AAC SPECIFICATION 418002 ISSUE 3 HYDRAULIC HOSE ...

AAC SPECIFICATION 418002 

HYDRAULIC HOSE & FITTINGS FOR USE IN 

COAL MINING APPLICATIONS 

ISSUE 3 

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CONTENTS PAGE 

1 SCOPE 2 

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 2 

3 DEFINITIONS 2 

4 REQUIREMENTS 3 

4.1 GENERAL 3 

4.2 HOSE AND FITTING TYPE 3 

4.3 CONSTRUCTION 5 

4.4 ADHESION 5 

4.5 RESISTANCE TO OIL IMMERSION 5 

4.6 MECHANICAL PROPERTIES 5 

4.7 COOL DOWN LEAKAGE 6 

4.8 FEMALE SWIVEL HOSE END FITTINGS 7 

4.9 SOCKETS 8 

4.10 CORROSION PROTECTION 8 

4.11 ASSEMBLY EQUIPMENT 8 

5 QUALITY ASSURANCE PROVISIONS 8 

5.1 QUALITY MANAGEMENT SYSTEM 8 

6 TEST AND INSPECTION METHODS 8 

6.1 FIRE RESISTANCE 8 

6.2 ABRASION RESISTANCE 8 

7 MARKING AND PACKAGING 8 

7.1 MARKING 8 

7.2 COLOUR CODING 9 

7.3 CLEANING 9 

7.4 PACKAGING 9 

8 WARRANTY 9 

APPENDIX A : RELATED DOCUMENTS 10 

APPENDIX B : RECORD OF AMENDMENTS 10 

AAC_SPEC_41800203 APPROVED 8 May 1991 Page 1 of 10 

Anglo Technical Division accepts no liability for any damage whatsoever that may result from the use of this material or 

the information contained therein, irrespective of the cause and quantum thereof.

1 SCOPE 





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This specification details the requirements for a standard range of double wire braid and 

four spiral hydraulic hose and fittings for rubber tyred mining vehicles. 

The hoses and fittings (other than Hi-Temp.) shall be suitable for use in systems with 

temperatures up to 100°C. 

Hi-Temp hoses shall be suitable for use with systems with temperatures up to 150°C. 

2 TECHNICAL REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 

The following requirements shall be specified in every invitation to tender and in orders or 

contracts: 

• Title, reference number, issue and date of this specification. 

• The overall hose length over the fittings. 

• The nominal bore. 

• The type of fittings. 

• The hose application. 

• Details of any accessories required. 

• The contract number, if applicable. 

3 DEFINITIONS 

For the purpose of this specification the following definitions shall apply: 

APPROVED/ACCEPTED : Approved by the Engineer in writing 

BATCH : The number of hose assemblies manufactured from one 

reel hose. 

BS : British Standard 

CEN : Committee European de Normalisation (European 

Committee for Standardization) 

DASH : SAE Terminology denoting hose size in sixteenths of an 

Inch. 

DIN : Deutsches Institut for Normung (German Standards 

Institute). 

ENGINEER : The Consulting Engineer, Consulting Mechanical and 

Electrical Engineer of AAC or his appointed 

representative. 

EN : Europäische Norm (European Standard). 







ISO : International Standards Organization. 


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QAR : Quality Assurance Representative; An independent 

inspection agency appointed by the Engineer. 

SABS : South African Bureau of Standards 

SAE : Society of Automotive Engineers 

SAQA : South African Quality Association 

The following terms are defined in the General Conditions of Contracts: 

AAC, Company, Contractor. 

4 REQUIREMENTS 

4.1 GENERAL 

Hoses and fittings, for all assembles, shall be from the same source of supply to ensure 

compatibility 

4.2 HOSE AND FITTING TYPE 

Hoses and fittings shall be as specified in Table 1 

4.2.1 Bore size: shall comply with the requirements of SAE J517 and EN Specifications 

TABLE 1: HOSE AND FITTING SPECIFICATION 

APPLICATION DASH 

Hydraulic 

Pressure And 

Return Lines 

NOMINAL BORE 

MM INCH 

HOSE FITTINGS 

-4 6 1/4 EN 835/2ST/6 15J09-4 a) O-Ring Face 

-6 10 3/8 EN 835/2ST/10 15J09-6 Seal Female 

-8 12 ½ EN 835/2ST/12 15J09-8 Swivel 

-12 19 ¾ EN 835/2ST/19 15J09-12 b) JIC 37° Female 

-16 25 1 EN 835/2ST/25 15J09-16 Swivel 

-20 31 1 ¼ EN 835/2ST/31 2781-20 

-24 38 1 ½ EN 835/2ST/32 2781-24 

-6 10 3/8 EN 835/2ST/10 EHP* SH222-6 

-8 12 ½ EN 835/2ST/12 EHP* SH222-8 

-12 19 ¾ EN 835/2ST/19 EHP* SH222-12 

-16 25 1 EN 835/2ST/25 EHP* SH222-16 








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*En 853 standard quoted for dimensional data only – does not cover extra high pressure hose. 

