Hose Assembly Guideline

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					WELCOME TO NAHAD’S HOSE ASSEMBLY GUIDELINES

With sincere thanks and appreciation to dozens of member volunteers, association staff and
industry leaders, The Association For Hose and Accessories Distribution (NAHAD) is pleased
to provide this comprehensive set of basic recommendations for the fabrication of hose
assemblies. NAHAD’s Hose Assembly Guidelines have been developed to assist hose
assembly fabricators and their end-user customers, by providing a basic set of performance
factors related to the selection of components, fabrication procedures and the testing of hose
assemblies. Consisting of five hose product groups (composite hose, hydraulic hose, industrial
hose, metal hose and hose of PTFE) the Guidelines are intended to compliment existing
industry and federal regulations. Aerospace and hydraulic brake hose assemblies are
specifically excluded from this document.
NAHAD developed these Guidelines in order to create a single reference work that compiles
information of value to NAHAD members, manufacturers, and customers in fabricating assemblies
that meet specific individual needs. To the extent that each assembly has unique characteristics, it
must be custom designed, engineered, and tested. Hopefully, these Guidelines will be useful in the
process. The NAHAD Hose Assembly Guidelines have been designed as a fluid document, to be
updated, edited, amended or modified on a regular basis, as necessary, based on changes in
manufacturing, technological or application techniques and standards.

In compiling standards and recommendations published by others, and in developing these Hose
Assembly Guidelines, NAHAD has not, and will not, engage in independent testing or verification of
the information provided to it. Users of these Guidelines should not, and cannot, rely on these
Guidelines, as a standard, certification, or approval of the data published herein. NAHAD does not
assume, and expressly declines and denies any and all liability for any product failures, damages,
or injuries that result in any way from utilization of these Guidelines or products based on these
Guidelines.
The NAHAD Guidelines incorporate pressure, corrosion and temperature recommendations
published by various hose manufacturers. NAHAD has not independently verified these
recommendations and specifically disclaims any and all liability, direct or indirect, for any failures,
damages or injuries resulting in whole or in part from the failure of any product, including hoses,
fittings and assemblies described in these Guidelines.

The NAHAD Hose Assembly Guidelines were made possible by the support of the following member
companies:

American BOA/Tubest
American Rubber & Metal Hose Co., Inc.
Band-It, Idex Inc.
Briggs Company
Campbell Fittings, Inc.
Crane/Resistoflex Company
Dana Corporation/Boston Weatherhead Division
Dayco Products, Inc.
Ever-Tite Coupling Products
Federal Hose Manufacturing, Inc.
Flex Enterprises, Inc.
Flexible Components
Flexible Metal Hose Company
Gates Rubber Company
Goodyear-Le Manfacturier Granford Inc.
Goodyear Tire & Rubber Company
Hose Master, Inc.
Ideal-Division of Stant Corporation/TR Hydraulics Corporation
Oetiker, Inc.
Omega-Flex, Inc.
Page International, Inc.
Penflex, Inc.
Punch-Lok, Inc.
Senior Flexonics, Inc. - Specialized Products Division
Specialty Hose Corporation
Summers Rubber Co.
Teleflex Fluid Systems, Inc.
Thermoid /HBD Industries, Inc.
Titeflex
Uland Supply company, Inc.
U-Nova Industries, Inc.
Valley Belting & Hose Company, Inc.
York Rubber Company
NAHAD extends its deep appreciation to the following individuals who participated in the
development of the NAHAD Assembly Guidelines:

Michael C. Armbruster
Jeff Berger
Edward Bobacher
James C. Brown, Jr.
George E. Carpenter
Angelo Carracino
Michael A. Chermak
Ron Chevalier
Sam Foti, Jr.
Ronald J. George
H. Lee Helfer
Hans R. Hinnen
William Hunter
Thomas G. Hutchins
Robert Keefe
Gene Mayo
Jerry McCool
Kevin McCoy
Nelson Metzler
Robert W. Myers
Linda Murphy
Mark Newberry
Eric D. Orcutt
Thomas J. Paff
James Parrino
Mike Pfister
Craig Pilkington
Terry Rossman
Tim Saupe
Erwin Schaub
Doug Schelhaas
Dave Street
Steve Treichel
Jay Weikel
John E. Willis
Jack L. Wisdom
Gary Wood
NAHAD Home               Section 1 Scope

