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Overall Length of Hose Assemblies

Being able to determine the correct overall length (OAL) of hose assemblies is necessary for measuring
and duplication. Hoses should have a small amount of slack when installed, to allow for flexing and
length changes under pressure, but will look neat and clean and avoid contact with other machine

Figure 1 – A hose assembly.

The overall length of the hose assembly (OAL) is the sum of the exposed length of the couplings and the
cut hose length, figure 1. The point at which the ends of the assembly are measured will depend on the
style and construction of the couplings. All flanges are measured from the center point of the flange
face, figure 2D. All straight male couplings are measured from the seal face, figure 2E. Straight female
couplings with SAE, JIC (FJX), NPSM (FPX), JIS and Komatsu specifications are measured from the
farthest point which the nut will extend, figure 2F. Straight female couplings with DIN, BSP, GAZ
specifications are measured from the face of the seal, figure 2G. Straight Flat Face O-ring seal (FFOR)
couplings are always measured from the face of the seal, figure 2H. All bent and block couplings (male
and female) are measured from the point at which the center line of the coupling intersects the seal face,
figure 2I. The Gates catalog lists the dimension between the appropriate measurement point of the
coupling and the shoulder where the hose butts as “C”.

Figure 2 – From left to right: Measurement of D) flange, E) straight male, F) US spec., G) International spec., H) FFOR and I) bent
(elbow) couplings.

The cut hose length is determined by taking the OAL and subtracting the exposed length of the
couplings, “C”. The hose cut must be within 5° of perpendicular1, on Ø 1” hose this is less than 3/32”.
The best practice is to start by dry fitting all components of the
assembly, then measure from one end of a coupling to the opposite Assembly OAL (in) Tolerance (in)
≤ 12 ±0.125
end of the cut hose, crimp the coupling and measure the change in
12 < L ≤ 18 ±0.1875
length. This will give a good estimate of change in hose length due 18 < L ≤ 36 ±0.25
to the crimping process, and allow for compensation. The SAE > 36 + 1%*
OAL tolerances are shown in figure 3. European tolerances vary *to the nearest 0.125 inches
slightly from this and are based on hose diameter and length2. Figure 3 – Hose assembly length tolerance1

Remember coupling orientation is very important, per SAE1 it must be within 2°, orientation which is
off by as little as 1% can half the life of a hose assembly. The use of witness marks to verify orientation
and coupling insertion depth are encouraged. Be sure to clean the inside of all hose assemblies before
placing them into service.
1. SAE J517
2. DIN 20066:2002 and EN853 to EN857

FPTN002001 WLG 4AUG2010