HYDRAULIC HOSE ASSEMBLIES: CUSTOM MANUFACTURED
Hydraulics Center is your go-to place for custom manufactured hydraulic hose assemblies. These assemblies will be constructed with SAE quality hoses, couplings, and fittings to ensure proper service on the job site.
A hydraulic hose assembly custom made for your business from Hydraulics Center will use hoses and construction methods specified for the type of work the assemblies will be subjected to. We use only the best materials and pressure test each assembly before sale. Fittings are crimped onto the ends of the hoses without compromising the structure of the hoses and creating a weak spot. With professionally-assembled units made of high-quality parts, you can be assured of maximum service from your hydraulic hose assemblies.
Not many companies will provide custom assemblies. At Hydraulics Center, we will assemble any quantity you order, regardless of the style. We also have a quick turn-around time so that your job site remains active with minimum downtime.
WE DO THE GUESSWORK
With our custom-made hydraulic hose systems, you no longer have to do the guesswork in matching hoses, fittings, and job site requirements. You provide us with your requirements regarding the variables, and we select the hydraulic hoses and fittings that will do the job for you. We need to know some particulars such as:
Temperature ranges, both mechanical and environmental
Type of fluid or gas being used
Machine or tool specifications
There will be other information we’ll need, based on each individual customer – it is a custom assembly, after all.
CRIMPING HYDRAULIC HOSE
Crimping hydraulic hoses should be done with care and the proper equipment. Hydraulic hoses are crimped when fittings are attached. Most professional crimping tools measure the amount of pressure being exerted so that the fittings can be attached at the maximum recommended pressure.
If the fitting is attached with too little force, the risk of failure is exponential. Once the hose is pressurized, the fitting may fly off of the end of the hose. This can injure anyone nearby as well as damage equipment.
If, when crimping hydraulic hoses, too much force is used, the hose may be damaged to the point of failure. The outer covering of the hose must remain intact for stability. If it is severed, the inner rubber tube will not be strong enough to withstand the pressures placed on it by the hydraulic fluids. This, too, can result in explosive failure, injuring people and damaging equipment.
Professional crimping tools can be quite expensive. Costs are between $1000 and $7000 each. Most of the tools, themselves, are powered by hydraulics. It is always recommended that the operator receives training in the use of crimping tools used for crimping hydraulic hoses. Skillful use of the proper equipment can pay for the cost of the tool in a number of ways.
First of all, skilled crimping of hydraulic hoses means less downtime on the job site. You no longer have to wait for a technician to come to your site, or for hoses to be prepared off site and brought in.
Second, having someone on staff who can properly crimp hoses will decrease the margin of error on jobs. Often, on-site repairs are done in a hurry with employees waiting to get back to work. A knowledgeable person can make good repairs under pressure.
Third, quality tools and trained personnel can reduce damage to equipment and machinery. Besides reducing the amount of downtime, equipment will run more effectively without damage.
HYDRAULIC HOSE END FITTINGS
Hydraulic hose end fittings are available in a variety of styles and materials. It is always important to follow the specifications for your tools and equipment when you select hydraulic hoses and crimp fittings. Using the wrong fitting can damage your equipment, reduce its efficiency, and fail under use. This is dangerous to workers and destructive to equipment.
Crimp fittings are manufactured for 1 and 2-wire hoses and 4-wire hoses. While it is often acceptable to use fittings designed for 4-wire on 1 or 2-wire hoses, it is not advisable to reverse that exchange. The fittings are designed to withstand certain pressure variations, and the incorrect fitting may fail under pressure, even if it has been crimped into place.
PTFE HOSE FITTINGS, T-SERIES
These are also crimped fittings that require pre-determined crimping pressure to insure proper function. This type of fitting is used with SAE PTFE hose.
THERMOPLASTIC FITTINGS, 3-SERIES
These are also crimp fittings. They are used with nylon hydraulic hoses, or thermoplastic hoses.
HYDRAULIC HOSE PREPARATION
Hydraulic hose preparation requires the proper tools and quality equipment, as well as a knowledgeable operator. Hydraulics Center Direct provides custom hydraulic hose assemblies for customers. There are several steps to preparing a hydraulic hose.