Legal Disclaimer         This National Association of Hose and Accessory Distributors Guideline is intended
                         to complement existing industry standards and federal regulations. This document
PDF version (without     recommends methods and requirements necessary for the selection of components,
interactive HAG)         fabrication, and testing of hose assemblies and pertains to five distinct families or
                         styles of hose. These are:
Search                       q Composite Hose
                             q   Hydraulic Hose
Comments
                             q   Industrial Hose
- Sections -                 q   Metal Hose
1. Scope                     q   Hose of Teflon® (PTFE)

2. Definitions           Aerospace and hydraulic brake hose assemblies are excluded from this document.

                         This document is not intended to prohibit either supplier or customer from attaching
3. Application
                         additional requirements for hose, couplings or hose assemblies, if necessary, to
Requirements -           satisfy the application. It is the responsibility of the fabricator and user to separately
Stamped                  qualify these applications and their unique requirements necessary to ensure
                         performance capability.
4. Composite Hose
                         >> continue to Section 2
5. Hydraulic Hose

old 6. Industrial Hose
(will be deleted)

6. Interactive Hose
Assembly Guideline |
General Fabrication
Methods | Pressure
Rating Chart

7. Metal Hose

8. Hose of Teflon®
(PTFE)

9. Testing Procedures

10. Quality Plan

11. Assembly
Identification,
Cleaning, and
Packaging
12. Installation &
Handling

Appendix A. Pressure
Conversion Chart

Appendix B. Hose
Ends

Appendix C.
References
Legal Disclaimer

After seven years of effort by dozens of member volunteers, association staff and industry leaders, the National
Association of Hose and Accessories Distributors (NAHAD) is proud to introduce a comprehensive set of
recommendations for the fabrication of hose assemblies. NAHAD’s Hose Assembly Guidelines web-based
draft document was developed to assist hose assembly fabricators, and their end-user customers, by providing
a basic set of performance factors related to the selection of components, fabrication procedures and the
testing of hose assemblies. Consisting of five hose product groups, the Guidelines are intended to compliment
existing industry and federal regulations.
Welcome to the draft of National Association of Hose and Accessories Distributors Assembly
Guidelines for the selection of components, fabrication and testing of hose assemblies.

These draft Guidelines relate to composite hose, hydraulic hose, industrial hose, metal hose and hose of
Teflon® (PTFE). Aerospace and hydraulic brake hose assemblies are excluded from this document.

These draft Guidelines are now being published for comments. All interested parties, including manufacturers,
distributors, users, trade associations, material suppliers, academics, standards organizations, consumers and
others will be invited to comment on the draft Guidelines.
NAHAD will review all the comments received and modify or revise the draft Guidelines where appropriate. The
Guidelines will then be posted to this web site in final format.

NAHAD invites you to carefully review the draft Guidelines and submit your comments. We emphasize that
these are draft Guidelines and have not been reviewed outside of NAHAD. This draft is not to be used as final
Guidelines and should not be relied upon in its present form. NAHAD hereby disclaims any liability for failures,
damages or injuries that may result from use of these draft Guidelines.

These Guidelines are not a final publication, and should not be treated as such. You may then have access to
the text.
Section 1 Scope

This National Association of Hose and Accessory Distributors Guideline is intended to complement existing
industry standards and federal regulations. This document recommends methods and requirements necessary
for the selection of components, fabrication, and testing of hose assemblies and pertains to five distinct families
or styles of hose. These are:
     q Composite Hose
    q   Hydraulic Hose
    q   Industrial Hose
    q   Metal Hose
    q   Hose of Teflon® (PTFE)

Aerospace and hydraulic brake hose assemblies are excluded from this document.

This document is not intended to prohibit either supplier or customer from attaching additional requirements for
hose, couplings or hose assemblies, if necessary, to satisfy the application. It is the responsibility of the
fabricator and user to separately qualify these applications and their unique requirements necessary to ensure
performance capability.

>> continue to Section 2
Section 2 Definitions

A B C D E F G H I J K L M N O P Q R S T U V W

-A-

abrasion: external damage to a hose assembly caused by its being rubbed on a foreign object; a wearing away
by friction.

abrasion tester: a machine for determining the quantity of material worn away by friction under specified
conditions.

absorption: regarding hose, the process of taking in fluid. Hose materials are often compared with regard to
relative rates and total amounts of absorption as they pertain to specific fluids.

accelerated life test: a method designed to approximate in a short time the deteriorating effects obtained
under normal service conditions.

acid resistant: having the ability to withstand the action of identified acids within specified limits of
concentration and temperature.

