You can find hydraulic fittings in almost every industry. They form secure, leak-proof connections between hoses, pipes, and other components in a hydraulic system. But with a wide range of types and sizes, navigating the world of hydraulic hose fittings can be tricky. This guide will equip you with the knowledge to choose, install, and connect these crucial components.
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This comprehensive hydraulic hose fittings guide will help readers understand the different types of hydraulic hose fittings, their materials, and how to install and maintain them.
A hydraulic system uses the properties of pressurized fluid to move mechanical energy. The energy is transferred from one point to another using fluid inside hydraulic hoses, which are attached to machinery using hydraulic fittings.
Hydraulic fittings must attach securely to the equipment and hose and must withstand high pressure and temperatures. Fittings are made in different sizes, materials, types of seals, and temperature and pressure tolerances.
Some fittings enable fluid flow, others prevent it, and some are designed to do both. The most important function of a fitting is to create a tight seal that keeps fluid in and contaminants out.
Fittings can be attached to hoses either permanently or with a field connection.
A permanently attached fitting is known as a crimped fitting. Crimped fittings are secured onto the hose with a crimping machine that crimps (bends) the fitting to ensure a resilient connection that is difficult to break.
Traditionally, all crimped fittings needed to be brought to a workbench to be attached to the hose, though with tool advancements, there are now portable crimpers that can be used in the field.
A field-connection hydraulic fitting, also known as a hydraulic coupler, can be installed anywhere without a crimping tool and used multiple times. It is comprised of a socket and a nipple, and it allows for a blend of convenience and adaptability when immediate adjustments or replacements are required.
However, field connections are not generally recommended as they offer limited pressure capabilities and are often points of hose failure. We recommend using permanent crimped fittings on all hydraulic systems.
Hydraulic hose fittings are manufactured using different materials, depending on the application and budget. Here are the most common hydraulic hose fitting materials and their characteristics:
Choosing the right hydraulic fitting material for your application is important for a long-lasting, safe solution.
There are many different types of hydraulic fittings. Different countries have different standards and types of fittings, though some machines and equipment may also favor one type over another.
Here are the main types of hydraulic hose fittings:
There are three main types of hydraulic hose fitting connections:
Choosing the right hydraulic fitting is crucial for a safe and efficient hydraulic system. Heres a breakdown of the key factors to consider. Several of these considerations are summarized as a STAMP acronym:
S
ize: This refers to the diameter and the thread type of the fitting. It should seamlessly match the hose or tubing youre connecting. Common sizing standards include NPT, BSP, and metric (ISO), which are described above.T
emperature: It is important to consider both the operating temperature of your system and the ambient temperature where the fitting will be used. Some materials may become brittle or lose strength at extreme temperatures.A
pplication: Consider the fittings function within the system. Fittings designed to handle high-vibration environments may be required, while quick-connect options might be ideal for easy assembly and disassembly.A
ssembly: Related to the application, how will the fitting be attached to the hose or tubing? Crimped fittings are permanent and durable, while reusable fittings are more flexible.M
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aterial: The fitting material needs to be compatible with the hydraulic fluid being used and withstand the systems pressure.P
ressure: The fittings pressure rating must exceed the maximum pressure your hydraulic system will generate. Selecting a fitting below the systems maximum pressure can lead to catastrophic failure.By carefully evaluating these factors, you can select the most appropriate hydraulic fitting for your application. If you have any doubts about the selection process, it is recommended that you consult a hydraulics professionalespecially for complex systems.
The key to a long-lasting hydraulic hose system is proper installation and maintenance.
To ensure a leak-free, secure connection, you must pay careful attention to detail. Here are five steps to installing a hydraulic hose fitting:
Choosing the appropriate fitting for the job requires considering the hose size, fitting type, connection type, and hydraulic systems psi and temperature ratings. The fitting should be rated for more pressure and temperature than the hydraulic systems rating to create room for a safety margin.
The next step in crimping a hydraulic hose is to prepare it by cutting it to the required length. To ensure the hose is contaminate-free, make sure the cut is clean and straight and remove debris inside and outside of the cut end.
Follow the manufacturers instructions on crimping your fitting. Youll need to choose the correct crimper diameter die set. Put the fitting all the way on the hose and secure the fitting at the insertion mark with a soft mallet.
Adjust your crimping machines settings to ensure the crimp is just right. Too tight or too loose, and the hose will fail. Set the hose on the machine so that the fitting sits just above the die and crimp it.
After crimping the fittings, inspect the assembly to ensure everything is properly aligned. There should be no defects or irregularities.
After crimping the hose, use a protective plug to prevent contaminants from entering the hose or fittings. Then, a pressure test will be performed to check for leaks or other problems. Be sure to follow safety protocols, as testing under high pressure represents several safety concerns.
Just like any component, hydraulic fittings require regular maintenance. Here are some key hydraulic fitting maintenance practices to keep your fittings in top shape:
Visually inspect the fitting for damage, deformations, cracks, or corrosion. Replace the fitting if there are any signs of decay. Remove the O-ring and thoroughly clean the fitting, then replace the O-ring with a new one, regardless of how the old O-ring looks. Check that the threads run true and the fitting is ready to be reused!
Note that permanently crimped hydraulic hose fittings are designed for one use only and cannot be reused.
Need help with your hydraulic fittings? IBTs expert Hydraulic Division is ready to assist you. Whether you need to know which fitting works best for your application or a full hydraulic system design, our professionals will walk you through the best solutions.
With over a million dollars in industrial hose and fitting inventory, we have all the parts you need. Browse our hydraulic fittings from our ShopIBT store.
Our Kansas City Industrial Hose Shop also provides everything from simple repairs to fully assembled hydraulic systems.
We also offer Hydraulic Systems 101 Academy Safety, Maintenance, and Troubleshooting classes to train your technicians.
Contact us to learn more about our hydraulic systems and fittings services and products.
The pressure affects the stresses to which the hose construction is subjected on a daily basis. The higher the pressure, the more robust the hose must be. Especially since constructions that are under high pressure always involve risks of injury.
The medium to be transported primarily influences the choice of material. On the one hand, companies should ensure that the hose does not become cracked or brittle under the influence of the medium. This can happen, for example, with fuels, acids or abrasive materials such as gravel or sand. The hose material should therefore have appropriate resistance. On the other hand, it is particularly important in the food or drinking water sector that the hose line does not contaminate the medium. Here, companies should make sure that the hose has the usual certifications in their industry.
The operating temperatures also have an impact on the service life of a hose design. Temperature extremes or strong fluctuations in particular can cause a hose to quickly become brittle. The most important factors here are the temperature of the medium to be transported and the ambient temperatures of the machine or system in which the hose is installed.
In addition, there are environment-specific operating conditions that can have a stressing effect on a hose construction. These include UV radiation and ozone exposure, weathering, and static or mechanical loads.
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