HOW TO USE OUR HOSE CONFIGURATOR

To get the best performance and longest life from your application, make sure to check what it needs before choosing a hose and starting the configuration.

Step 1: Choosing the Right Hose

The typical considerations when selecting a hose include size, flexibility, abrasion resistance, pressure rating, temperature range, and material quality.

More specifically, you should be able to answer the following questions:

What hose size is needed?
Choosing the correct internal hose diameter is crucial to ensure optimal flow rate and performance. A diameter that’s too small can reduce efficiency, while one that’s too large may cause excessive pressure and risk of leakage or damage.

What are the space constraints for hose routing? (Flexibility)
If installation space is tight, pay close attention to the hose’s bend radius. All hoses have a minimum bend radius they can withstand. Bending a hose beyond its limit weakens performance and lifespan – in the worst case, it could cause the hose to burst.

How resistant does the hose need to be? (Abrasion & Environment)
If your application requires extra durability, we offer hoses designed for tougher conditions. For example, hoses that rub against other materials face significant mechanical wear – one of the harshest stress factors. In such cases, consider adding our Safeplast protective sleeves or choosing MegaTuff^® hoses.

Environments with aggressive elements can cause corrosion or rust on the spiral layers or reinforcement braiding. Harsh conditions include UV exposure, ozone, seawater, and chemicals. For these, XtraTuff^® hoses are recommended. For UV exposure only, a Safeplast sleeve may suffice. If the hose is at risk of conducting electricity, opt for thermoplastic hoses, as they contain no metal.

Note: MegaTuff®, XtraTuff®, and thermoplastic hoses are not available in the hose configurator. For special configurations, please contact us at +45 97 35 05 99.

What fluid will flow through the hose?
Most hoses are compatible with mineral-based hydraulic fluids. However, if the hose material isn’t suitable for the specific fluid used, it can deteriorate faster, e.g., due to corrosion. Be sure to select the correct rubber compound and check the “Application Area” for fluid compatibility.

What is the fluid temperature?
Temperature also affects hose lifespan. Select a hose with the appropriate temperature range.
Check two values:

• Min./Max. operating temperature – the range the hose can handle during regular use.

• Maximum intermittent temperature – the short-term peak the hose can withstand.

What pressure requirements does the hose need to meet?
Hydraulic hoses are rated for two types of pressure:

• Working pressure – the pressure the hose must withstand during normal operation. Staying within the rated range is essential to maintain performance and durability.

• Burst pressure – the pressure at which the hose will fail. This is typically at least four times the working pressure, but your focus should be on working pressure for safety and performance.
  
  

What length is needed?

Once you’ve chosen the hose, specify the required length.

Measuring the Hose

When to choose “cone to cone” measurement:
This is the standard method. Measure the distance from one connection point to the other, including fittings. For angled couplings, measure to the centerline of the sealing surface.

Note: Read Step 2 regarding slack before entering the final length.

When to choose “cut length”:
If exact length isn’t critical, use the cut length. The overall length will vary based on fitting choice, but the hose length itself will match what you enter.

When to choose “hose only”:
Choose this option if no fittings are required. Often used for custom-length hoses without couplings.

Tip: Click the “i” icon next to each checkbox to see illustrations explaining the difference between cone-to-cone and cut length.

Allow for Slack
Never mount a hose fully stretched. Hydraulic hoses expand and contract under pressure – by up to 4%. If a hose is too short, it may pull loose from fittings and cause leaks. A slightly longer hose is better, but too much length can cause abrasion.
As a rule of thumb, allow for about 2% expansion and 4% contraction under pressure.

Step 2: Choosing the First Coupling Type

Analyze which coupling types are required for your application. Also, consider the fluid being used – some applications may require stainless steel couplings.

Tip: It’s best to use hoses and fittings from the same manufacturer, as insertion designs and sleeves are often not standardized.

You can choose between one-piece and two-piece fittings:

When to choose one-piece:
One-piece couplings have an integrated sleeve and are ideal for high-pressure applications.

Note: One-piece couplings are only available with Gates hoses.

When to choose two-piece:
This option includes a separate sleeve (automatically selected). You don’t need to choose the sleeve yourself.

Important: Couplings may have a lower maximum pressure rating than the hose. The lower of the two ratings determines the limit for the entire assembly.

Step 3: Choosing the Second Coupling Type

Choose the coupling for the other end of the hose. It can be the same or different from the first.

Tip: Having angled couplings on both ends can reduce hose lifespan. If needed, ensure the angles align correctly. You’ll be prompted to select the orientation during configuration.

Again, keep in mind that the lower max. pressure of either the hose or coupling sets the limit for the full assembly.

Step 4: Marking, Hose Protection, and Cleaning

When is additional marking useful?
The production date is always printed on the hose, but you can also add custom markings – such as your own part number or specific pressure rating.

When is hose protection (Safeplast) needed?
Use protective sleeves if people will be working around the hose while it's in use. The sleeve also offers protection against sunlight. Use yellow and black Safeplast sleeves for added mechanical wear protection.

When is hose cleaning necessary?
If your components or valves are highly sensitive, cleaning is recommended to remove contaminants like rubber shavings from cutting. Hose cleaning ensures optimal cleanliness and protection of sensitive parts.