Hydraulic High 

Pressure Lines 

-6 10 3/8 EN 856/4SP/19 2755-6 a) Code 62 

-8 13 ½ EN 856/4SP/19 2755-8 Flange 

-10 16 5/8 EN 856/4SP/19 2755-10 b) O-Ring Face 

-12 19 ¾ EN 856/4SP/19 2755-12 Seal female 

-16 25 1 EN 856/4SP/19 2755-16 swivel 

c) Metric female 

-16 25 1 EN 856/4SH/25 GH506-16 DKOS 

-20 31 1 ¼ EN 856/4SH/31 GH506-20 d) JIC 37° female 

-24 38 1 ½ EN 856/4SH/38 GH506-24 swivel 

-32 51 2 EN 856/4SH/51 GH506-32 

Hydraulic -20 31 1 ¼ EN856/6SP/31 GH466-20 a) Code 62 

Ultra High -24 38 1 ½ EN856/6SP/38 GH466-24 Flange 

Pressure lines -32 51 2 EN856/6SP/51 FC273-32 

Suction Lines -12 19 ¾ SAE100R4 FC619-12 

-16 25 1 SEA100R4 FC619-16 

-20 31 1 ¼ SAE100R4 FC619-20 

-24 38 1 ½ SAE100R4 FC619-24 

-32 51 2 SAE100R4 FC619-32 

Engine -4 6 ¼ 

Transmission -6 10 3/8 

Lines -8 12 ½ 

-12 19 ¾ 

EN 853/2SN6* 

(HI-TEMP) 

EN 853/2SN10* 

(HI-TEMP) 

EN 853/2SN12* 

(HI-TEMP) 

EN 853/2SN19* 

(HI-TEMP) 

GH195-4 

GH195-6 

GH195-8 

GH195-12 

a) O-Ring Face 

Seal female 

swivel 

b) JIC 37° Female 

Swivel 

a) CODE 61 

Flange 

b) O-Ring Face 

Seal Female 

Swivel 

c) JIC 37° Female 

Swivel 

a) O-Ring Face 

Seal Female 

Swivel 







-16 25 1 

-20 31 1 ¼ 

-24 38 1 ½ 

EN 853/2SN25* 

(HI-TEMP) 

EN 853/2SN31* 

(HI-TEMP) 

EN 853/2SN38* 

(HI-TEMP) 

GH195-16 

GH195-20 

GH195-24 


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a) Code 61 

Flange 

b) O-Ring Face 

Seal Female 

Swivel 

*En 853 Standard Quoted For Dimensional Data Only – Does Not Cover High Temperature Hose. 

4.3 CONSTRUCTION 

The hoses shall be constructed as follows 

4.3.1 Inner Lining: Shall be a seamless extrusion from fabric reinforced polymer or Neoprene 

synthetic rubber. The material shall be compatible with mineral based oil to ISO 6743-4. 

4.3.2 Reinforcement: Shall comprise layers of high tensile steel wire, in accordance with the 

standards quoted above. 

4.3.3 Outer Cover: Shall provide protection against oil and abrasion and shall be manufactured 

from fire retardant non-toxic synthetic rubber. 

4.3.4 Abrasion resistance: When tested in accordance with the requirements of Clause 6.2 

herein, shall show a rubber loss of not greater than 0,5 gram per 2000 cycles. 

Note: Suction and high temperature hoses shall not be subjected to abrasion testing. 

4.3.5 Concentricity: Shall comply with the requirements of SAE J517 and EN 853 through EN 

857 when measured in accordance EN 24671. 

4.4 ADHESION 

When tested in accordance with the requirements of EN 28033 the adhesion between the 

hose cover and reinforcement shall not be less than 2,5 KN/m. 

4.5 RESISTANCE TO OIL IMMERSION 

The resistance to oil shall be tested according to SAE J343 and EN ISO 1817 as required 

and shall comply with the requirements of the appropriate hose specifications. 

4.6 MECHANICAL PROPERTIES 

The mechanical properties the hose cover and lining for the hoses and assemblies as 

specified in Table 1, before and after aging, shall be tested according to SAE J343 and 

EN ISO 1402 as required and shall comply with the requirements of the appropriate hose 

specifications. 