SELECTION OF MATERIALS
Follow the brand recommendations of your equipment. Your owner’s manuals should tell you which type of hoses and fittings to use to ensure proper function of your equipment. If you no longer have the operator’s manuals, contact the manufacturer or Hydraulics Center Direct for information.
Since hydraulic hoses have different weaves and materials in the construction, you’ll have to make sure you purchase the hoses that work best with the types of hydraulic fluids you use on site.
In most cases, stainless steel fittings are recommended. Other materials are allowable in some circumstances.
HYDRAULIC HOSE PREPARATION
Once you have selected the correct type of hydraulic hose, you cut it to the length you need. Allow for flexibility when you do this, and the need to turn any corners or move with hand-held tools.
Insert the ferrule into the end of the hose up to the collar.
Next, insert the fitting. This may be a tight fit, so you may want to lubricate the fitting.
Push the fitting in firmly, until it is all the way in. The fitting should go to the shoulder of the ferrule.
Once the fittings are assembled onto the hose, check your crimp chart to see the proper pressures necessary for crimping the fittings. Cross-reference that the hose and fitting match, and see the crimping pressure.
Make sure your crimping tool has the correct die tool installed, if it uses a die.
Set the pressure on your crimping tool, or keep an eye on the gauge as you crimp the fittings.
Once the crimping is complete, check the measurements with the chart to make sure the outer diameter is correct. If you have applied too much force, the diameter will be smaller than the recommended measurement. If you used too little force, the measurement will be bigger than recommended.
HYDRAULIC HOSE PRESSURE TESTING
Before a hydraulic hose is used on a job site, it should be tested. If there is a leak or weakness anywhere in the hose or in the fitting, it is much better to find it under controlled testing than in the field.
If you purchase custom made hydraulic hose assemblies from Hydraulics Center Direct, the assemblies are already tested. If you have made repairs in your shop or in the field, you should conduct the testing yourself.
HYDRAULIC HOSE BURST PRESSURE TESTING
Burst pressure is the pressure determined necessary to burst a hydraulic hose. Maximum working pressure is deliberately lower than the minimum burst pressure. Hose batches are tested at the manufacturer to make sure they can withstand the minimum burst pressure. The sample hose has to withstand 30 seconds at the minimum burst pressure. At this pressure, there should be no signs of leakage from the hose or any fittings being tested.
HYDRAULIC HOSE PROOF PRESSURE TEST
The proof pressure test takes the hose and fitting assembly up to working pressure. That pressure is held for a minimum of 30 seconds.
SAE has established standards for each of the different types of hydraulics. Any testing should be done with no air in the line, as it can create a projectile if the hose bursts. Safety measures are crucial during testing. Check SAE standards for each specific hydraulic hose assembly being tested.
STAINLESS STEEL FITTINGS: MANUFACTURED HOSE ASSEMBLIES
Hydraulic hose assemblies manufactured with stainless steel fittings can save you hours of down time on your job. They can save you money, too.
Hydraulic hoses must be assembled with the proper tools. Crimpers are pre-set to crimp fittings onto hydraulic hoses to a specific pressure. Any pressure variance from that which is recommended can result in failure of the fitting. It can also damage the hydraulic hose, causing it to leak or rip.
Many business owners purchase their own crimping tool that measures the pressure necessary to secure the fitting. In some cases, though, the fittings and hoses may require off-site assembly. Hydraulics Center provides custom made hydraulic assemblies.
Stainless steel is a much-preferred material for hydraulic hose fittings. This material is strong and durable, able to withstand some of the extreme conditions found on work sites.
Temperature has little effect on stainless steel, which has little expansion or contraction in extreme variations. Environmental temperatures, as well as the heat from machinery and hydraulic fluids, can cause less durable fittings to weaken over time.
Some hydraulic fluids, as well as electrical currents and static buildup, can contribute to corrosion on fittings that are not stainless steel.
Pressure can also cause failure of weaker metals. That’s why so many SAE fittings are made of stainless steel – it can withstand the pressures generated by pumps and generators.
In most cases, the hoses themselves will fail before a stainless steel fitting fails.
These fittings are also reusable in most cases.