Hydraulic Hose Assembly procedure

1. Identify and select the correct products/components to correctly manufacture the assembly work in progress. 2. These products/components being, i. ii. iii. The correct hose type required for the assembly application. The correct ferrules designed for use with this hose. And finally the correct end termination inserts to be used on the assembly.

3. Look at the Correct Swage Wall Charts published by for use with the approved hose and fittings to clarify and check that all the components are correctly matched. 4. Select the correct chart for the hose type applicable, you then locate the hose size in the left-hand or right hand columns and then trace this across to the specific hose type column. 5. On some wire braided hoses you will see that there may be more than one ferrule type listed for use with that particular hose, i.e. it may list a non-skive ferrule and also a skive type ferrule

6. On some of the multi spiral hoses you will also see that there may be than one ferrule type listed for use with that particular hose, i.e. it may list an external skive ferrule for use with standard inserts and also a internal and external Interlock skive type ferrule for use with an interlock insert. 7. The respective part numbers for the ferrules are shown on the charts. 8. This Swage / Crimp dimension is shown with the dimension stated in millimeters. 9. This Swage / Crimp dimension gives the outside measurement of the finished product and therefore it is the swage machine setting reference that you will need. 10. If the assembly that you are making is a skive type hose, the other important information that you require from the respective chart is the external Skive Length or for an Interlock assembly both the external Skive Length and also the internal Skive Length. 11. This skive dimension / dimensions are stated in millimeters. 12. Note Flexor 4SP has the option to use either an external skive type universal ferrule with a standard insert and also the interlock ferrule system.

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13. HOSE CUTTING 14. Calculate the overall length of the hose. 15. The hose cut length calculation will take into consideration; i. ii. The overall length of the finished hose assembly including the length of the two end fittings. That the swaging / crimping process marginally increases the hose length.

16. FOR VERBAL ORDERS RECEIVED FOR ASSEMBLIES, IT IS ESSENTIAL THAT YOU DETERMINE:i. THE SPECIFIC HOSE TYPE REQUIRED. ii. THE SPECIFIC END TERMINATIONS and CONFIGURATION. iii. HOW THE CUSTOMER HAS MEASURED THE ASSEMBLY. iv. THE SPECIFIC ANGLE SET IF APPLICABLE. 17. Unless specified by the customer / customer manufacturing drawing, listed below is the standard assembly length tolerance chart.

18.

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Hydraulic Hose Assembly Manufacture

Assemblies can have many end termination configurations so you also need to know how to measure these different configurations.

19. 20. Once you have determined the calculated required hose cut length the hydraulic hose is measured and marked at the cut off point. 21. The hose must be cut squarely to ensure even contact internally when the ferrule is pressed onto the hose. 22. A maximum deviation up to 5% is allowable. However, every effort should be made to reduce this as a cut of 20 degrees off square reduces the sealing area and end retention of the fitting by as much as 15%. 23. It is important to the life of the assembly that the cutting procedure does not deform, fray or burr the inner tube. 24. Towards the end of the cutting process on each hydraulic hose, pressure on the blade should be eased to ensure that the outer layer of the hose wire reinforcement is not pulled loose from the hose cover. This requires considerable attention and scrutiny in relation to spiral hose construction. 25. The cutting blade should not be allowed to overheat. Should this occur, the heat within the blade will cause the melting and bonding of different elements within the hose.

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26. A build up in blade heat can also be avoided by ensuring that the hose is bent during the cutting cycle. This will reduce friction of the cutting blade and apart from heat reduction, it will allow the blade to stay sharp. 27. Once the hose has been cut, check that the length is correct. 28. The overall assembly length is important, especially on shorter assemblies, assemblies too long or too short will put undue stress at the critical point in the assembly which is where the fitting is attached to the hose. 29. If you are making a production batch of the same assembly, it is important that prior to any further hose being cut to a specific length, the first off cut length should be prepared and a finished first off completed assembly manufactured in accordance with the assembly procedures. 30. Only when the first off assembly is completely manufactured and verified as being correct should a production run commence.