adapter, adaptor: 1) fittings of various sizes and materials used to change an end fitting from one type to
another type or one size to another. (i.e., a male JIC to male pipe adapter is often attached to a female JIC to
create a male end union fitting); 2) the grooved portion of a cam & groove coupling.

adhesion: the strength of bond between cured rubber surfaces or between a cured rubber surface and a
non-rubber surface.

adhesion failure: (1) the separation of two bonded surfaces at an interface by a force less than specified in a
test method; (2) the separation of two adjoining surfaces due to service conditions.

adhesive: a material which, when applied, will cause two surfaces to adhere.

aerostatic testing: see pneumatic testing.

afterglow: in fire resistance testing, the red glow persisting after extinction of the flame.

algaflon®: a registered trademark of Ausimont USA. See PTFE.

air oven aging: a means of accelerating a change in the physical properties of rubber compounds by exposing
them to the action of air at an elevated temperature at atmospheric pressure.

air under water testing: see pneumatic testing.

ambient temperature: the temperature of the atmosphere or medium surrounding an object under
consideration.

ambient/atmospheric conditions: The surrounding conditions, such as temperature, pressure, and corrosion,
to which a hose assembly is exposed.

amplitude of vibrations and/or lateral movement: the distance a hose assembly deflects laterally to one side
from its normal position, when this deflection occurs on both sides of the normal hose centerline.

anchor: a restraint applied to eliminate motion and restrain forces.

angular displacement: displacement of two parts defined by an angle.

annular: refers to the convolutions on a hose that are a series of complete circles or rings located at right
angles to the longitudinal axis of the hose (sometimes referred to as “bellows”).
anodize, anodized: an electrolytic process used to deposit protective or cosmetic coatings in a variety of colors
on metal, primarily used with aluminum.

ANSI: American National Standards Institute.

anti-static: see static conductive.

application working pressure: unique to customer’s application. See pressure, working.

application: the service conditions that determine how a hose assembly will be used.

armor: a protective cover slid over and affixed to a hose assembly; used to prevent over bending or for the
purpose of protecting hose from severe external environmental conditions such as hot materials, abrasion or
traffic.

assembly: a general term referring to any hose coupled with end fittings of any style attached to one or both
ends.

ASTM: American Society for Testing and Materials.

attachment: the method of securing an end fitting to a hose (e.g., banding, crimping, swaging, or
screw-together-2 piece or 3 piece-style-reusable fittings).

autoclave: an apparatus using superheated high pressure steam for sterilization, vulcanization and other
processes.

axial movement: compression or elongation along the longitudinal axis.
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-B-

backing: a soft rubber layer between a hose tube and/or cover and carcass to provide adhesion.

band: (1) a metal ring that is welded, shrunk, or cast on the outer surface of a hose nipple or fitting; (2) a thin
strip of metal used as a non-bolted clamp. See hose clamp.

barb: the portion of a fitting (coupling) that is inserted into the hose, usually comprised of two or more radial
serrations or ridges designed to form a redundant seal between the hose and fitting.

barbed and ferrule fitting: a two-piece hose fitting comprised of a barbed insert (nipple), normally with
peripheral ridges or backward-slanted barbs, for inserting into a hose and a ferrule, usually crimped or swaged.

basket weave: a braid pattern in which the plaits of wire alternately cross over and under two strands (two
over-two under).

bench marks: marks of known separation applied to a specimen used to measure strain (elongation of
specimen).

bench test: a modified service test in which the service conditions are approximated in the laboratory.

bend radius: the radius of a bent section of hose measured to the innermost surface of the curved portion.
bend radius, minimum: the smallest radius at which a hose can be used.

       For Metal Hose: - the radius of a bend measured to the hose centerline, as recommended by the
       manufacturer.

bend radius, dynamic: the radius at which constant or continuous flexing occurs.

bend radius, static: the smallest fixed radius at which a hose can be subjected.

bending force: an amount of stress required to induce bending around a specified radius and hence, a
measure of stiffness.

bevel seat fitting: see fitting, Bevel Seat.

beverly shear: hand or pneumatically operated, table mounted, metal cutting shear used to cut medium
pressure hose of Teflon® (PTFE).
billet: (1) a compressed cylinder of Teflon® (PTFE) resin, from which raw tubing is extruded. Also called a
preform. (2) a solid piece of material from which a fitting is manufactured.

bleeding: surface exudation. See bloom.

blister: a raised area on the surface or a separation between layers usually creating a void or air-filled space in
a vulcanized article.

