressure: 3,000 psi
Min. Bend Radius: 1” to 10”
Usage: High-pressure applications where non-conductive tubes are required.
SAE 100R19
Reinforcement: One or two braids steel.
Diameter Range: 3/16” to 1”
Max. Operating Pressure: 4,000 psi
Min. Bend Radius: 2” to 6”
Usage: High-pressure applications, rated for general industrial purposes.
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While these SAE hydraulic hose standards are widely accepted and used by the industry, SAE does not certify that a product meets them. Ensure that you’re purchasing your hydraulic hoses from a reputable vendor to ensure you’re getting high-quality merchandise that meets the hydraulic hose standards.
You’ll also find that many manufacturers offer products that exceed the SAE hydraulic hose standards, giving you more flexibility when using them in your particular applications. Some hoses have higher temperature or pressure ratings, or they have a tighter bend radius.
Several notable SAE standards are particularly important for hydraulic hoses:
SAE J517: This standard outlines the specifications for various types of hydraulic hoses, including the materials used, construction methods, and performance criteria. It categorizes hoses into different classes based on their intended use and pressure ratings. For example, SAE 100R1 and SAE 100R2 are standards for braided hydraulic hoses, while SAE 100R12 and SAE 100R13 pertain to spiral-wound hoses.
SAE J343: This standard details the testing procedures for hydraulic hoses to ensure they meet the required performance and safety criteria. The tests include burst pressure tests, impulse tests, and abrasion resistance tests, among others. These rigorous testing protocols help verify that the hoses can withstand the demanding conditions they will face in real-world applications.
SAE J: This standard provides guidelines for the design and use of thermoplastic hydraulic hoses, which are known for their excellent resistance to chemicals and environmental conditions. It specifies the materials, construction, and testing requirements for these hoses to ensure they meet high standards of performance and durability.
Adhering to SAE hydraulic hose standards is crucial for several reasons:
Safety: Hydraulic systems operate under high pressure, and a failure in a hose can lead to serious accidents and injuries. By following SAE standards, manufacturers ensure that their hoses can withstand the required pressure levels, minimizing the risk of failures and enhancing safety.
Performance: SAE standards ensure that hydraulic hoses perform reliably under various operating conditions. This includes maintaining flexibility at low temperatures, resisting degradation at high temperatures, and withstanding abrasion and wear. Consistent performance is vital for the smooth operation of hydraulic systems in critical applications.
Quality Assurance: By adhering to SAE standards, manufacturers can produce hoses that meet consistent quality benchmarks. This is particularly important for industries requiring high precision and reliability levels, such as aerospace and automotive.
Compatibility and Interchangeability: SAE standards provide a common framework that ensures hydraulic hoses are compatible with other components and systems. This standardization facilitates easier replacement and maintenance, reducing downtime and costs.
Braided hoses are commonly used in hydraulic systems due to their flexibility and durability. These hoses feature one or more layers of braided wire reinforcement, which provides the necessary strength to withstand high pressure while maintaining flexibility. The key characteristics of braided hoses include:
Construction: Typically, braided hoses consist of an inner tube made of oil-resistant synthetic rubber, one or two braided layers of high-tensile steel wire, and an outer cover made of synthetic rubber that is resistant to oil, weather, and abrasion.
Standards: Common SAE standards for braided hoses include:
SAE 100R1: This standard specifies a single layer of steel wire braid reinforcement. It is suitable for medium-pressure applications.
SAE 100R2: This standard specifies two layers of steel wire braid reinforcement, making it suitable for high-pressure applications.
Braided hoses are widely used in applications such as automotive hydraulic systems, industrial machinery, and agricultural equipment due to their ability to handle moderate to high pressure and their resistance to kinking and abrasion.
Spiral hoses are designed for high-pressure and high-impulse applications, where durability and reliability are paramount. These hoses feature multiple layers of spiral-wound wire reinforcement, providing exceptional strength and resistance to pressure spikes. The key characteristics of spiral hoses include:
Construction: Spiral hoses consist of an inner tube made of oil-resistant synthetic rubber, four or six layers of high-tensile steel wire spirally wound in alternating directions, and an outer cover made of synthetic rubber that is resistant to oil, weather, and abrasion.
Standards: Common SAE standards for spiral hoses include:
SAE 100R12: This standard specifies four layers of spiral-wound wire reinforcement, suitable for very high-pressure applications.