4.6.1 Design working pressures, bend radio and flexibility of hydraulic hose assemblies: 

shall be as shown in Table 2. 




4.7 COOL DOWN LEAKAGE 





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All hose end fittings must meet Class 0 cool down leakage performance as per SAE 

J1176. 

TABLE 2: HYDRAULIC SUCTION, PRESSURE AND RETURN LINES 

DASH 

SIZE 

NOMINAL BORE 

MM INCH 

DESIGN 

WORKING 

PRESSURE 

(MPA) 

MINIMUM BEND 

RADIUS (MM) 

HYDRAULIC SUCTION LINES 

IMPULSE PERFORMANCE 

(CYCLES) 

-12 19 ¾ 2,0 64 N/A 

-16 25 1 1,7 76 N/A 

-20 31 1 ¼ 1,4 102 N/A 

-24 38 1 ½ 1,0 125 N/A 

-32 51 2 0,7 152 N/A 

HYDRAULIC PRESSURE AND RETURN LINES 2 BRAID 

-4 6 ¼ 40,0 100 200K @ 133% WP 

-6 10 ⅜ 34,5 130 200K @ 133% WP 

-8 12 ½ 29,5 180 200K @ 133% WP 

-12 19 ¾ 21,5 240 200K @ 133% WP 

-16 25 1 17,5 300 200K @ 133% WP 

-20 31 1 ¼ 15,5 420 200K @ 133% WP 

-24 38 1 ½ 12,5 500 200K @ 133% WP 

-32 51 2 90,0 630 200K @ 133% WP 

HYDRAULIC EXTRA HIGH PRESSURE LINES 2 BRAID 

-6 10 ⅜ 34,5 130 500K @ 133% WP 

-8 12 ½ 29,5 180 500K @ 133% WP 

-12 19 ¾ 27,6 240 500K @ 133% WP 

-16 25 1 36,0 300 500K @ 133% WP 

HYDRAULIC HIGH PRESSURE LINES 4 SPIRAL 

-6 10 ⅜ 49,0 180 400K @ 133% WP 

-8 12 ½ 42,0 230 400K @ 133% WP 

-10 16 ⅝ 40,0 250 400K @ 133% WP 








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-12 19 ¾ 38,0 300 400K @ 133% WP 

-16 25 1 32,0 340 400K @ 133% WP 

-16 25 1 38,0 340 400K @ 133% WP 

-20 31 1 ¼ 35,0 460 400K @ 133% WP 

-24 38 1 ½ 30,0 560 400K @ 133% WP 

-32 51 2 25,0 700 400K @ 133% WP 

HYDRAULIC EXTRA HIGH PRESSURE LINES 6 SPIRAL 

-20 31 1 ¼ 38,0 420 500K @ 120% WP 

-24 38 1 ½ 38,0 510 500K @ 120% WP 

-32 51 2 35,0 640 500K @ 120% WP 

ENGINE AND TRANSMISSION LINES 

-4 6 ¼ 40,0 100 200K @ 133% WP 

-6 10 ⅜ 33,0 130 200K @ 133% WP 

-8 12 ½ 27,5 180 200K @ 133% WP 

-12 19 ¾ 21,5 240 200K @ 133% WP 

-16 25 1 16,5 300 200K @ 133% WP 

-20 31 1 ¼ 12,5 420 200K @ 133% WP 

-24 38 1 ½ 9 500 200K @ 133% WP 

Note: The minimum bend radius is measured to the external surface of the hose on the 

inside of the bend. 

4.8 FEMALE SWIVEL HOSE END FITTINGS 

The Contractor shall submit his design for female swivel hose end fittings for approval. All 

JIC female hose ends to have a double hex design to alleviate hose twist at installation. 

All metric hose ends to be of the DKO design. All hose end nipples, straight & elbows, for 

use on ultra high pressure hose shall be manufactured from solid material. (No brazed 

joints) All hose end nipples for use on spiral hose from DN25 upwards to incorporate the 

wire trap design. 

4.8.1 Material: Shall be free cutting leaded steel that complies with the requirements of DIN 

1651. 

4.8.2 Surface texture and tolerances: Shall comply with the requirements of SAE J516. 




4.9 SOCKETS 





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For braided hoses types, the sockets shall have machined grooves to identify the number 

of wire reinforcement layers in the matching hose. The spiral sockets will be stamped with 

a part number for identification purposes. 

The dash size of the hose to which the sockets must be matched shall be stamped on the 

socket. 

