Eaton Aeroquip Assembly Instructions How To Put Together Section of Catalog

Fluid Conveyance ProductsMaster Catalog

Hose

Hose Fittings

Adapters & Tube Fittings

Accessories/Equipment

6

Instructions

Brazing and assemblingLifesaver reusable fittingsis a simple process

Eaton Lifesaver reusablehose fittings are designedto simplify the replacementof failed hose lines whichhave unusual, steel, endconfigurations or threadstyles. The process involvesremoving the old tube con-figuration, silver brazing itto an unused lifesaver nip-ple and assembling the fit-ting onto the hose in theusual manner. A fewLifesaver fittings, some bulkhose, the appropriate handtools and accessories plusbasic silver brazing equip-ment are all that is neces-sary to make up hoseassemblies anywhere. Besure to follow all applicablesafety procedures whenmaking Lifesaver fittings.

Step 1: Measuring

Measure and record thelength of the old assembly.For elbow assemblies,scribe a very light mark 5/16”or more from the existinghose socket. The distancefrom the scribe mark to theend of the other fittingshould be recorded as thefabrication length. In thecase of double elbows,make the scribe marks inline with one another sothat you can duplicate thephase angle later on.Record the distancebetween the two scribemarks as the fabricationlength.

Step 2: Cutting

Using a hacksaw or tubingcutter, cut the tube at thejuncture of the tube and thehose socket. It is importantto cut the tube so there isat least a 1/4” length ofstraight, unbent tubing inorder for it to properly enterinto the counterbore of theLifesaver nipple.

Step 3: Preparing the tube for brazing

Avoid touching the tube —oily or greasy surfaces tendto repel the flux and silvermaterial leaving voids andinclusions. Clean the tubethoroughly using a residue-free degreasing agent orhot caustic soda.

Using a flat file, remove theburrs on the outside of thetube and use a rat tail file toremove the burrs on theinside.

Polish the end of the tubeon the outside with anemery cloth to remove theplating down to the basemetal. It is important toremove oil and grease firstbecause abrasives tend toscrub the oil into the sur-face and/or impregnate itwith a fine abrasive powder,resulting in further contami-nation. Remember, attempt-ing to brazecontaminat-ed orimproperlycleaned sur-faces willgenerallyresult in anunsatisfac-tory joint!Continued onnext page.

309EATON Aeroquip Fluid Conveyance Products A-HOOV-MC001-E1 March 2011

APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

AssemblyInstructions

How to BrazeLifesaver Reusable Fittings

Materials needed:

• Eaton FF9705 silverbraze rings or 1/16” diame-ter 45% silver alloy brazewire

• Water-soluble flux

• Brazing outfit capable of+1200ºF (propane or mapp gas)

• Small files – rattail andflat

• Spray paint (quick drying)

• Water (to cool joint)

• Needle-nose pliers

• Tape measure

• Emery paper

• Hacksaw

• Pliers

• Pair of diagonals (or othertool to cut silver wire)

• Residue-free degreasingagent

• Wire brush

Page 2

http://www.HoseWarehouse.com/aeroquip

310 EATON Aeroquip Fluid Conveyance Products A-HOOV-MC001-E1 March 2011

SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Step 4: Preparing theLifesaver fitting for braz-ing

Clean the nipple and tubeend thoroughly. Place thetube into the counterbore(it should fit freely into it).Measure the diameter ofthe counterbore to deter-mine the braze ring sizeneeded. At this point, youhave the option of selectinga ready-made Eaton brazering or making a ring for theapplication from bulk silverbraze wire.

For quick, easy assembly,Eaton offers the followingsize range of FF9075 brazerings:PART TUBE SIZE NUMBER O.D.

mm in.FF9075-19 6,4 .25FF9075-06 9,7 .38FF9075-74 12,7 .50FF9075-08 16,0 .63FF9075-09 19,1 .75FF9075-86 25,4 1.00FF9075-87 31,8 1.25FF9075-88 38,1 1.50

To assemble, simply placethe appropriate size EatonFF9075 braze ring into thecounterbore of theLifesaver nipple.

To make the braze ring, multiply the diameter of thecounterbore by 3 to deter-mine the length of silverwire needed. For example,if the counterbore diametermeasures 3/4 of an inch, a21/4 - inch length of wirewould be needed (3/4" x 3 =9/4" or 21/4").Now cut off apiece of silver wire justshort of 21/4 inches, so it isabout 23/16 inches long.Using needle nose pliers,form the wire into a ringand, after wiping it off,place the ring into thecounterbore of theLifesaver nipple.

Step 5: Fluxing

Cover the counterbore,ring, outer hex and threadsof the Lifesaver nipple andthe outside of the tube withwater soluble flux.

Step 6: Brazing

Place the tube assemblyinto a vise. Place the nipplewith its braze ring over thetube. Light the brazingtorch and adjust the flameso that the base is bluewith orange “feather-likeflicks” at the end. Try toheat both the nipple andthe tube uniformly so theyboth reach the brazing tem-perature at the same time.Don’t overheat the thin sec-tion. As the temperatureincreases, the flux willundergo several changes:

• At 212ºF the water boils off.

• At 600ºF the fluxbecomes white and puffyand starts to “work”(snow balling).

• At 800ºF it lays againstthe surface and has amilky appearance.