bloom: a discoloration or change in appearance of the surface of a rubber product caused by the migration of a
liquid or solid to the surface, (e.g. sulfur bloom, wax bloom). Not to be confused with dust on the surface from
external sources.

blow out force: the force generated from the internal pressure attempting to push the fitting from the hose.

body wire: normally a round or flat wire helix embedded in the hose wall to increase strength or to resist
collapse.

bolt hole circle: a circle on the flange face around which the center of the bolt holes are distributed.

bore: (1) an internal cylindrical passageway, as of a tube, hose or pipe; (2) the internal diameter of a tube,
hose, or pipe.

bowl: (1) the exterior shell of an expansion ring type coupling; (2) the larger internal diameter of the internal
portion of a ferrule.

braid: the woven portion of a hose used as reinforcement to increase pressure rating and add hoop strength.
Various materials such as polyester, cotton or metal wire are used. A hose may have one or more braids,
outside or between layers of hose material.

braid angle: the angle developed at the intersection of a braid strand and a line parallel to the axis of a hose.

braid coverage: the relative amount of braid material covering a hose expressed as a percent.

braid make up: description of braid (i.e., 32-12-.015, T321 SS), where: 32 is the number of carriers; 12 is the
number of wires on each carrier; .015 is the wire diameter in inches; and T321 SS is the material, (Type 321
stainless steel).

braid sleeve/ring/ferrule: a ring made from tube or metal strip placed over the ends of a braided hose to
contain the braid wires for attachment of fitting and ferrule, and to immobilize heat affected corrugations.

braid wear: motion between the braid and corrugated hose, which normally causes wear on the outside
diameter of the corrugation and the inside diameter of the braid.

braided braid: a braid where the strands of wire on each carrier of the braiding machine are braided together,
and then braided in normal fashion.

braided ply: a layer of braided reinforcement.

braid-over-braid: multiple plies of braid having no separating layers.

brand: a mark or symbol identifying or describing a product and/or manufacturer, that is embossed, inlaid or
printed.

brass: a family of copper/zinc alloys.

brazing: a process of joining metals using a non-ferrous filler metal having a melting point that is lower than the
“parent metals” to be joined, typically over +800ºF.

bronze: an alloy of copper, tin and zinc.

buffing (sizing): grinding a surface to obtain dimensional conformance or surface uniformity.

bumped convoluted: a type of hose (typically fluoroplastic) made by re-forming a smooth bore tube to create
annular or helical ridges or convolutions, and allow the cuffed ends to extend through the end fittings, and be
flared over the fitting face, providing a seamless assembly with no metal contacting the medium; typically used
in high corrosion and sanitary applications.

bunch braid: braid applied to hose in bundles rather than flat strands (plaits), usually done to achieve high
pressure versus hose weight.

butt weld: process in which the edges or ends of metal sections are butted together and joined by welding.

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-C-

C of C: certificate of conformance or certificate of compliance; a document, typically signed and dated
pertaining to a particular lot or purchase order of item(s), which describes any standards, specifications, tests,
materials and/or performance attributes to which the referenced item(s) have met or will meet.
cam & groove: see fitting/coupling - Cam & Groove.

capped end: a hose end covered to protect its internal elements.

carcass: the fabric, cord and/or metal reinforcing section of a hose as distinguished from the hose tube or
cover.

casing: see armor.

cement: unvulcanized raw or compounded rubber in a suitable solvent used as an adhesive or sealant.

cemented end: a hose end sealed with the application of a liquid coating.

chafe sleeve: an outer sleeve providing resistance to chafing and external resistance to damage to braided
hoses, available in wide variety of materials to meet the application requirements (e.g., chafe sleeves include
slip-on, heat shrinkable, integrally extruded).

chalking: the formation of a powdery surface condition due to disintegration of surface binder or elastomer by
weathering or other destructive environments.

checking: the short, shallow cracks on the surface of a rubber product resulting from damaging action of
environmental conditions.

chemical compatibility: the relative degree to which a material may contact another without corrosion,
degradation or adverse change of properties.

chemical resistance: the ability of a particular polymer, rubber compound, or metal to exhibit minimal physical
and/or chemical property changes when in contact with one or more chemicals for a specified length of time, at
specified concentrations, pressure, and temperature.

clamp: see hose clamp.

cloth impression: see fabric impression.

coefficient of friction: a relative measure of the surface lubricity.

cold flex: see low temperature flexibility.

cold flexibility: relative ease of bending while being exposed to specified low temperature.

cold flow: continued deformation under stress. See creep.

