Gates Hydraulic Hose Selection Chart | Sizes & Pressure
Gates Hydraulic Hose Selection Chart | Sizes & Pressure
Gates Hydraulic Hose Selection Chart
Choosing the correct hydraulic hose is critical for the safety, reliability, and performance of a hydraulic system. The right hose must match the system’s working pressure, flow rate, temperature, hydraulic fluid, hose size, application, and connection requirements.
This Gates hydraulic hose selection chart provides a practical reference for comparing hydraulic hose types, pressure ratings, temperature ranges, reinforcement structures, and applicable SAE, EN, and ISO standards.
Whether you are replacing an existing hydraulic hose, designing a new hydraulic system, or sourcing hydraulic hose assemblies for industrial and mobile equipment, the technical requirements should be evaluated together rather than selecting a hose based only on diameter or pressure.
How to Select a Hydraulic Hose
Hydraulic hose selection should begin with the actual operating conditions of the system.
The following parameters should be checked before selecting a hose:
- Hose inside diameter
- Maximum working pressure
- System flow rate
- Operating temperature
- Ambient temperature
- Hydraulic fluid or media
- Minimum bend radius
- Hose reinforcement
- Application and operating environment
- SAE, EN, or ISO requirements
- Fitting and connection type
- Hose length
- Mechanical movement and vibration
- Abrasion and external environmental conditions
A hose that meets the system pressure requirement may still be unsuitable if its temperature rating, fluid compatibility, bend radius, or application requirements are not appropriate.
Gates Hydraulic Hose Working Pressure
Hydraulic hose working pressure is one of the most important selection criteria.
The hose assembly should be rated for the maximum pressure expected in the hydraulic circuit, including pressure spikes that may occur during operation.
Gates hydraulic hose products are available in different pressure classes. Depending on the product series and size, Gates hoses may be designed for applications ranging from relatively low-pressure return lines to high-pressure hydraulic circuits.
Some Gates high-pressure hose products are available with working pressure ratings reaching approximately 6,000 psi, depending on the specific hose size and product configuration.
Always verify the pressure rating for the exact hose size and product code before installation.
Working Pressure vs. Burst Pressure
Working pressure and burst pressure are not the same value.
Working pressure is the maximum recommended operating pressure under specified conditions.
Burst pressure is a higher test or failure-related pressure and should not be treated as an allowable operating pressure.
Hydraulic systems should always be operated within the manufacturer's specified working pressure limits.
Hydraulic Hose Size and Flow Rate
Selecting the correct hydraulic hose size is essential for controlling fluid velocity and pressure loss.
A hose that is too small for the required flow can increase fluid velocity and pressure drop. This can contribute to higher heat generation, reduced system efficiency, and unnecessary stress on hydraulic components.
For this reason, hose size should be selected based on both flow rate and application requirements.
The basic relationship is:
Flow Rate → Fluid Velocity → Hose Inside Diameter → Pressure Drop
The nominal hose size is commonly identified using dash sizes such as:
- -4
- -5
- -6
- -8
- -10
- -12
- -16
- -20
- -24
Dash size alone should not be used as the only selection criterion. The actual inside diameter, flow rate, pressure rating, and connection requirements should also be verified.
Gates Hydraulic Hose Temperature Rating
Temperature is another critical factor when selecting hydraulic hose.
The operating temperature of a hydraulic hose depends on its construction, materials, product series, and application.
Depending on the specific Gates hose, temperature ranges may include applications around:
- -40°F to +212°F
- -40°F to +250°F
- -40°F to +275°F
- Other application-specific temperature ranges
The temperature of the hydraulic fluid and the surrounding environment should both be considered.
If a hydraulic system operates near the upper temperature limit of the hose, the manufacturer's technical documentation should be checked carefully before selecting the product.
Temperature compatibility should also be evaluated together with hydraulic fluid compatibility.
Gates Hydraulic Hose Standards
Hydraulic hoses are manufactured according to different international standards. These standards define requirements related to hose construction, dimensions, pressure performance, and application.