• At 1100ºF it is completelyclear and active and hasthe appearance of water.At this point, a brightmetal surface will beapparent underneath.

• The silver wire melts at1125ºF and flows at1145ºF.

CAUTION

Never heat the parts to abright red color.

When the silver alloy melts,the flux will draw itthroughout the joint and asmall fillet of silver alloy willappear around the tube.When this happens, thebraze is completed.Remove the heat sourceand allow the fitting to coolfor five to ten seconds.Using pliers, place the fit-ting into water until it iscompletely cool.

CAUTION

Steam may be directedthrough the fitting ends. Toprevent burns, handle thefitting carefully! Hot waterwill facilitate flux removal.

Step 7: Removing flux

It is necessary to removeresidual flux from the areasince it is corrosive andpresents an uncleanappearance and condition.Simply rub the surfaceusing hot water and a wirebrush. The water should beat least 120ºF or hotter tobe truly effective inside andout.

Step 8: Hose assembly

To determine the requiredamount of new hose,measure the distance fromthe scribe mark on the tube(refer to Step 1) to theshoulder hex of theLifesaver nipple. Add thismeasurement to theLifesaver “D” dimensionfound in the “Fittings” sec-tion of the Eaton Hose &Reusable Fittings Catalog.For each Lifesaver fitting,subtract this sum from thefabrication length previouslyrecorded. When usingEaton fittings other than theLifesaver type, subtract theappropriate “D” dimensionfound in the catalog. Cutthe hose to this length andinstall both fittings.

Align the scribe marks toestablish the phase angle.Spray paint the brazedjoints to prevent rusting.

Page 3


4. Inspect ORS adapter andORS-TF components fordamage. Assure sealingsurfaces are free fromall surface gouges,scratches, dirt and contaminants. Inspect o-ring to insure that it is properly seated in thegroove and is free fromdamage. Apply a thinfilm of compatible lubri-cant to the o-ring prior toinstallation.

5. Place a nut, ferrule andsleeve onto tubing,assuring that the identifi-cation groove of the ferrule is toward the nut.Assemble the nut to theadapter until “hand-tight” with the tubingfully inserted into the fitting until bottomedout. Mark the nut in relation with the adapterand tighten 11/2 turnswith wrench. The ORS-TF sleeve cannotbe used to preset multiple tube assem-blies. It may be usedonce for presetting.

6. The ORS-TF tube assem-blies are designed for re-use and can be rein-stalled by tightening nutuntil a sharp increase inresistance is felt (approx-imately 1/4 turn beyond“hand-tight”).

7. WARNING

Tubing must be fullyinserted into the fittingand the nut tightened asspecified above toensure performance andto prevent leakage andpotential fitting blow-off.Excessive tightening ofthe nut beyond the rec-ommended level mayaffect performance.

8. If connections must betemporarily disassem-bled, use a threadedplug to contain the ORS-TF componentsand keep contaminantsand dirt from enteringthe system.

1. Measure the length ofthe tube assembly fromthe flat face of the ORSadapter in one port to theface of the ORS adapterin the opposite port. Thelength of the tube shouldthen be adjusted toaccount for the shoulderthickness of the sleeve.

2. Inspect the tubing toinsure that no scratches,gouges, burrs or othersurface defects are pres-ent. Cut the measuredtubing squarely (±1°). A tubing cutter is thebest tool for this, but a hacksaw or abrasivewheel can be used. Use only SAEJ356,SAEJ524, SAEJ525, orSAEJ526 tubing with a hardness not to exceedRockwell B65.

3. Deburr the tube endswith a deburring tool orfine cut file. After debur-ring, be sure to removeall contaminants and dirtfrom the interior andexterior of the tube.

It is imperative that therouting leave a length ofunbent tubing to fully enterthe ORS fitting. This straightlength must be free fromsurface defects, thin-outdistortion, and ovality.

Assembly InstructionsORS-TF (Wedge Type)Tube Fittings


APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

SLEEVE STRAIGHT TUBINGSHOULDER REQUIRED

SIZE TUBE O.D. THICKNESS “A” “B”

in. mm in. mm in.–04 .25 (1/4) 1,8 .07 19,8 0.78–06 .38 (3/8) 2,0 .08 22,3 0.88–08 .50 (1/2) 2,3 .09 25,4 1.00–10 .63 (5/8) 2,3 .09 26,9 1.06–12 .75 (3/4) 2,3 .09 30,2 1.19–16 1.00 (1) 2,3 .09 31,7 1.25–20 1.25 (11/4) 2,3 .09 33,3 1.31–24 1.50 (11/2) 2,3 .09 35,0 1.38

Page 4



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Brazing InstructionsORS-Braze Type TubeFittings

Tube Preparation

1. Establish the requiredlength of tubing. Allow forinsertion depth in theORS-Braze Type shoulderby adding the properlength of straight unbenttubing to enter into theshoulder counterbore. Thecounterbore depth is de -pend ent upon the ORS-Braze Type shoulder size.

2. Cut the tubing squarely(±1°) to the properlength. A tubing cutter isthe best tool for this,but a hacksaw or anabrasive wheel can beused.

3. Lightly deburr both l.D.and O.D. of tube.

Prepare the Shoulder

6. Degrease the shoulderthoroughly. Inspect forpresence of rust. If rustis present, follow thesteps detailed previouslyto emery the counter-bore.

