How to Properly Crimp a Hydraulic Hose in 8 Simple Steps
Once you have identified the hose and crimp fitting you need, follow these subsequent steps:
Step 1. Determine and Trim the Hose Length
Begin by measuring the required hose length and then cut it to the appropriate size using a hose saw. If a designated cut-off length for the fitting is available, use it for both ends of the assembly and subtract it from the overall hose length. In cases where a cut-off length is not specified, you can ensure the correct hose length with the following method:
Place the hose on a measuring table at the desired overall length. Mark the fitting where the cut length should be if it’s not indicated on the fitting itself. Then, run the hose along the measuring table and position the other fitting at the beginning of the table, aligning the hose with the fitting. Once the hose matches the fitting’s cut length, mark your cutting line on the hose.
Step 2. Indicate the Insertion Depth
Properly marking the insertion depth is crucial to ensure correct fitting insertion. Determine the insertion depth of the fitting using a hose insertion depth block. This mark will indicate when the crimp fitting is correctly seated on the hose. If you don’t have an insertion block available, you can calculate the insertion depth by subtracting the cut-off length from the overall length or by aligning the fitting with the hose and marking it. The ferrule should align with the marked line on the hose after inserting the fitting.
Step 3. Clean the Hose
Use a foam projectile to remove any debris that may have accumulated during hose cutting, a process known as “pigging the hose.” Cleaning the hose will minimize contamination and prevent hose assembly failure. If you lack pigging equipment, blowing air through the hose can also help.
Step 4: Load the Correct Specifications and Die
If you have a programmable crimper, load the specific crimp specifications for the hose and crimp fitting you are assembling. Select the appropriate crimp die specified for your Hydraulic Cylinder Repair Near Me hose and crimp fitting. Always double-check the data before proceeding with the crimping process.
Step 5: Insert the Hose into the Crimping Machine
Insert the Hydraulic Cylinder Repair Near Me hose into the crimping machine and through the die so that the hydraulic hose fitting emerges above the die. Ensure that the top of the hose, now concealed inside the fitting, does not extend beyond the die. While most fittings are full crimp fittings, some may have specific crimp length requirements for that particular fitting, often referred to as bubble crimp fittings.
Step 6: Crimp the Hose
With the hose in position, activate the machine. The cylinder head will gradually move downward, compressing the die as it pushes the collar. Avoid any contact with the machine until the collar is firmly at the bottom of the die. The machine will stop automatically at this point.
Step 7: Verify the Crimp Diameter
Ensure that the hose has been crimped to the correct diameter by checking the chalk mark you made on the Hydraulic Cylinder Repair Near Me hose. If the chalk mark is no longer at the base of the fitting, it indicates that either the hose or the fitting shifted during the crimping process, which is not considered a proper crimp. However, if the chalk mark remains in place, you have successfully crimped the hydraulic hose ends. Use calipers to measure the outside diameter of the finished crimp, comparing it to the specified diameter for your specific hose and fitting.
Step 8: Cap and Label the Hose Assembly
After cleaning the hose again, it is advisable to cap both ends of the assembly using plastic caps or heat shrink caps. Additionally, label the hose if requested by the client.
In summary, these steps, although straightforward, must be executed accurately to ensure the safety of personnel working near the Hydraulic Cylinder Repair Near Me hose and the reliability of the entire hydraulic system. A dependable crimp will prevent costly damage and downtime resulting from a failure.
There are a couple of methods to carry out the crimping of a hydraulic hose, typically involving the use of machinery to achieve a precise and uniform crimp. When it comes to crimping your hydraulic hose, you have the option of either employing a mechanical crimping machine or visiting a local hydraulic hose shop to utilize an electric crimping machine. Although machinery calibration may vary, we believe you’ll find this broad overview as a valuable starting point for learning how to crimp a hydraulic hose.
Before you begin, it’s essential to understand that it’s advisable to use the same brand for both your hydraulic hose and fittings. This is because dimensions and fitting tolerances can differ between manufacturers, and a mismatch could result in hose failure.
Instructions for Crimping a Hydraulic Hose:
Measure and Cut Your Hydraulic Hose
- Start by consulting the information provided by your hose and fitting manufacturer to determine the cut-off factor. Measure your hose end-to-end and subtract this cut-off factor from the total hose length. Then, mark the hose and cut it to the appropriate length using a hose saw.
Clean Your Hydraulic Cylinder Repair Near Me Hydraulic Hose
- After cutting the hose, there may be accumulated debris. To minimize the risk of contamination or hose failure, use a foam projectile to clean the hose thoroughly.
Select the Correct Die Set
- Ensure that you have chosen a die set that precisely matches your specifications, as there are die sets available in various sizes designed for different hoses and fittings.
Choose Your Crimp Diameter
- Next, select the appropriate crimp diameter and input these specifications into your crimping machine.
Install the Fitting
- Select the appropriate fitting for your Hydraulic Cylinder Repair Near Me hose, taking into consideration factors such as the working type, style, and attachment method. It’s crucial to ensure that fittings are securely placed before crimping, as incomplete fitting installation is a common cause of hose failure. To prevent this, secure the fitting at the insertion mark using a soft mallet.