31. HOSE PREPARATION PRIOR TO SWAGING / CRIMPING 32. Hose preparation is dependant on the type of hose selected for the application of the hose assembly, the three main hose preparation methods are for hoses that require:i. ii. iii. Non Skive External Skive Internal and External Skive (Interlock)

33. Each method relates to the hose/fitting/ferrule combination required For method i. Non Skive The only hose preparation required is cutting the hose to the required length. For method ii. External Skive The hose preparation required is cutting the hose to the required length and the external skiving (removal of the rubber) of the hose outer cover. For method iii. Internal and External Skive (Interlock) The hose preparation required is cutting the hose to the required length and both external skiving of the hose outer cover and internal skiving of the hose tube/liner. 34. HOSE PREPARATION PRIOR TO SWAGING / CRIMPING 35. EXTERNAL SKIVE. (OUTER COVER REMOVAL)

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36. The process of removing the outer rubber cover includes the removal of all the rubber for a specified length down to the wire reinforcement; this allows the ferrule to be assembled directly onto the hose wire reinforcement. The approach and methods of outer cover removal may vary either using a blade type skive tool, brushing machine (with a wire embedded rubber brush) or cutting knife. 37. Check the skive length carefully; If the outer cover is not correctly removed undue stress will be built into the end of the insert tail. This will show up by the cover bulging at the end of the ferrule. 38. Ensure the external skiving process is completed accurately. 39. EXTERNAL SKIVE. (OUTER COVER REMOVAL) 40. Where a bladed skive tool is used, the cutting head is normally preset to the nominated rubber cover thickness as detailed in the hose specification. 41. If an adjustable bladed skive tool is used, set the tool to the correct skive length. After setting up the tool, it should be tested on a small section of the to be skived area to ensure accuracy of the cutting depth. 42. It may be necessary to adjust the skiving tool to ensure the depth of the cut does not damage the wire reinforcement. 43. The skiving tool mandrel is then inserted into the hose. Fitting and alignment will be enhanced through prior lubrication of both the mandrel and the inner tube of the hose with an appropriate lubricating oil, a soluble mineral - based oil mixed with 95% water, and application of a steady pressure on the hose during this process. 44. The skive tool is preset to commence cutting at the point by bottoming the hose end to the tool. The tool is turned on and the hose is slowly pushed into contact with the blade which rotates in a counter clockwise direction. The hose should be slowly pushed onto the mandrel and then pulled slowly out of the tool thus removing the rubber cover in the process. (All of the rubber must be removed) 45. It is important to use the correct skive mandrel which should be no smaller than the nominal internal diameter by a tolerance factor of + 0.4mm 46. INTERNAL SKIVE (INTERNAL TUBE / LINER REMOVAL)

47. Internal skiving is the process of removing the inner tube / Liner and includes the removal of the tube rubber from the inner spiral wire reinforcement.

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48. Refer to the Swage Chart for the specific inner skive lengths for Interlock couplings. 49. Internal skiving is done in the opposite direction (clockwise) to external skive. 50. The spiral wire reinforcement must not be damaged in the skiving process. This is achieved by adjusting the inner skive depth on the skive tool, allowing for tolerance changes in the inner tube size. 51. During the internal skive process, the hose should be turned continuously which will assist in the removal of the entire inner tube. This will expose the first inner layer of wire spiral reinforcement. 52. Ensure this internal skiving process is completed accurately 53. After the hose cutting and skive processs are completed all particles and debris should be removed from the inside of the hose. 54. FERRULE AND INSERT FITMENT 55. Before attempting to insert the hose tail of the insert, the respective ferrule is first placed over the hose. It is important that the ferrule collar is in line and touching the hose end. The ferrule should be pushed all the way onto the hose in both the skive and non-skive styles. Look into the open end of the assembly to be sure this has been done. 56. Dip the end of the hose insert hose tail stem into a suitable lubricant, it is advisable to use a soluble mineral - based oil mixed with 95% water. 57. Insert the selected hose tail firmly into the bore of the hose until it contacts the front face of the ferrule and nips the ferrule against the hose end. 58. Push the insert hose tail securely into the end of the hose and ferrule combination. Ensure that the insert hose tail is secured fully. If the insert is not pushed fully in as described, the assembly could still look visually satisfactory prior to swaging, but it is not, so double check the pre-assembled end before you put it into the swage machine to make sure the fitment is correct and that the locking collar of the ferrule will correctly engage the hose tail locating groove during the swaging process. 59. FERRULE AND INSERT FITMENT 60. It may in some instances be necessary to use a soft hammer to fit some inserts but most should go quite easily. Fitment problems usually arise if the hose bore is at the bottom end of the hose I.D. specification tolerance and the fitting is at the top end of the manufacturing tolerance.