Prepare Braze Rings

7. Degrease rings thorough-ly. Preformed silver brazerings are available fromEaton. The preformedrings (Part NumberFF9075-Size) will saveyou time and simplifyyour brazing even more.

If site-made rings are used,cut off a piece of silverwire* just short of threetimes the counterbore'sdiameter. For example, if the counterbore meas-ured 3/4” you would cut21/16” of wire (3/4” x 2πr = 21/4”). Use needle-nosepliers to shape the silverwire into a ring.

*If bulk wire is used it must contain aminimum of 45% silver content.

ORS-BRAZE TYPESHOULDER SIZE DEPTH OF COUNTERBORE

mm in.–04 6,3 .25–06 6,3 .25–08 9,6 .38–10 9,6 .38–12 9,6 .38–16 12,7 .50–20 12,7 .50–24 12,7 .50

Prepare the Tube

4. Clean the end of the tubethoroughly using a liquidsolvent* such as dena-tured alcohol, alkalinecleaner or equivalent.

Avoid touching it becauseoily or greasy surfacestend to repel the flux andsilver material leavingvoids and inclusions.*CAUTION: Follow solvent manufactur-er's recommendations for proper use.Follow approved procedures for disposal.

5. Polish tube end to baremetal using silicon carbideemery cloth. It is impor-tant to remove all oil andgrease first because abra-sives tend to scrub the oilinto the surface and/orimpregnate it with a fine

abrasive powder resultingin further contamination.Clean the tube end toremove the grit producedby the emery operation.Use either a clean solventrinse or a clean, oil freesoft cloth.

Silver Braze RingPART TUBE SIZE NUMBER O.D.

mm in.FF9075-19 6,4 .25FF9075-06 9,7 .38FF9075-74 12,7 .50FF9075-08 16,0 .63FF9075-09 19,1 .75FF9075-86 25,4 1.00FF9075-87 31,8 1.25FF9075-88 38,1 1.50

Trial Assembly

8. Fit the shoulder onto the tube; it should fitfreely for the full counterbore depth. Eatonrecommends minimal diametrical clearance. Donot touch or contaminatemating surfaces.

Page 5


9. Clamp the tube snugly ina vise. Properly slip ORS-Braze Type nut (FC2326-SIZE-186) over the tube.The flux (high tempera-ture 700°F to 1800°F isrecommended) shouldbe applied to all compo-nents and adjacentareas. This will minimizethe heat scale formed,act as a temperature

indicator, and promoteproper alloy flow duringthe brazing process.


APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Braze Inspection

13. To properly braze theapplication of heatshould bring both thetube and shoulder up tobrazing temperature uni-formly. Therefore, mostof the heat should bedirected to the shoulderand not the tube. Theflux may be used as aguide:

A. At +212°F the waterboils off.

B. At +600°F to +700°Fthe flux becomespuffy and starts to“work” (bubbles).

C. At +800°F it laysagainst the surfaceand has a translucentappearance.

D. At +1100°F it has theappearance of darkclear water.

E. At +1125°F the silverbraze ring melts andflows at +1145°F. At thispoint the shouldershould drop onto thetube a distance equal tothe diameter of thebraze ring, which is notmelted and filling in thearea between the coun-terbore and tube O.D.There should be visiblebraze material at bothends of the shoulder.

The braze joint area needsto be heated uniformly notjust the O.D. surface. Atbrazing temperature thecomponents will have adark red to medium cherryred appearance. Do notoverheat the parts as tochar the flux. Remove theheat after the alloy has melt-ed and pulled through thejoint. Settle the shoulderonto the tube to insureproper insertion.NOTE: The heating source should be var-ied. When using a flame, the fuel mix-ture should be adjusted so that the baseof the flame is blue and there are alsoorange featherlike licks at the end of theflame.

15. Inspect braze for a filletall the way around thetube. Inspect the shoul-der sealing surface.There should be noalloy overrun or alloybuild-up on the sealingsurface. An accumula-tion of braze alloy onthe sealing surface or avoid in the fillet is unac-ceptable and the shoul-der should be replaced.

16. It is recommended toproof test the assemblyin an enclosed cham-ber. Proof test pressureshould be twice thesystem’s operatingpressure but should notexceed twice therecommenced operat-ing pressure of the tubeor end connections.

NOTE: The preceding procedure is rec-ommended only. No guarantee or war-ranty is implied.

10. Lightly flux ORS-BrazeType shoulder (FC1229-SIZE) counterbore,install clean braze ringto bottom of counter-bore, reflux counter-bore.

11. Slip shoulder onto tubesquarely and so thatbraze ring is snugbetween the tube andcounterbore lip.

12. Flux outside surfaces ofshoulder.

Fluxing and Assembly Brazing the Assembly

14. Allow braze alloy tosolidify completelybefore quenching. Coolthe assembly in hotwater (+180°F pre-ferred) to help facilitateflux removal. Readilyavailable flux removerscan be added to thewater. It is necessary toremove the flux residuebecause it is corrosive.

Page 6


Hand Tighten

Hand Tighten


SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

1. Inspect sealing surfacesand O-Ring groove fordamage or foreign mate-rial. Check the O-Ring toinsure that it is properlyseated in the O-Ringgroove.

2. Lubricate threads withheavy lubricant such asAeroquip 222070 Lube.

3. Align the ORSTube Fitting tothe flat sealingconnections andtighten the nut byhand. The nutshould tighteneasily by hand ifproperly aligned.

