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MAINTENANCE &
SAFETY
TIPS TO PREVENT DOWNTIME AND SAVE YOU MONEY
TM
TABLE OF CONTENTS
BENEFITS
Reduce downtime
Improve production
Increase efficiency of maintenance personnel
Enhance control of spare parts inventory
Decrease safety hazards and accidents
Extend equipment service life
Reduce capital outlays for new equipment
HOSE CONSTRUCTION
Cover
Size
Application
Temperature
P
Pressure
Material
D
Delivery (Volume)
Ends/Couplings
C5 Series,
C14 and AC134a
Dash Size
Inches
Millimeters
Inches
Millimeters
-2
1/8
3.2
-3
3/16
4.8
-4
1/4
6.4
3/16
4.8
-5
5/16
7.9
1/4
6.4
-6
3/8
9.5
5/16
7.9
-8
1/2
12.7
13/32
10.3
-10
5/8
15.9
1/2
12.7
-12
3/4
19.0
5/8
15.9
-14
7/8
22.2
-16
25.4
7/8
22.2
-20
1-1/4
31.8
1-1/8
28.6
-24
1-1/2
38.1
1-3/8
34.9
-32
50.8
1-13/16
46.0
-36
2-1/4
57.6
-40
2-1/2
63.5
2-3/8
60.3
-48
76.2
-56
3-1/2
88.9
-64
101.6
-72
4-1/2
115.2
AGENCY SPECIFICATIONS
INDUSTRY AGENCIES
ABS American Bureau of Shipping
AS Australia Standard
DIN Deutsche Industrial Norme, German
DNV Det Norske Veritas for North Sea Floating Vessels
EN European Norm/Standard
GL Germanischer Lloyd
IJS Industrial Jack Specifications
RCCC Regular Common Carrier Conference for Fleet Truck and Bus
SAE Society of Automotive Engineers
GOVERNMENT AGENCIES
DOT/FMVSS U.S. Department of Transportation/
Federal Motor Vehicle Safety Standards
MSHA U.S. Mine Safety and Health Administration
USCG U.S. Coast Guard
COUPLING IDENTIFICATION
Identifying couplings is as easy as 1-2-3.
1. Determine seat type:
Thread interface
O-ring
Mated angle or mechanical joint
Mated angle with O-ring
2. Visually identify
3. Measure threads
A hydraulic coupling consists of two functional ends:
1. The hose end for hose attachment
2. The thread end for port attachment
Hose End
Thread End
The hose end is identified by the hose size and type to which
it is attached. Serration patterns are specified by the coupling
manufacturer to meet performance requirements.
The thread end of a coupling (or adapter) can be identified by
comparing it with the coupling being replaced or by measuring
the port or thread end to which it will be attached. The thread
end may also come in different configurations.
10
Straight
45
90
Block
8 G-8MP
1/2" MegaCrimp
Male Pipe
Coupling
1/2" Nominal
Thread Size
11
Description
Code
Description
Adapterless
Inverted Flare
AB
Air Brake
API
API Unions
O-Ring Boss
JIS
Japanese Industrial
Standard
BJ
Banjo
BKHD
Bulkhead
Komatsu Style
(Japanese 30 Seat)
BL
Block
LH
Long Hex
BS
Bite Sleeve
LN
Long Nose
British Standard
Pipe Parallel
Male
BSPP
MBAX
BSPT
Male Boss
Adapterless Swivel
MFA
Caterpillar Flange
Dimension
Male Flareless
Assembly (Ermeto)
MKB
Metric Kobelco
CC
Clamping Collar
MLSP
DH
DIN Heavy
Metric Light
Stand Pipe
DL
DIN Light
MM
Metric Male
Female
MN
Metric Nut
FBFFOR
Female British
Flat-Face O-Ring
MPG
Male Special
Grease Fitting
Female Braze-On
Stem
MSP
FBO
NASP
FF
Flat-Face
North American
Stand Pipe
Female French
GAZ Swivel
OR
O-Ring
FFGX
FFN
Pipe Thread
(NPTF or NPSM)
PL
Press-Lok
FFS
Female Flareless
Sleeve
PT
Port
FG
PWX
FKX
Pressure Washer
Swivel
Field Attachable
FL
Code 61 O-Ring
Flange
SP
Special
FLC
Caterpillar-Style
O-Ring Flange
(Code 62)
TS
Tube Sleeve
TSN
Swivel
FLH
Code 62 O-Ring
Flange Heavy
FLOS
Flange O-Ring
Special (Code 62)
22
22-1/2 Drop
30 Drop
FOR
Flat-Face O-Ring
30
45
45 Drop
FT
60 Drop
HLE
60
67-1/2 Drop
HLEC
67
90
90 Drop
HM
Hose Mender
110
110 Drop
135
135 Drop
12
Read In
Dimension
Using the pitch gauge, determine the number of threads per inch.
Comparison of gauge and coupling threads against a lighted
background will ensure an accurate reading.
