How to Make Hydraulic Hoses

Posted by Jerry Murphy on 27th Jul 2021

How to Make Hydraulic Hoses (Step-By-Step Guide)

While getting your hydraulic hoses assembled by a professional shop, like Greenshields, is always the ideal, many companies also keep a crimping machine on-site for quick emergency hose replacement.

If you’re facing a hose crisis but are new to hose assembly, here is a step-by-step guide on how to make hydraulic hoses.

1. Gather Required Tools and Materials

Ready to make your own hydraulic hoses? The first step is to gather all the equipment and materials needed. Here’s a checklist to get you started:

  • Crimping machine
  • Reel of hydraulic hose
  • Hydraulic hose fittings
  • Crimping die and collar
  • Hose saw
  • Hose lubricant
  • Calipers
  • Safety goggles
  • Paint pen
  • A cleaning nozzle and cleaning projectiles
  • Clean seal caps

Of course, when it comes to how to make hydraulic hoses, a key step is ensuring that the replacement hose and fittings you’ve selected are an exact match for the hose assembly you’re replacing.

2. Put on Safety Equipment

Assembling a hose means working with high-powered equipment. Put on your safety goggles to ensure you’re appropriately protected from flying projectiles.

3. Prep the Hose and Fittings

Figure out how long your new hose needs to be by measuring the failed hose.

Now measure out a length of new hose, making sure to account for the cutoff portions. Lock the hose in place and cut it with your hose saw.

It’s important to create a clean cut, so check the edges to ensure they’re smooth. If there are any deformities, use a file to create a flush edge.

4. Clean the Hose

Cutting and filing the hose will clutter the inside of the hose with debris. If left inside, this debris can damage hydraulic systems by contaminating fluids. Debris can also create fractures in a hose if caught between a fitting and the inner tube.

The best way to clean your hose is to use a projectile cleaner, like Ultra Clean. To ensure your hose is free of contaminants, fire two projectiles through your hose — one from each end.

5. Attach the Fittings

Use a hose insertion depth block to check how deep the fittings need to be. Use your paint pen to mark the insertion depth on the hose.

Next, lubricate the hose and push the fitting inside. Again, make sure that the fitting you’ve selected is compatible with the hose, the hydraulic fluid, the operating pressures, and the application. Do not interchange fitting and hose brands.

Secure the hose in a vice and use a rubber mallet to press the fitting in place. Ensure the fitting reaches the painted line.

6. Set Up Crimping Machine & Verify Die

Now it’s time to lock your fitting in place with the crimping machine. To start, verify that your crimping machine is compatible with the hose/fitting assembly you’re creating. Change the die or adjust settings as necessary.

Make sure you’re using the correct crimper die set. Using the wrong diameters can result in a crimp that is too tight or too loose — something that can cause your hose to leak.

7. Insert and Crimp Hose

Put your fitting and hose into the crimping machine with the fitting resting just above the die. If you need to use a compression ring, attach it now.

Next, turn on the machine and allow it to crimp the hose. Don’t touch the hose or machine until the collar has compressed the bottom of the die.

8. Check Crimp Diameter

Once again, check the paint mark you made on the hose earlier. Is it still flush with the fitting? Or has the hose moved to cover it or moved away from it?

If the distance between the paint mark and the fitting has changed, then this means that the fitting moved during crimping. If this is the case, you’ll need to redo the hose and fitting.

You’re almost done learning how to make hydraulic hoses! The next step is to check the crimp diameter with the calipers. Does it match the crimp diameter listed on the decal? If yes, you’re good to go! If not, you’ll need to recreate the hose assembly.

9. Cap Off the Hose Assembly

Now that your hydraulic assembly is verified and cleaned, it’s important to cap each end to prevent contamination. You can use heat shrink caps or plastic caps to protect the fitting ends.

Once you’ve capped the assembly, you’re complete. Congratulations, you’ve made a hydraulic hose assembly!

Professional Hydraulic Hose Assembly Near You

While making hydraulic hoses yourself can work as a short-term solution, you should try to work with a professional hose assembly company whenever possible. This is because incorrectly assembled hoses can cause a hose to fracture and fail.

  1. For fast hose replacement and assembly in 15 minutes or less, contact Greenshields Industrial Supply today. Simply bring in your hose assembly (hose & fittings) and our expert technicians will have you set up with a fresh hose and back on the job right away.