4. Complete the assemblyby wrench tightening thenut to the recommendedtorque value on page286.

Align Fittings

Assembly Instructionsfor ORS Tube Fittings,Pipe Threads and SAE37° (JIC) Flared TubeFittings

Assembly Instructions forPipe Threads

1. Assemble connectionhand tight.

2. Mark male and female.

3. Rotate male; 11/2 turns ifusing thread sealant. 2turns if not using threadsealant.

Assembly Instructions for Standard SAE 37° FlareType Tube Fitting

Use SAE J524 or SAE J525tubing for best bending andflaring results.

1. Cut the tubing with atube cutter. If a finetooth hacksaw is used,make sure cut-off issquare; remove burrswith deburring tool,emery paper or fine file.Clean all dirt and gritfrom the l.D. and O.D. ofthe tube.

2. Place the nut and thenthe sleeve onto tube.The threaded end of nutand flared end of sleevemust face the end oftube.

3. Flare the tube end witha flaring tool to provide a37° flare. Check the flarefor correct diameter,excessive thin out andburrs or cracks.

4. Lubricate all mating sur-faces of nut, ferrule andbody with a heavy lubri-cant such as Aeroquip222070 Lube.

5. Assemble the nut andsleeve to body. Turn thenut hand tight thenwrench tighten for aleakproof joint. See page378, torque values, forassembly using a torquewrench.

The Eaton standard 37°flare fitting is easy to disas-semble and may bereassembled repeatedly.

Assembly Instruction forORS Tube Fittings

Page 7



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Assembly Instructionsfor Versil-Flare Tube Fittings

5. Slide the ferrule and nut against body and tighten thenut onto the body “Hand Tight.” Mark the nut in rela-tion to the body for location.

6. Hold tube against body and tighten nut a total of 11/4turns on –3 through –10 and 11/2 turns –12 through –32.

Reassembly

1. Slide nut against the body and tighten to “Hand Tight.”Mark the nut for location.

2. Tighten nut a minimum of one “Hex” flat. The Versil-Flare flareless tube fitting is designed for a maximum of 10 reassemblies.

Cutting

To insure a leak-proof joint, the tubing should be cut square(±1°). A tube cutter is preferred, but a hacksaw or abrasivewheel can be used.

Deburring

All cut tubes should be deburred. However, deburring iseven more important if the tubing was cut with a hacksawor abrasive wheel. Remove any burrs, both internally andexternally, with a deburring tool, emery paper or fine file.Clean the tube before assembly. Clean all dirt and grit fromthe I.D. and O.D. of the tube.

Tubing cut-off

1. Tube should be cut to fit tight against the face of stan-dard SAE 37° flare body.

Initial assembly

1. Deburr the end internally and externally. Clean all dirt andgrit from I.D. and O.D.

2. Slide the nut and then the ferrule into the tube. Makesure the tapered end of ferrule points toward the nut.

3. Lubricate all mating surfaces of nut, ferrule and bodywith a heavy lubricant such as Aeroquip 222070 Lube.

4. Place end of tube against standard SAE 37° flare body.

Assembly Instructionsfor Versil-Flare Tube Fitting

Out of Square Cut Square Cut

Page 8



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

The o-ring and back-upwasher should be in theproper position on non-threaded section nearest tolocknut. Lubrication of theo-ring is recommended.

Tighten the fitting by handinto the straight threadedboss until back-up washercontacts face of boss (left)or check washer whenthread is BSPP (right.)

In order to position the fit-ting, unscrew up to one fullturn then hold fitting indesired position and tightenlocknut so that the back-upwasher contacts face ofboss and forces the o-ringwithin boss cavity. WithBSPP threads use sameprocedure. The differencebetween the two threadtypes exist in the checkwasher being in contactwith face of boss (rightinset). Assemble to therespective assembly torquespecified on page 378.

Assembly Instructions –Adjustable O-Ring Boss

On BSPPthreads with check washer

On SAE, andBSPP threads without check washer

Page 9



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Assembly Instruction Tips

Terms

• Skive—Removal of thecover material exposingthe reinforcement prior tofitting assembly.

• Dash Size—The hose orfitting size expressed in 1/16 of an inch.The numerator of a frac-tion whose denominatoris 16. Example: –8 or –08is 8/16” = 1/2”.

• Nipple—The part of ahose fitting that goes intothe hose tube.

• Socket—The part of ahose fitting that goesover the hose cover orreinforcement.

• Mandrel—A round, prop-erly sized, steel bar usedfor support duringassembly of the fitting orskiving the hose cover.

• Annular Rings—A seriesof concentric rings insidethe socket.

Reusable fitting tips toremember for easy assembly

• Part numbers and dashsizes are indicated onfitting sockets.

• It is essential the fittingbe mated with a compati-ble hose style with thesame dash size. SeeSocket Data pages 63-65.

• Reusable fittings thathave a notch in the sock-et serve as a referencefor the cover skivinglength.

• Familiarize yourself withthe assembly instructions before you start to makean assembly.

• For hoses that requireskiving, be sure to skivethe hose to the properlength and down to thewire reinforcement.

• Use Aeroquip 222070hose assembly lube liber-ally on both the inside ofthe hose and on the fit-ting nipple. (Check for compatibility.)