4.10 CORROSION PROTECTION 

The hose end fittings and sockets shall comply with the requirements of SAE J516 

4.11 ASSEMBLY EQUIPMENT 

4.11.1 Crimping machine shall be supplemented with a built-in micrometer to enable setting the 

correct socket crimp diameter. The machine shall also carry a qualification certificate in 

accordance with the SAQA requirements. 

4.11.2 The die numbers shall be clearly indicated on the die so as to facilitate matching with the 

corresponding die number as indicated on the crimp chart. 

4.11.3 A crimp chart displaying the correct die numbers and assembly requirements for 

the hoses as specified in Table 1 must be issued with the crimping machine. This crimp 

chart must be issued as a controlled document. 

5 QUALITY ASSURANCE PROVISIONS 

5.1 QUALITY MANAGEMENT SYSTEM 

The requirements of QAP 100 shall apply. 

6 TEST AND INSPECTION METHODS 

Test and inspection shall comply with the requirements of SAE J343 and the relevant EN 

specifications. 

6.1 FIRE RESISTANCE 

Fire resistance shall be tested in accordance with the requirements of SABS 879. 

6.2 ABRASION RESISTANCE 

Abrasion resistance shall be tested in accordance with the specific requirements of the EN 

specification in conjunction with EN ISO 6945. 

7 MARKING AND PACKAGING 

7.1 MARKING 

Each length of hose shall be indelibly and legibly marked, in accordance with the relevant 

EN or SAE specification, by printed layline or embossed at intervals of not more than 

500mm with the following information: 







• The hose manufacturer’s name 

• The hose type and dash size 

• The number of the European Standard e.g. EN 853 

• The type e.g./2ST 

• The nominal bore e.g./6 

• The date of manufacture e.g. 2Q98 

• Number of circles indicating reinforcement (optional) 

7.2 COLOUR CODING 

Hoses shall be colour coded as follows: 


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7.2.1 Double wire braided high pressure hoses: Shall be black with the layline in yellow 

indicating the information specified in clause 7.1 

7.2.2 Double wire braided extra high pressure hoses: Shall be black with the layline in red 

indicating the information specified in clause 7.1 

7.2.3 Four & six wire spiral pressure hoses: Shall be black with embossed layline indicating 

the information specified in clause 7.1 

7.2.4 Engine and Transmission hoses: Shall be blue with layline embossed indicating the 

information specified in clause 7.1 

7.2.5 Suction hoses: Shall be black with orange layline indicating the information specified in 

clause 7.1 

7.3 CLEANING 

Hose assemblies shall be cleaned by means of propelling of foam pellet, with compressed 

air, through the entire length of the assembly. This process shall be repeated with a new 

pellet until the pellet shows no more signs of contamination. 

7.4 PACKAGING 

Hoses shall be packaged in such a manner that they will be protected from the effects of 

loading, off-loading, transportation and storage. Each end shall be sealed with an 

approved closure, which will not dislodge under the above conditions. 

8 WARRANTY 

All hose assemblies shall carry a warranty period of no less than 3 years from date of 

manufacture as detailed on the layline of the hose. The manufacturer must warrant that 

its products are free from failure due to defects in material and workmanship. This 

warranty excludes normal wear and tear. 




APPENDIX A : RELATED DOCUMENTS 





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The latest issue of the following documents shall be deemed to form part of this specification: 

AAC QAP 100 : Quality management system for critical and major equipment 

AAC QAP 163 : Concession request requiring customer approval 

BS 3592 Part 2 : Steel wire for rubber hose reinforcement 

DIN 1651 : Free cutting steels; Technical conditions of delivery 

EN ISO 6945 : Rubber hoses – Determination of abrasion resistance of the outer cover 

EN 853 : European Specification – Wire braid reinforced hydraulic rubber hoses 

and hose assemblies 

EN 856 : European Specification – Spiral wire reinforced hydraulic hoses and hose 

assemblies 

SAE J343 : Test procedures for SAE 100R series hydraulic hose and assemblies 

SAE J516 : Hydraulic hose fittings 

SAE J517 : Hydraulic hose 

SAE J1176 : Cool Down Leakage performance 

SABS Method 876 : Resistance to flaming of vulcanized rubber 

APPENDIX B : RECORD OF AMENDMENTS 

Issue 1 : Definitions amended. Clause 1.0; 150°C was 125°C 

Clause 5.0 amended 

Clause 7.2.4 amended (M. Capper) 

Issue 2 : Clause 4.3.4 amended (R.T. Mcloughlin) 

Issue 3 : (5 year review) Title changed to Coal Mining Applications. Specification updated to 

include new EN/ISO standards (G. Dryden 2001/05/087)

AAC SPECIFICATION 418002 ISSUE 3 HYDRAULIC HOSE ...

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