Depending on the product series, Gates hydraulic hoses may correspond to standards including:
- SAE 100R1AT
- SAE 100R2AT
- SAE 100R12
- SAE 100R13
- SAE 100R15
- EN 853 1SN
- EN 853 2SN
- EN 857 1SC
- EN 857 2SC
- EN 856 4SP
- EN 856 4SH
- ISO 1436
- ISO 3949
The correct standard should be selected according to the equipment manufacturer's requirements and the actual application.
Gates Hydraulic Hose Selection Chart
The following chart provides a general reference for Gates hydraulic hose product families and their typical technical characteristics.
| Gates Hose Series | Reinforcement | Typical Temperature Range | Working Pressure* | Common Standard / Equivalent |
|---|---|---|---|---|
| EFG6K | Multi-spiral wire | -40°F to +250°F | Up to 6,000 psi | EN 856 4SH/4SP, SAE 100R15 |
| G6K | Multi-spiral wire | -40°F to +250°F | Up to 6,000 psi | EN 856 4SH/4SP, SAE 100R15 |
| EFG5K | Spiral wire | -40°F to +250°F | Up to 5,000 psi | EN 856 R13, SAE 100R13 |
| G5K | Spiral wire | -40°F to +250°F | Up to 5,000 psi | EN 856 R13, SAE 100R13 |
| EFG4K | 4-wire spiral | -40°F to +250°F | Up to 4,000 psi | EN 856 R12, SAE 100R12 |
| G4K | 4-wire spiral | -40°F to +250°F | Up to 4,000 psi | EN 856 R12, SAE 100R12 |
| G3K | Spiral wire | -40°F to +250°F | Up to 3,000 psi | SAE 100R12 / applicable standard |
| M6K | 2-wire braid | -40°F to +212°F | Up to 6,000 psi | EN 857 2SC |
| M5K | 2-wire braid | -40°F to +212°F | Up to 5,000 psi | EN 857 2SC |
| M4K+ | 2-wire braid | -40°F to +212°F | Up to 4,000 psi | EN 857 2SC |
| M3K | Wire braid | -40°F to +212°F | Up to 3,000 psi | EN 857 1SC/2SC, SAE 100R17 |
| G2 | 2-wire braid | -40°F to +212°F | Up to 5,800 psi* | EN 853 2SN, SAE 100R2AT |
| G1 | 1-wire braid | -40°F to +212°F | Up to 3,260 psi* | EN 853 1SN, SAE 100R1AT |
| G2L | 2-wire braid | -70°F to +212°F | Up to 5,800 psi* | EN 853 2SN, SAE 100R2AT |
| G2H | 2-wire HT braid | -40°F to +275°F | Application dependent | SAE 100R2AT |
| G1H | 1-wire HT braid | -40°F to +275°F | Application dependent | SAE 100R1AT |
| 3TE | Textile braid | -40°F to +212°F | Application dependent | EN 854 3TE |
| 2TE | Textile braid | -40°F to +212°F | Application dependent | EN 854 2TE |
| GMV | Spiral/textile reinforcement | -40°F to +275°F | Application dependent | SAE 100R4 |
*Hydraulic hose pressure ratings can vary according to hose size, product configuration, application, and manufacturer specifications. Always verify the current technical datasheet for the exact hose and size before selection.
Hydraulic Hose Construction: Wire Braid vs. Spiral
Hydraulic hoses are available with different reinforcement constructions.
Wire-Braid Hydraulic Hose
Wire-braid hoses are commonly used in mobile equipment, industrial machinery, construction equipment, and general hydraulic applications.
Depending on the hose construction, they may be suitable for medium- to high-pressure hydraulic circuits.
Spiral-Wire Hydraulic Hose
Spiral-wire hoses are commonly selected for demanding high-pressure and high-impulse applications.
Multiple layers of spiral wire reinforcement can provide high pressure capability and resistance to hydraulic pressure impulses.
The correct construction depends on the pressure, impulse conditions, hose routing, flexibility requirements, and application.