• Always cut hose squareby using a sharp instru-ment (hacksaw or cutoffwheel).

• For volume production of hose assemblies, use Eaton AssemblyEquipment.

Cutting the hose

1. To determine the “J” length (cut length ofhose) from “OA” (over-all length) de duct “D”dimensions of both endfittings. Consult fittinginformation pages for“D” dimensions. Forhose assemblies withSOCKETLESS fittings,add 1/2” to “J” length.Tip: If the old Aeroquipassembly was the rightlength, simply removethe hose fittings andmeasure the hose.

2. Cut the hose square.Use a cut-off wheel orfine-tooth hacksaw.

3. Clean the hose bore.Blow out shavings withshop air, blow a foamprojectile through thehose using theJetCleaner System (seepage 296) or flush witha solvent compat iblewith the hose construc-tion.

CAUTIONFollow proper safety procedures.

Phase angle (offset)

When making doubleelbow assemblies, the fol-lowing steps should be fol-lowed to obtain the desiredangle between elbows.Tighten both elbows tomaximum allowable gapbetween socket and nipplehex. Start to position forrelative angle betweenelbows. Finish assembly byadjusting both elbows.Backing off to get desiredangle should be avoided.

Page 10



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Cleaning, Inspection, Testing and Storage

Maintenance

Hose assemblies in opera-tion should be inspectedfrequently for leakage, kink-ing, abrasion, corrosion orany other signs of wear ordamage. Worn or damagedhose assemblies should bereplaced immediately.

Clean

At minimum a hose assem-bly should be blown outwith clean compressed air.Eaton recommends usingthe Jetcleaner HoseCleaning System (See page296 for details). Assembliesmay be rinsed out withmineral spirits if the tubestock is compatible with oil,otherwise hot water at+150°F max. may be used.Consult Eaton for specialcleaning equipment.

Inspect

Examine hose assemblyinternally for cut or bulgedtube, obstructions, andcleanliness. For segmentstyle fittings, be sure thatthe hose butts up againstthe nipple shoulder; bandand retaining ring are prop-erly set and tight, and seg-ments are properly spaced.Check for proper gapbetween nut and socket orhex and socket. Nutsshould swivel freely. Capthe ends of the hose withplastic covers to keepclean.

Proof test - hydrostatic

The hose assembly shouldbe hydrostatically tested attwice the recommendedworking pressure of thehose.

Test pressure should beheld for not more than one minute and not less than30 seconds. When testpressure is reached, visual-ly inspect hose assemblyfor: a) Any leaks or signs ofweakness. b) Any move-ment of the hose fitting inrelation to the hose. Any ofthese defects are cause forrejection.Caution: Testing should be conducted inapproved test stands with adequateguards to protect the operator.

(See Assembly EquipmentSection for Eaton Proof TestStands.)

Proof test - pneumatic

Hose assemblies intendedfor gas or air service shouldbe tested with air or nitro-gen at 100 psi with theassembly immersed inwater. Random bubbles mayappear over the hose and fitting area when assemblyis first pressurized. Thisshould not be construed asa defect. However, if thebubbles persist in forming at a steady rate at any par-ticular point on the hose,the assembly should berejected.

Caution: Testing should beconducted in approved teststands with adequate guardsto protect the operator.

Storage and handling

Hose should be stored in adark, dry atmosphere awayfrom electrical equipment,and the temperature shouldnot exceed +90°F. Storagein the original shipping con-tainer is preferred.

Clean Inspect Proof test - hydrostatic Proof test - pneumatic

Page 11



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Hose and Reusable Fittings

Standard (mandrelless) reusable fittings with single wire braid, multiple textile braid,hydraulic and LPG hose.

FC234, FC300, FC321, FC350, FC355, 302A,303, 1503, 2580, 2651 (for fittings requiring mandrel, see page 324).

Step 1

Cut hose square with fine-tooth hacksaw or cut-offwheel.

Step 2

Put socket in vise.

Screw hose counterclock-wise into socket until it bottoms.

Back off 1/4 turn.

When assembling longlengths of hose, it may bepreferred to put hose invise just tight enough toprevent from turning, andscrew socket into the hosecounterclockwise until itbottoms.

Back off 1/4 turn.

Back off FC300, FC350 andFC355 1/4 to 1/2 turn.

Step 3

Lubricate nipple andthreads LIBERALLY. Useheavy oil or Aeroquip222070 hose assemblylube.

Step 4

Screw nipple clockwise intosocket and hose. Leave 1/32”to 1/16” clearance betweennipple hex and socket.

Recommendations forcleaning, inspection andtesting are summarized onpage 318. Disassemble inreverse order.

SOCKETLESS Fittings with textile braid low pressure hose

FC332, FC647, 2556, 2565, 2575

To Assemble

Step 1

Cut hose to required lengthwith a sharp knife. Oilinside of hose and outsideof nipple LIBERALLY.

Step 2

Push hose on fitting untilhose end bottoms under-neath protective cap asshown. For quantity produc-tion use a SOCKETLESSFitting assembly ma chine.Recom menda tions forcleaning, inspection andtesting are summarized onpage 318.

To Disassemble

Step 1

Slit hose lengthwise fromprotective cap to end ofnipple.

Step 2

Bend hose, then snaphose off with a quick tug.

Page 12



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Step 2

Put socket in vise.