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61. When using angled fittings on an assembly, where possible, place either with or against the natural curve of the hose. 62. If fitment problems do arise, never put the hose or fitting into a standard jaw vice without first placing protective clamping blocks inside the vice jaws to avoid either the hose or fittings being damaged.

63. FERRULE AND INSERT FITMENT 64. To assemble an Interlock coupling the insert hose tail is to be pushed into the bore of the hose and turned in a clockwise threading motion to ease entry. Dip the end of the hose insert hose tail stem into a suitable lubricant to ease entry, it is advisable to use a soluble mineral - based oil mixed with 95% water. 65. Interlock fitment requires the hose to be fully positioned into both the insert hose tail stem and the ferrule. 66. The placement of the insert hose tail inside the hose has to be carefully executed to ensure that the spiral wire reinforcement is not damaged or displaced. 67. THE ANGULAR ROTATION OF THE INSERTS MUST BE DETERMINED AND SET PRIOR TO SWAGING / CRIMPING. 68. The swaging/ crimping of the end terminations onto the hose is the final operation in manufacturing a hydraulic assembly. 69. The finished assembly consists of a pallet swaged crimped ferrule and insert being permanently attached to both ends of the hydraulic hose. 70. The attachment is achieved in the Swaging / Crimping machine as the action of the machine by means of a multi-jawed swaging head (usually 8 jaws) causes a tightly compressed cross section of the hose to be entrapped between the insert hose tail and the ferrule. 71. SWAGING / CRIMPING PROCEDURES 72. It is important that the correct swage / crimp diameter is selected to suit both the type of hose and ferrule combination being swaged. 73. Once you have established the correct final swage / crimp diameter, you need to select the correct set of dies required to achieve the required 74. Most Swaging / Crimping machines come with a specific chart stating the machines die set numbers and the swage / crimp diameter ranges for each specific die set. The dimensions are usually stated in millimeters.

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75. In most cases the die set number is the machine series type then the minimum swage dimension for that specific die set. i.e. Minimum swage for that die set 10 would be 10mm. 76. The diameter range stated on the charts for each die set shows the minimum swage dimension that can be achieved up to and including the maximum swage dimension that can be achieved using that particular die set. 77. The die set number is stamped on each of the 8 individual die segments. 78. Once you have completed the first swage check the final swage diameter with an accurate and calibrated vernier gauge (either dial or digital) and note the +0.13mm / -0.13mm tolerance variation allowable, as stated on the swage chart. 79. If the reading is not within this tolerance, adjust the swaging machine setting as appropriate and re-swage the end. 80. When the correct swage is achieved you can now swage the second end, check this end also. 81. The final swage should leave an even pattern on the surface of the ferrule and not look unduly distorted. 82. If you are doing more than 10 assemblies (20 ends) check the swage dimension after every 10 hoses and again at the end of the batch in case the adjustment moves as you work. 83. The point of measurement must be the mid point along the length of the ferrule below. Measurements must be taken at this mid point at two different planes 90 to each other and the maximum reading (any variation will be due to slight ovality) taken as the swage dia

84. 85. FINAL INSPECTION 86. The finished assembly should now be fully checked and verified to ensure that it meets the customer requirements. The end terminations should be checked to ensure that the nuts (if applicable) swivel freely and that the assembly is not

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twisted. Visually, the hose assembly should also be checked for external damage such as cuts, kinking, crushing. 87. As an added precaution and in the interests of customer satisfaction, it is recommend that you clean the inside and outside of all assemblies prior to delivery. 88. The hose ends should have plastic caps inserted to keep the hose clean internally and also the assembly should be adequately packaged to avoid damage in final transit to customer.

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