Hydraulic Hose Bend Radius
Minimum bend radius is an important but frequently overlooked hydraulic hose specification.
Forcing a hose into a bend tighter than the manufacturer's specified minimum bend radius can damage the reinforcement and reduce hose service life.
During installation, the hose should not be:
- Twisted
- Kinked
- Crushed
- Stretched
- Installed below the specified minimum bend radius
- Forced against sharp edges
- Routed near excessive heat without proper protection
A proper hose routing design should allow the hose to move naturally during equipment operation.
Hydraulic Hose Fittings and Connections
Selecting the hose alone is not enough to create a reliable hydraulic hose assembly.
The following components must be compatible:
Hydraulic Hose + Fitting + Crimp Specification + Connection Standard
The fitting must be correctly matched to the hose construction and size.
Connection standards may include SAE, JIC, ORFS, BSP, metric, and other thread or connection configurations depending on the equipment and application.
The fitting orientation should also be considered when designing the hose assembly.
Hydraulic Hose Assembly
A properly manufactured hydraulic hose assembly requires more than simply cutting a hose and installing fittings.
The assembly process should consider:
- Correct hose identification
- Correct hose length
- Correct fitting selection
- Correct insertion depth
- Correct crimp diameter
- Proper fitting orientation
- Cleanliness during assembly
- Final inspection
- Pressure testing when required
For critical hydraulic applications, cleanliness and pressure testing are especially important.
Hydraulic Hose Replacement Guide
When replacing an existing hydraulic hose, collect as much information as possible before ordering a replacement.
Check:
- Original hose manufacturer
- Hose model or part number
- Hose inside diameter
- Hose length
- Working pressure
- Temperature requirements
- Hydraulic fluid
- Fitting type
- Thread size
- Fitting orientation
- Bend radius
- Equipment application
- Operating environment
Do not select a replacement hose based only on its outside diameter or fitting thread.
A visually similar hose may have a different pressure rating, temperature rating, reinforcement structure, or fluid compatibility.
STAMP Method for Hydraulic Hose Selection
The STAMP method is a useful way to organize hydraulic hose selection.
S – Size
Determine the required hose inside diameter based on the system flow rate and acceptable fluid velocity.
T – Temperature
Identify the minimum and maximum operating temperature of the hydraulic fluid and surrounding environment.
A – Application
Consider how and where the hose will be used, including movement, vibration, abrasion, routing, and external conditions.
M – Media
Identify the hydraulic fluid or other media flowing through the hose and verify chemical compatibility.
P – Pressure
Determine the maximum working pressure, including pressure spikes and impulse conditions.
Using these five criteria helps reduce the risk of selecting a hose based on only one specification.
Hydraulic Hose Selection for Mobile Equipment
Construction equipment, agricultural machinery, mining equipment, material handling equipment, and mobile hydraulic systems can expose hoses to demanding operating conditions.
These applications may involve:
- High pressure
- Pressure impulses
- Continuous vibration
- Mechanical movement
- Abrasion
- Extreme temperatures
- Contaminated environments
- Limited installation space
For mobile equipment, hose routing and mechanical protection can be just as important as the hose pressure rating.
Hydraulic Hose Selection for Industrial Systems
Industrial hydraulic systems may have different requirements from mobile equipment.
Hydraulic power units, presses, injection molding equipment, steel production equipment, mining systems, and automated machinery may require hoses selected for continuous operation, high pressure, temperature stability, cleanliness, and specific connection standards.
For these applications, the hose should be selected as part of the complete hydraulic circuit rather than as an isolated component.
Gates Hydraulic Hose Selection: Key Points
Before selecting a Gates hydraulic hose, verify:
1. Pressure
Does the hose meet the maximum system working pressure?
2. Flow
Is the inside diameter suitable for the required flow rate?
3. Temperature
Does the hose meet the fluid and ambient temperature requirements?
4. Fluid Compatibility
Is the hose construction compatible with the hydraulic fluid?
5. Application
Can the hose withstand vibration, movement, abrasion, and environmental conditions?