Screw hose into socket coun-terclockwise until it bottoms.

When assembling longlengths of hose, it may bepreferred to put hose invise just tight enough toprevent from turning, andscrew socket onto the hosecounterclockwise until itbottoms.

NOTE: Sockets for hose fit-tings in the –16, –24 and–32 sizes are furnishedwith internal annulargrooves in place of helicalgrooves (all FC310 andFC510 hose sockets areannular grooved). Installsocket by pushing hose intosocket with a back andforth rocking and twistingmotion until hose bottomson shoulder of socket.

Step 3

Lubricate nipple threadsand inside of hose liberally.Use heavy oil or Aeroquip222070 hose assembly lube.

Step 4

Screw nipple clockwise intosocket and hose.

Leave 1/32” to 1/16” clearancebe tween nipple hex andsocket.

Recommendations forcleaning, inspection andtesting are summar ized onpage 318. Dis assemble inreverse order.

Standard reusable fittings with Hi-Pac and two wire braid hose FC195, FC310, FC510, 2766, 2781

Step 1

Cut hose to length requiredusing a fine-tooth hacksawor cut-off wheel. Clean hose bore.

Hose must be stripped ofits rub ber cover beforeinserting in socket. Locateskiving point by puttinghose end next to socket asshown. Measure from hoseend of socket to notch onsocket.

Step 1A

Skive Hose:

By Hand: Cut rubber coveraround down to wire rein-forcement. Slit lengthwise.Raise flap and pull off withpliers. Clean excess rubberoff wire reinforcement withwire brush or soft wirewheel. Do not fray or flarewire reinforcement whenbrushing.

Skive Tool: Use the correctsize FT1229 hose coverskiving tool. Mount the toolin a vise. Push the hoseover the mandrel. Rotatethe hose clock wise until itbottoms or secure hose ina vise and attach FT1279auger to the skive tool.Insert mandrel into thehose and rotate clockwiseuntil it bottoms.

Machine: Use the S1102cut-off and skivingmachine. Consult the own-ers manual. Select the cor-rect mandrel. Turn on themachine. Put the hose overthe mandrel and rotate.Note: when skiving, remove the rubbercover until the wire reinforcement isexposed around the circumference ofthe hose.

Page 13



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Standard reusable fittings withfour spiral wire hose

FC324, GH493, FC736

Skive Tool: Use the correctsize Eaton FT1229 hosecover skiving tool. Mountthe tool in a vise. Push thehose over the mandrel.Rotate the hose clockwiseuntil it bottoms or securehose in a vise and attachFT1279 auger to the skivetool. Insert mandrel into thehose and rotate clockwise

until it bottoms.

Machine: Use the EatonS1102 cut-off and skivingmachine. Consult the own-ers manual. Select the cor-rect mandrel. Turn on themachine. Put the hose overthe mandrel and rotatecounterclockwise.Note: when skiving, remove the rubbercover until the wire reinforcement isexposed around the circumference of thehose.

Step 2

Sockets for hose fittings arefurnished with internalannular grooved design.Install socket by pushinghose into socket with aback and forth rocking andclockwise twisting motionuntil hose bottoms onshoulder of socket.

An alternate method is toinsert the hose in a vise.Install socket by pushingonto the hose with a backand forth rocking and clock-wise twisting motion untilthe hose bottoms on theshoulder of socket.

A rawhide hammer or simi-lar tool may be used to tapthe socket onto the hosebut avoid damage to inter-nal socket threads. Be surenot to damage hose coveror wire reinforcement.

Step 3

Liberally lubricate nipplethreads and inside of hose.Use heavy weight oil orAeroquip 222070 hoseassembly lube.

Step 4

Screw nipple clockwiseinto socket and hose.Leave a 1/32” to 1/16” clear-ance between nipple hexand socket.

Recommendations forcleaning, inspection andtesting are summarized onpage 318. Dis assemble inreverse order.

Thru-the-cover style reusable fittings with hoseFC211, FC212, GH663, GH793

Step 4

Screw nipple clockwise intosocket and hose. Leave 1/32”to 1/16” clearance betweennipple hex and socket.

Recommendations for clean-ing, inspection and testingare summarized on page318. Dis assemble in reverseorder.

Place socket in vise and turnhose into socket counter-clockwise until it bottoms.

When assembling longlengths of hose, it may bepreferred to put hose in visejust tight enough to preventfrom turning, and screwsocket onto the hose coun-terclockwise until it bottoms.

Step 3

Liberally lubricate nipplethreads and inside of hose.Use heavy weight oil orAeroquip 222070 hoseassembly lube.

Step 1

Cut hose to length requiredusing a fine-tooth hacksawor cut-off wheel. Cleanhose bore.

Hose must be stripped ofits rubber cover beforeinserting into socket.Locate skiving point by put-ting hose end next to sock-et as shown. Measure fromhose end of socket to notchon socket.

Step 1A

Skive Hose

By Hand: Cut rubber coveraround down to wire rein-forcement with a knife. Slitlengthwise. Raise flap andpull off with pliers. Cleanexcess rubber off wire rein-forcement with wire brushor soft wire wheel. Do notfray or flare wire reinforce-ment when brushing.

Step 1

Cut hose to length requiredusing a fine tooth hacksawor cut-off machine. Cleanhose bore.

Step 2

Liberally lubricate hosecover with Aeroquip222070 hose assemblylube.

