Complete Guide to Hydraulic Hose Assembly

Hydraulic hose assembly can seem to be a daunting task and this guide will solve that for you. We have put together all the necessary steps and few tricks that can help make it very easy.

At HoseMart, we understand the value of hydraulic hose assembly and know exactly how crucial it is. Therefore, getting this right always, is one of our main strengths. Be it any type of assembly, rest assured we can handle it and deliver it to you on time.

Our facility is equipped with the latest technology and our experts have carried numerous challenging projects. We have an excellent track record of designing and delivering hydraulic hose assemblies.

It is very important to get the assembly done the right way as it can lead to a number of disadvantages. Some of them being loss of time & resources to loss of manpower. A safety concern is always associated with the hose assembly and trust us, you don’t want it to go wrong.

To proceed with the hydraulic hose assembly and how to do it, it is important you know what hydraulic hose assembly is?

What is Hydraulic Hose Assembly?

A hydraulic hose assembly is when the hose pipe is attached with fittings on the ends, which enables it to connect with machines and systems. It then helps transfer media/fluid from one end of the hose pipe to another.

From our years of experience we know that it is not possible to have a definite guide for a hydraulic hose assembly. This is due to the complexities involved which at times, have more to do with the environment of use.

Therefore, we can say that the hydraulic hose assembly depends on the external and internal conditions. However, there are few things which remain common in most of the assemblies.

We have covered these common steps and have summarised it into a complete guide for hydraulic hose assembly for beginners.


Complete Step by Step Hydraulic Hose Assembly Guide

Step 1 : Gather Tools & Materials Required

It is always better to have all the required things in one place, or close by. This helps reduce time and wastes. These are some of the things that you usually need,

  • Hydraulic Hose
  • Hose Fittings
  • Lubricants
  • Safety Gear
  • Crimping Machine
  • Caliper
  • Marker / Chalk
  • Crimping Die Sets and Collar
  • Measuring Tape

These are the things that you need most often. They help you to complete your assembly without wasting time and easily.

Step 2 : Measure & Cut the Hose

After you have the tools and materials ready, you need to get the hydraulic hoses into the specific required lengths.

Measure the hose and mark the specific lengths that you need on it. After that, you can cut the hydraulic hose on the specific marks using a saw or a hose cutting machine. Make sure the ends of the specific cut outs are clean, smooth and even. If it is not so, use a file and clean the edges to make it even, this reduces hose assembly failures.

Do note, safety is of key importance, take utmost care during this process. It is important you hold the hose properly or tighten it in the cutting machine so that it does not bounce due to friction. A number of times, these precautions are ignored and leads to injuries.

Step 3 : Hose Dressing

This is the time to complete the hose dressings if any. After this it will not be possible as we will seal the ends.

This is completely application specific, sometimes spring guard, additional braiding is required to prevent the hose from external environmental damages. These help to increase the working life of the hydraulic hose.

Step 4 : End Fitting Series

Select the end fitting series that you need to assemble with the hose. This helps the hose to connect with the machines or the systems where it is going to be applied.

You can choose the end fittings from our wide range of options. Any sort of end fitting you need, we have it covered. If you need custom made fittings, do not hesitate and send us an email.

End fittings can be really complex. It depends on the machines in-out port / point of application. You have to match the specifications for a perfect operation. You need to consider attachment method, orientation, working pressure and material for corrosion resistance.

After you have done that, it is important you place the right hose with the right set of fittings. If you make an error here, it can cost you the entire assembly.

Step 5 : Attach the Fittings with Hose

Attach the fittings on the hose ends and prepare it for crimping. You need to place the hose cap and insert the fitting in the hose. Keep in mind the insertion depth and it should have a firm hold inside before you crimp.

Step 6 : Crimping

Once everything is verified, you are now ready to crimp the hose. We recommend running a check before crimping as it can save a lot of trouble. Wrong fittings, incomplete hose dressings are easy to deal before crimping.

Prepare the crimping machine by placing the right set of dies and adjusting the crimping settings. After that, push the hose end into the crimping machine (usually bottom loading) through the die. The hose cap or collar needs to be crimped so hold the fitting accordingly.

Put on your safety gear and turn on the machine. Push the button and the machine will compress the collar on the hose to hold the fittings as tightly as possibly. Do not the touch machine when it is in action/operation. After the compression, the machine will pull back or stop and you can check the assembly.

Step 7 : Verify Crimping

Check if the crimping was properly done or not. Always follow the crimp diameters and look for if the fittings moved during the process. If it is so, then it is not a good crimp.

Some of the ways to check is by placing a mark at the bottom of the fitting and if the mark is visible the same way after crimping, the hose or the fitting did not move.

It is very important you check if the crimping was properly done. We have a complete state of the art, testing facility in place where we can test the if the hose fitting is being able to withstand the pressure. This helps to firmly assure if the fitting has been done correctly and possible leakages.

Step 8 : Clean Hose Assembly

After  the crimping is done and it is approved, you should always clean the hose assembly for any impurities that might have stayed within the hose. You can do this by using chemicals or by compressed air that can blow out the contaminants.

Step 9 : Cap Hose Assembly

After cleaning the hose assembly, make sure you seal the ends to ensure no further contaminants enter the hose assembly. You can apply a cap to protect the threads and seal entry.

You can either use a plastic cap or a heat shrink cap to seal and protect your hose assembly.

If you order a hose assembly from us, be rest assured you will receive nothing less than a perfect hose assembly. We have the facility and technology to carry out your requirements. If you any custom requirements, we can take care of that too.

We know that hoses assemblies are a safety concern and therefore we take utmost care, precaution and only use the best quality materials.

If you want your hoses to be properly assembled, leakage free and on time, email us your requirement and leave the rest to us. You can also connect with us on Facebook or Instagram.

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