collar: 1) the portion of a fitting that is compressed by swaging or crimping to seal the hose onto the fitting
barbs and create a permanent attachment; also called a ferrule. (With reusable fittings, the lock and seal are
accomplished mechanically by the collar without swaging or crimping); 2) a raised portion on the hose shank
which functions as a connection for a ferrule or other locking device or functions as a hose stop.

combustible liquid: a combustible liquid is one having a flash point at or above +100°F (37.8°C).

composite hose: non-vulcanized hose that consists of the following:

       An internal wire helix;

       A multi-ply wall of thermoplastic films and reinforcing fabrics in proportions that give the required
       physical properties and provide a complete seal. (Note: The film content may be built of tubular
       films.)

       A cover consisting of fabric with an abrasion resistant polymeric coating;
       An external helix wire.

compound: the mixture of rubber or plastic and other materials, which are combined to give the desired
properties when, used in the manufacture of a product.

compression fitting: see fitting/coupling - Compression

compression set: the deformation which remains in rubber after it has been subjected to and released from a
specific compressive stress for a definite period of time at a prescribed temperature. (Compression set
measurements are for evaluating creep and stress relaxation properties of rubber.)

concentricity: the uniformity of hose wall thickness as measured in a plane normal to the axis of the hose.

conditioning: the exposure of a specimen under specified conditions, e.g., temperature, humidity, for a
specified period of time before testing.

conductive: the ability to transfer electrical potential.

configuration: the combination of fittings on a particular assembly.

control: a product of known characteristics, which is included in a series of tests to provide a basis for
evaluation of other products.

controlled flexing: occurs when the hose is being flexed regularly, as in the case of connections to moving
components (e.g., platen presses, thermal growth in pipe work).

convoluted: description of hose or innercore having annular or helical ridges formed to enhance flexibility.

convolution/corrugation: the annular or helical flexing member in corrugated or strip wound hose/corrugation.

convolution count: the number of ridges or corrugations per inch of a hose.

copolymer: a blend of two polymers.

core: the inner portion of a hose, usually referring to the material in contact with the medium.

corrosion: the process of material degradation by chemical or electrochemical means.

corrosion resistance: ability of metal components to resist oxidation.

corrugated cover: a ribbed or grooved exterior.

corrugated hose: hose with a carcass fluted, radially or helically, to enhance its flexibility or reduce its weight.

coupler: the female portion of the cam & groove connection with the cam arms.

coupling: a frequently used alternative term for fitting.

cover wear: the loss of material during use due to abrasion, cutting or gouging.

cover: the outer component usually intended to protect the carcass of a product.

CPE: chlorinated polyethylene; a rubber elastomer.

cracking: a sharp break or fissure in the surface, generally caused by strain and environmental conditions.

creep: the deformation, in material under stress, which occurs with lapse of time after the immediate
deformation.
crimp diameter: the distance across opposite flats after crimping.

crimp/crimping: a fitting attachment method utilizing a number of fingers or dies mounted in a radial
configuration. The dies close perpendicular to the hose and fitting axis, compressing the collar, ferrule, or
sleeve around the hose.

CSM: chlorosulfonated polyethylene.

cure: the act of vulcanization. See vulcanization.

cut off factor: the hose length to be subtracted from the overall assembly length that allows for the hose
coupling end connection extension beyond the end of the hose.

cut resistant: having that characteristic of withstanding the cutting action of sharp object.

cycle-motion: movement from normal to extreme position and return.

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-D-

date code: any combination of numbers, letters, symbols or other methods used by a manufacturer to identify
the time of manufacture of a product.

deburr: to remove ragged edges from the inside diameter of a hose end; an important fabrication step for
assembling hose of Teflon® (PTFE) in order to insure a good seal.

deduct length: the amount of fitting length deducted from a hose to result in the desired finished assembly
length.

design factor: a ratio used to establish the working pressure of the hose, based on the burst strength of the
hose.

design pressure: see application working pressure and pressure, working.

developed length: see overall length.

diamond weave: braid pattern in which the strands alternately cross over one and under one of the strands
(one over-one under); also known as “plain weave.”

die: a tool used to swage or crimp a fitting onto a hose. Swage dies usually consist of two halves machined to a
predetermined diameter, designed for a specific hose type and size. A crimp die set is typically six to eight
“fingers” designed for infinite diameter settings within a range or preset to a specific diameter for a given hose
type and size.

dielectric strength: the relative measure of a material’s ability to resist conducting an electrical charge.

displacement: the amount of motion applied to a hose defined as inches for parallel offset and degrees for
angular misalignment.

dog-leg assembly: two hose assemblies joined by a common elbow.