RIGHT
Centerlines
At An Angle
WRONG
13
T
H2
C1
C2
Tolerance
1/8"
3/16"
1/4"
+1% of length
measured to the
nearest 1/8"
14
HOSE ROUTING
Many assemblies fail because of improper routing. To minimize
damage caused by excessive flexing or whipping, all replacement
hose should be restrained, protected or guided using clamps.
Protective armor, spring guards or sleeves made of abrasion-,
temperature- or chemical-resistant material will help protect hose
from cuts, abrasions, corrosives or hot components.
Here are some hose routing tips that will prevent unnecessary
assembly failures:
Abrasion
Run hose in the installation
so that it avoids rubbing
and abrasion. Often, clamps
are required to support long
hose runs or to keep hose
away from moving parts.
Use clamps of the correct
size. Too large a clamp
allows hose to move inside
the clamp and cause wear.
WRONG
RIGHT
Appearance
Route hose directly by using 45
and/or 90 adapters and fittings.
Avoid excessive hose length to
improve appearance.
WRONG
RIGHT
15
Collapse
To avoid hose collapse
and flow restriction, keep
hose bend radius as large
as possible. Refer to hose
specification tables for
minimum bend radius.
WRONG
WRONG
High Heat
High ambient temperatures
shorten hose life, so make
sure hose is kept away
from hot parts. If this is
not possible, insulate hose
with Gates HeatGuard
protective sleeving.
RIGHT
Length Change
When hose installation is
straight, allow enough slack in
hose line to provide for length
changes that will occur when
pressure is applied.
Movement/Flexing
Adequate hose length is
necessary to distribute
movement on flexing
applications and to
avoid abrasion.
Reduce Connections
Reduce the number of
pipe thread joints by using
hydraulic adapters instead
of pipe fittings.
16
RIGHT
WRONG
RIGHT
WRONG
WRONG
RIGHT
RIGHT
Strain
Elbows and adapters should
be used to relieve strain on
the assembly, and to provide
neater installations which
will be more accessible for
inspection and maintenance.
WRONG
Tight Bend
1. When radius is below the
required minimum, use
an angle adapter to avoid
sharp bends.
RIGHT
WRONG
RIGHT
2. Use proper angle adapters
to avoid tight bends in hose.
WRONG
Twist
1. Prevent twisting and
distortion by bending
hose in same plane as
the motion of the port to
which hose is connected.
WRONG
WRONG
WRONG
RIGHT
RIGHT
RIGHT
RIGHT
17
HOSE CLEANLINESS
System contaminants can decrease equipment life and cause
expensive failures, so its important to use clean components and
assemblies. Cleaning methods vary based on shop capabilities, the
cleanliness level required and the critical nature of the equipment.
18
ASSEMBLY INSTALLATION
Be sure to follow these seven steps when installing
a hydraulic assembly:
1. Clean the surrounding area where
the connection will be made.
Do not let dirt or contaminants
into the opening.
19
INSTALLATION TORQUE
Installation torque is important to ensure a proper leak-free seal.
Over-torquing of a threaded connection can stretch and damage
threads and seat angles. It can also damage the staking area of
a nut or possibly break a bolt on the port area. Under-torquing
does not allow proper sealing. Torque should always be checked
to ensure tightening is within accepted limits. The most reliable
method of torquing threaded connections is to first hand-tighten
the connection, then use a torque wrench to measure the torque.
Torque values vary by thread configuration as follows:
Size
Dash
-4
-5
-6
-8
-10
-12
-16
-20
-24
-32
Fraction
(In.)
1/4
5/16
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2
2
Ft.-Lbs.
Min.
Max.
10
11
13
15
17
19
34
38
50
56
70
78
94
104
124
138
156
173
219
243
Newton-Meters
Min.
Max.
13
15
18
20
23
26
47
52
69
76
96
106
127
141
169
188
212
235
296
329
BRASS
Size
Dash
-4
-5
-6
-8
-10
-12
-16
-20
-24
-32
20
Fraction
(In.)
1/4
5/16
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2
2
Ft.-Lbs.
Min.
Max.
5
6
7
9
12
15
20
24
34
40
53
60
74
82
75
83
79
87
158
175
Newton-Meters
Min.
Max.
6-3/4
9
10
13
17
20
27-2/3
33
46-1/3
55
72-1/3
82
100-1/2
111
101-1/2
113
107
118
214
237
Size
Dash
-4
-6
-8
-10
-12
-16
-20
-24
Size
Dash
-3
-4
-5
-6
-8
-10
-12
-14
Fraction
(In.)
1/4
3/8
1/2
5/8
3/4
7/8
1
1-1/4
1-1/2
Ft.-Lbs.
Min.
Max.
10
12
18
20
32
40
46
56
65
80
65
80
92
105
125
140
150
180
Newton-Meters
Min.
Max.