6. Bend Radius
Can the hose be routed without exceeding the minimum bend radius?
7. Fittings
Are the fittings compatible with the hose and equipment?
8. Standards
Does the hose meet the applicable SAE, EN, ISO, or equipment manufacturer requirements?
Gates Hydraulic Hose vs. Application Requirements
There is no single hydraulic hose that is suitable for every application.
A high-pressure hose may be appropriate for a demanding hydraulic circuit but unnecessary for a low-pressure return line. Similarly, a hose designed for high temperature may not automatically be the correct choice for a specific hydraulic fluid or application.
The correct approach is to match the hose specification to the actual operating conditions.
Hydraulic Hose Testing
Hydraulic hose assemblies used in critical applications may require pressure testing and inspection before being placed into service.
Depending on the application, testing can help identify:
- Leakage
- Incorrect crimping
- Fitting installation problems
- Assembly defects
- Hose damage
- Pressure-related weaknesses
Pressure testing should be performed according to the applicable procedure and safety requirements.
High-pressure hydraulic testing can be hazardous. Testing equipment, protective measures, and procedures should be appropriate for the pressure involved.
Custom Hydraulic Hose Assemblies from Hidroman
Hidroman provides hydraulic hose solutions for industrial, mobile, construction, mining, and heavy-duty applications.
Our hydraulic hose services can include:
- Custom hydraulic hose assemblies
- High-pressure hydraulic hoses
- Industrial hydraulic hose lines
- Custom hose lengths
- Hydraulic hose fittings
- Hose routing solutions
- Hose cleaning and flushing
- Pressure testing
- Replacement hose assemblies
- OEM hydraulic hose solutions
For demanding applications, hose selection can be evaluated according to pressure, flow, temperature, fluid compatibility, connection type, installation conditions, and equipment requirements.
The objective is not simply to select a hose that fits. The objective is to develop a hydraulic hose assembly that is suitable for the complete operating environment.
Frequently Asked Questions
What is the best Gates hydraulic hose for high-pressure applications?
The appropriate hose depends on the actual working pressure, hose size, impulse conditions, temperature, fluid, and application. High-pressure spiral-wire Gates hoses are commonly used for demanding hydraulic applications, but the exact product and size should be verified against the current manufacturer specifications.
How do I choose the correct hydraulic hose size?
Start with the required system flow rate and determine the appropriate inside diameter based on acceptable fluid velocity and pressure loss. Then verify pressure, temperature, fluid compatibility, bend radius, and fitting requirements.
What does SAE 100R2AT mean?
SAE 100R2AT identifies a specific hydraulic hose construction and performance classification under the SAE standard. The actual pressure rating depends on the hose size and manufacturer's specifications.
What is the difference between 1-wire and 2-wire hydraulic hose?
The primary difference is the reinforcement construction. A 1-wire braid hose uses one layer of wire reinforcement, while a 2-wire hose uses two layers. The appropriate construction depends on the required pressure, flexibility, application, and manufacturer's specifications.
Can I replace one hydraulic hose with another brand?
A replacement hose may be possible if it meets the required pressure, temperature, fluid compatibility, dimensions, bend radius, connection, and applicable standards. Brand name alone should not be the only selection criterion.
Why is minimum bend radius important?
Exceeding the minimum bend radius can place excessive stress on the hose reinforcement and shorten service life. Proper routing and installation are essential for hydraulic hose reliability.
Conclusion
Selecting the correct hydraulic hose requires more than matching a hose diameter to a fitting.
A reliable hydraulic hose selection should consider:
Size + Pressure + Temperature + Application + Media + Bend Radius + Fittings + Standards
The Gates hydraulic hose selection chart provides a useful starting point for comparing hose constructions and specifications. However, the final product selection should always be confirmed against the latest manufacturer documentation and the actual operating conditions of the hydraulic system.
Hidroman can support hydraulic hose selection, custom hose assembly, pressure testing, and application-specific hydraulic hose solutions for industrial and mobile equipment.
Prevent hydraulic failures before they happen — not after the failure occurs.