Page 14



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Step 1

Cut hose square to lengthrequired with fine-toothhacksaw or cut-off wheel.Clean hose bore.

Step 2

Put socket in vise. Screwhose counterclockwise intosocket until hose bottoms.Back off 1/4 turn.

When assembling longlengths of hose, it may bepreferred to put hose in visejust tight enough to preventfrom turning, and screwsocket into the hose coun-terclockwise until it bot-toms. Back off 1/4 turn.

NOTE: For 2550, 2554 and2570 hose: Sockets forthese hose fittings are furnished with internalannular grooved design.Install socket by pushinghose into socket with aback and forth rocking andtwisting motion until hosebottoms on shoulder ofsocket. Back off 1/4 turn.

Step 3

Lubricate nipple threadsand inside of hose LIBER-ALLY with Aeroquip222070 hose assemblylube or heavy weight oil.

Step 4

Screw nipple clockwise intosocket and hose. Leave a1/32” to 1/16” clearancebetween nipple hex andsocket.

Recommendations forcleaning, inspection andtesting are summarized onpage 318. Dis assemble inreverse order.

Standard (mandrelless) reusable fittings withengine, air brake and railroad air brake hose1531, 1531A, 2550, 2554, 2570(for fittings requiring mandrel, see page 324)

Page 15



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

Step 1

Wrap hose with maskingtape at cut-off point and cutsquare to length throughtaped area using a cut-offmachine or fine-tooth hack-saw. Remove tape and trimany loose wires flush withtube stock. Any burrs onthe bore of the tube stockshould be removed with aknife. Clean the hose bore.Some times wire braid willtend to “neck down” onone end and flare out, onthe opposite end. This is acharacteristic of wire braidhose and can be used to anadvantage in the assemblyof the “super gem” sock-ets. Slip two sockets backto back over the “neckeddown” end of the hose.

“super gem”® Fittings with PTFE hose

FC465, 2807, 2808

Step 2

a. Push the sleeve over theend of the tube and underthe wire braid by hand.Complete positioning of thesleeve by pushing the hoseend against a flat surface.Visually inspect to see thattube stock butts against theinside shoulder of thesleeve.

b. Set the sleeve barbs intothe PTFE tube by usingassembly tool FT1038A orworking the hose bore overthe nipple into the end ofthe sleeve and tube.Assembly kit FT1081 is alsoavailable.

Step 3

Lubricate nipple and socketthreads. For stainless steelfittings, use a molydisulfidebase lubricant (e.g.,Molykote* Type G), lubri-cants containing chlorideare not recommended.Other material combina-tions use standard petrole-um lubricants. Hold the nip-ple with hex in vise. Pushhose over nipple with twist-ing motion until seatedagainst nipple chamfer.Push socket forward andhand start threading ofsocket to nipple.

Step 4

Wrench tighten nipple hexuntil clearance with sockethex is 1/32” or less. Tightenfurther to align corners ofnipple and socket hexes.Recommenda tions forcleaning, inspection andtesting are summarized onpage 318.

To disassemble: Unscrewand remove nipple; slidesocket back on hose by tapping against flat surface;remove sleeve with pliers.New sleeves are recom-mended upon reuse of the fitting.*Molykote Type G is a registered trade-mark of the Dow Corning Corporation.

Page 16



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Hose and Reusable Fittings

Step 1

Cut hose square with fine-tooth hacksaw or cut-offwheel. Clean hose bore.

Step 2

Put socket in vise.

Screw hose counterclock-wise into socket until it bot-toms.

When assembling longlengths of hose, it may bepreferred to put hose invise just tight enough toprevent from turning, andscrew socket onto the hosecounterclockwise until itbottoms.

Back off 1/4 turn.

Back off FC300, FC350 andFC355 hose 1/4 to 1/2 turn.

Step 3

MALE ENDS: Push assem-bly tool into nipple.

SWIVEL ENDS: Tighten nip-ple and nut on assembly tool.

Lubricate nipple, mandreland inside of hose liberally.Use heavy oil or Aeroquip222070 hose assembly lube.

Step 4

MALE ENDS: Screw nippleclockwise into socket andhose. Leave a 1/32” to 1/16”clearance between nipplehex and socket.

SWIVEL ENDS: Screw nippleclockwise into socket and hose.Leave 1/32” to 1/16” clearancebetween nut and socket.

Recommendations for clean-ing, inspection and testingare summarized on page 318.Dis assemble in reverse order.

Nipple and clamp with suction hose

2661, FC619

Step 1

Cut hose square to lengthrequired using a fine-toothhacksaw or cut-off wheel.Clean hose bore. Slide bandclamp over hose cover.

Step 2

Insert nipple into hose untilhose end bottoms on nippleshoulder.

Step 3

Evenly space two bandclamps from end of hose toend of nipple (see above).The band clamps should betightened 180˚ from eachother. Tighten clamps to 100in-lbs. Recommendations for cleaning, inspection andtesting are summarized onpage 318.