SAE 100R13: This standard specifies six layers of spiral-wound wire reinforcement, providing even higher pressure capacity and durability.
Spiral hoses are ideal for demanding applications such as heavy construction equipment, mining machinery, and high-performance industrial systems, where consistent performance under extreme conditions is required.
Thermoplastic hoses are made from synthetic materials, offering excellent resistance to chemicals and environmental conditions. These hoses are lightweight, flexible, and suitable for a variety of specialized applications. The key characteristics of thermoplastic hoses include:
Construction: Thermoplastic hoses typically consist of an inner tube made of thermoplastic material, one or two braided layers of synthetic fiber reinforcement, and an outer cover made of thermoplastic material that is resistant to abrasion, chemicals, and weather.
Standards: Common SAE standards for thermoplastic hoses include:
SAE 100R7: This standard specifies a thermoplastic hose with a synthetic fiber braid reinforcement, suitable for medium-pressure applications.
SAE 100R8: This standard specifies a thermoplastic hose with a synthetic fiber braid reinforcement, suitable for high-pressure applications.
Thermoplastic hoses are used in applications where chemical resistance, low weight, and flexibility are critical, such as hydraulic systems in aerospace, medical equipment, and chemical processing industries.
Function: These layers provide the necessary strength to withstand internal pressures and prevent the hose from expanding or bursting.
Types: Reinforcement can be either braided or spiral-wound:
Braided Reinforcement: Involves one or more layers of braided wire (usually steel) or textile fibers, offering flexibility and moderate pressure resistance. Common in hoses specified by standards like SAE 100R1 and SAE 100R2.
Spiral Reinforcement: Consists of multiple layers of high-tensile steel wire wound in a spiral pattern, providing higher pressure resistance. Found in hoses like SAE 100R12 and SAE 100R13.
One of the most critical factors in selecting a hydraulic hose is its ability to handle the system’s maximum operating pressure. Using a hose that cannot withstand the required pressure can lead to failures, posing safety risks and causing system downtime. To determine the appropriate hose, consider the following:
Maximum Working Pressure: This is the highest pressure that the hose will be exposed to during operation. It should not exceed the hose’s rated maximum working pressure.
Burst Pressure: This is the pressure at which the hose is likely to fail. Ensure that the burst pressure is significantly higher than the maximum working pressure to provide a safety margin.
Pressure Spikes: Hydraulic systems often experience transient pressure spikes. Choose a hose that can handle these spikes without compromising performance.
The hose’s operating environment can significantly impact its performance and lifespan. It’s essential to consider environmental factors when selecting a hydraulic hose:
Temperature Range: Ensure the hose can operate within the expected temperature range. Both ambient and fluid temperatures should be considered.
Abrasion Resistance: In environments where the hose may be subjected to wear and tear, choose a hose with a durable outer cover that resists abrasion. This is particularly important in construction and industrial applications.
Chemical Exposure: If the hose will be exposed to chemicals, solvents, or other corrosive substances, select a hose with a cover that offers chemical resistance.
UV Resistance: For hoses used outdoors, UV resistance is crucial to prevent degradation from sunlight exposure.
Flexibility and Bend Radius: The hose should be flexible enough to accommodate the system’s movement without kinking or reducing flow. Consider the minimum bend radius specified by the hose’s SAE standard.
Apart from the primary factors mentioned above, there are other considerations to keep in mind when selecting a hydraulic hose:
Hose Size and Length: Ensure the hose has the appropriate diameter and length for the application. A hose that is too long or too short can cause issues with flow and pressure.
End Fittings: Choose compatible end fittings that match the hose’s size and material. Properly fitted ends ensure a secure connection and prevent leaks.
System Compatibility: Ensure the hose is compatible with other system components, including pumps, valves, and actuators.
Regulatory Compliance: Verify that the hose complies with industry standards and regulations relevant to your application. This includes SAE, ISO, and other applicable standards.
SAE hydraulic hose standards are essential for ensuring the safety, reliability, and performance of hydraulic systems across various industries. By adhering to these standards, manufacturers and users can maintain high-quality, durable hoses that meet rigorous performance criteria. Ensuring proper selection, installation, and maintenance of hydraulic hoses according to SAE guidelines is crucial for minimizing risks and maximizing system efficiency. Staying informed about the latest industry standards and technological advancements will help you maintain the integrity and effectiveness of your hydraulic systems, providing long-term reliability and safety.
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