14
16
24
27
43
54
60
75
90
110
90
110
125
240
170
190
200
245
156
184
212
250
11
13
1/4
14
16
20
22
5/16
18
20
24
27
3/8
24
26
33
35
1/2
50
60
68
78
5/8
72
80
98
110
3/4
125
135
170
183
7/8
160
180
215
245
-16
200
220
270
300
-20
1-1/4
210
280
285
380
-24
1-1/2
270
360
370
490
21
Fraction
(In.)
1/8
1/4
3/8
1/2
5/8
3/4
1
1-1/4
1-1/2
2
Ft.-Lbs.
Min.
Max.
7
9
11
18
19
28
30
36
37
44
50
60
79
95
127
152
167
190
262
314
Newton-Meters
Min.
Max.
9
12
15
24
26
38
41
49
50
60
68
81
107
129
172
206
226
258
355
426
7
15
10
20
-8
15
26
20
35
-10
-8
18
30
25
40
-12
-10
22
33
30
45
-14
-12
26
37
35
50
-15
-14
30
52
40
70
-16
30
52
40
70
-18
44
74
60
100
-22
-20
59
89
80
120
-28
-25
74
111
100
150
-30
74
163
150
220
-35
133
184
180
250
-42
-38
148
221
200
300
22
PERIODIC INSPECTIONS
23
INSPECTION PROCEDURES
Heres a checklist to help keep your equipment running strong:
1. First, turn off and lock out the equipments power.
2. Place the equipment and components in a safe
and/or neutral position.
3. Remove access panels and inspect hose and
fittings for damage or leaks.
4. Repair or replace assemblies as needed.
5. Inspect other hydraulic components.
6. Reinstall access panels.
7. Turn power back on.
8. Pay attention to unusual noises, vibrations, etc.
OPERATORS:
Stop Isolate each step in a task and identify past and potential
accidents, injuries and violations.
Measure Evaluate the risks associated with the task and
barriers that have allowed hazards to cause injuries.
Act Implement controls to minimize or eliminate any hazards
that make the risk unacceptable.
Review Conduct frequent work site visits to observe practices
and audit accidents, injuries and violations to identify root causes.
Train Develop a human factor-based action plan and involve
and train the miners.
www.msha.gov
24
HOSE TROUBLESHOOTING
The goal of troubleshooting is to identify the cause or causes of a
hose failure, and then take the appropriate corrective action. Heres
a list of some common causes of premature hose failure and some
everyday solutions to correct the problems:
1. Hose Abrasion
Solution Reroute the hose to keep it
away from abrasive sources or guard the
hose with a protective sleeve.
2. Hose Burst at Body
Solution Inspect system operating
pressure and select a hose that meets or
exceeds the systems maximum pressure.
Try rerouting the hose to prevent
excessive flexing or keep the hose from
exceeding its minimum bend radius.
3. Hose Burst at Coupling
Solution Increase the hose assemblys
length to accommodate contraction
under pressure; increase the hose
bend radius or install bend restrictors;
or replace the hose assembly with a
properly crimped assembly.
4. Leak at Thread End/Seat
Solution Remove the connection
and inspect.
a. Certain couplings require the use of
an O-ring. If its missing, replace it. If
an O-ring is used, check for damage caused during installation
or possible material breakdown from heat or fluid incompatibility.
Alternative O-ring materials may be required. Replace if necessary.
b. Check the threads and/or seat angles on both mating surfaces
for damage that may have occurred prior to or during installation.
Any ding or burr may be a potential leak path. Replace if necessary.
c. If the coupling was misaligned during installation, threads may
have been damaged. Replace and carefully install.
d. It is possible to thread together some components that are
not compatible. Use Gates thread ID kit to assist in identifying
mating components. Some thread end configurations have better
sealability than others. Also, ensure proper coupling selection.
25
26
SAFE HYDRAULICS
There you have itan overview of hydraulic safety and preventive
maintenance. If you are looking for more information on this topic,
Gates offers a special hydraulic preventive maintenance training
program called Safe Hydraulics. The class provides you with
everything you need to know to properly maintain your hydraulic
equipment for safe operation:
Fitting orientation
Coupling identification
Agency specifications
Hydraulic fluids
Hose storage life
Proper installation
torque values
HYDRAULIC
HOSE + COUPLINGS
Safe
Hydraulics
Crimper preventive
maintenance
TM
Troubleshooting
Gates has resources that can assist with your needs.
eCrimp helps you quickly find a hose and a hydraulic crimp
specification. Visit Gates.com/eCrimp for more information.
For additional hydraulic product information,
download the Gates Hydraulic Products Catalog
at Gates.com/HydraulicProducts.
Gates technical experts are available to help. Email Gates
Engineering Support at FPPASupport@gates.com.
For additional information, contact your local Gates hydraulic
distributor or visit us online at Gates.com/SafeHydraulics.
27
GATES CORPORATION
Gates.com/SafeHydraulics
2015 Gates Corporation 39595-P 05/2015