Mandrel Type Fittings—

Standard reusable fittings with single wirebraid, multiple textile braid, hydraulic, LPGhose, engine and air brake hoseFC234, FC300, FC321, FC350, FC355, 302A,303, 1503, 2580, 2651

Page 17



APP

ENDICIES

HOSE

ASS

EMBLY

EQ

UIPMEN

TACC

ESSO

RIES

&

ASSE

MBL

Y INST

RUCT

IONS

ADAPT

ERS &

TUBE FITT

INGS

HOSE

FITTINGS

HIG

H PRE

SSURE

HOSE

LOW

& M

EDIU

M

PRES

SURE

HOSE

SPEC

IALTY &

TRUCK

HOSE

900952 Plastic coilsleeve

Step 1

Follow the appropriate hoseassembly instructionsthrough the assembly ofboth end fittings. Insert endfitting in vise.

Step 2

Cut coil length. Coil shouldbe cut to overall assemblylength “OA” minus the sumof the overall length of eachend fitting. (“A” dimension).

Step 3

Wrap the coil on the hose.

900705 sleeve

900564 spring

900705 Steel protec-tive coil sleeve

900564 Steel protec-tive coil spring

Step 1

Follow the appropriateassembly instructionsthrough the assembly ofone end fitting. Insert oneend fitting in vise.

Step 2

Cut coil length. Coil shouldbe cut to overall assemblylength “OA” minus the sumof the overall length of eachend fitting. (“A” dimension).

Step 3

3a) 900705 Steel ProtectiveCoil Sleeve

The hose and the coilshould be held straight.Taping or capping the hoseend can prevent frayed wireends from snagging on thecoil. Bend one end to thecoil outward to form aslight tab to assist grasp-ing. (Cut off or bend backwhen installation is com-plete.) Hold the tab withthe thumb of one handwhile twisting the coilclockwise approximatelyone foot back from the coiltab. When the coil opensup sufficiently, slip the tabend to the coil over thehose. Move the coil ontothe hose by pulling at thetab end while pushing withthe other hand. Be carefulnot to exceed the resiliencyof the coil by stretching ittoo far.

3b) 900564 Steel ProtectiveCoil Spring

Slide coil over hose.

Step 4

Proceed with assembly ofsecond end fitting.

Silicone hoseFC252/FC352

Step 1

Cut hose square to lengthrequired with a sharp knife.Slide extended hose clamp(FF9148) over hose cover.

Step 2

Push hose over beadedtube.

Step 3

Locate extended hoseclamp (FF9148) near theend of hose and tighten theclamp.

Clamps: Extended hoseclamps or clamps with ashoe are recommended forsecuring to formed andbeaded male tube ends.

CAUTION: Do not use wiretype clamps for securingsilicone hose.Note: Use of the FF9148 hose clampwill help prevent extrusion of the rubbercover through the clamp.

Page 18



SPECIALTY &

TRU

CK HOSE

LOW

& M

EDIU

M

PRESSURE H

OSE

HIG

H PRESSU

RE HOSE

HOSE FITTIN

GS

ADAPTERS &

TUBE FITTIN

GS

ACCESSO

RIES &

ASSEMBLY IN

STRUCTIONS

HOSE A

SSEMBLY

EQUIPM

ENT

APPEN

DICIES

Step 3

Small sizes: The coil can beworked into the hose byhand without difficulty.Remove all burrs from thecoil prior to insertion. Thiswill prevent cutting of thehose tube. Position the coilmidway between hoseends.

Large sizes: With the pipestill in position, as in Step2, assemble the hose overthe coil. With the coil fullycentered in the hose,remove the pipe and clamp.

Internal support coils

222005, 222022

Firesleeve

624

Step 1

Cut coil length. The coilsshould be cut to the hoselength, minus the nippleintrusion. For any given hoseassembly the support coillength equals the overallhose assembly length minusthe sum of the overalllengths of each end fitting.(“A” dimensions.)

Small size of the coil can usu-ally be cut with strap cuttersor sheet metal shears. Thelarger sizes are best cut witha heavy sharp chisel or boltcutter. With small sizes skipdirectly to Step 3.

Step 2

Compress the coil (largesizes only). It is necessary toreduce the coil diameterslightly in order to insert itinto the hose. The easiestapproach is to use a length ofpipe with a notch cut in oneend. Clamp the plain end ofthe pipe in a vise, slide thecoil over the pipe and insertthe free end of the coil intothe notched end of the pipe.Then clamp the coil and pipefirmly together. Twist the coilto compress it prior to instal-lation into the hose.

Step 1

Follow the appropriate hoseassembly instructionsthrough the assembly of oneend fitting. Cut firesleeve tosame length as hose; usingFiresleeve End Dip(AE13702–003) dip ends offiresleeve to a depth of threequarters of an inch and allowto dry at room temperature.

Start firesleeve over cut endof hose. Note: If applyingsleeve over PTFE or strippedcover assemblies, wrap ex -posed wire with tape. Graspsleeve and slip over the hoseassembly as illustrated.

Step 2

Skin sleeve back from cutend of hose enough toallow assembly of secondend fitting. (2A)

Then center sleeve so thatit completely covers bothsockets. (2B)

Step 3

Insert tail of band clampinto hand clamping tool.

Step 4

Position band clamp oversleeve as shown and thendraw tight with hand tool.Remove tool and cut freeend of band clamp. Repeaton other end of assembly.To complete, bend protrud-ing tail of clamp over clampbuckle. Also repair anyscuffs or minor abrasions offiresleeve by brush applica-tion of End DipAE13702–003.

Page 19


Documents

Eaton Aeroquip Assembly Instructions How To Put Together Section of Catalog