DOT: Department of Transportation.

duplex assembly: an assembly consisting of two hose assemblies-one inside the other, and connected at the
ends; also known as “jacketed assemblies.”

durometer: an instrument for measuring the hardness of rubber and plastic compounds.
durometer hardness: a numerical value, which indicates the resistance to indentation of the blunt indentor of
the durometer.

dye penetrant inspection/test: non-destructive inspection method for detecting surface defects.

dynamic bend radius: see bend radius, dynamic.

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-E-

eccentric wall: a wall of varying thickness.

eccentricity: the condition resulting from the inside and outside diameters not having a common center. See
eccentric wall.

ECTFE: ethylene-chlorotrifluoroethylene.

effective thrust area-hose: cross-sectional area described by the mean diameter of the hose.

effusion: the escape, usually of gases, through a material. See permeation.

elastic limit: the limiting extent to which a body may be deformed and yet return to its original shape after
removal of the deforming force.

elastic/intermittent flexure: The smallest radius that a given hose can be bent to without permanent
deformation to the metal in its flexing members (convolutions or corrugations).

elastomer: any one of a group of polymeric materials, usually designated thermoset, such as natural rubber, or
thermoplastic, which will soften with application of heat.

electrostatic discharge: the sudden discharge of static electricity from an area of buildup to a grounding point.

elongation: the increase in length expressed numerically as a percentage of the initial length.

encapsulated fitting: see fitting/coupling-Encapsulated fittings.

endurance test: a service or laboratory test, conducted to product failure, usually under normal use conditions.

enlarged end: an end having a bore diameter greater than that of the main body of the hose, in order to
accommodate a larger fitting.

EPDM: Ethylene Propylene Diene Monomer; an elastomer.

exothermic: releasing heat.

extrude/extruded/extrusion: forced through the shaping die of an extruder; extrusion may have a solid or
hollow cross section.

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-F-

fabric impression: impression formed on the rubber surface during vulcanization by contact with fabric jacket
or wrapper.

fabricator: the producer of hose assemblies.

fatigue: the weakening or deterioration of a material occurring when a repetitious or continuous application of
stress causes strain, which could lead to failure.

FDA: United States Food and Drug Administration.

FEP: fluorinated ethylene propylene.

ferrule: a metal cylinder placed over a hose end to affix the fitting to the hose. See braid sleeve, interlocking
ferrule, and sleeve.

fire sleeve: slip-on or integrally extruded sleeve used to retard the effects of fire in certain applications; most
often made with silicone and/or ceramic fiber.

fitting/coupling: a device attached to the end of the hose to facilitate connection. The following is only a partial
list of types of fittings available:
         Banjo Fitting - a through bolted designed featuring a hollow       circle or “donut” attached to one
         end of the fitting barb so that the inner diameter is along the hose axis.

       Butt Weld Fittings - a hose fitting designed to be permanently welded to a connecting member
       such as another pipe or a butt weld flange.

       Cam & Groove Fittings - a type of fitting that allows connection and disconnection by means of
       arm(s) or cam(s) on the female fitting. The seal is accomplished by means of a gasket, available
       in various materials. These fittings are frequently used on product transfer hose assemblies.

       Compression Fitting - a fitting style that seals on a mating tube by compressing an internal ferrule
       against the tube O.D..

       Encapsulated Fittings- a metal fitting of various styles usually encased in a thermoplastic or
       fluoroplastic material by means of molding or coating. Most often done for sanitary purposes or to
       eliminate corrosion.

       Field Attachable Fitting - a fitting designed to be attached to hose without crimping or swaging.
       This fitting is not always a Reusable type fitting.

       Flange Retainer Fittings - a hose fitting flared to a 90° surface, designed to hold a circular rotating
       flange, such as a slip-on or lap joint style flange.

       Flange Style Fittings - pipe flanges and flanged fitting standards are listed under ANSI B16.5.
       Flanges are rated for pressure and listed as “American Class 150, 300, 400, 600, 900, 1,500 or
       2,500”. Pressure-Temperature ratings can be obtained by consulting the ANSI specification or
       ASME B16.5 (American Society of Mechanical Engineers). Designs vary by neck and face style,
       or other dimensional changes based on use. Various finishes or grooves may be applied to the
       face for sealing on a gasket or o-ring. Bolt holes and other dimensions are per the ANSI standard.

       Slip-on Flange - a flange designed to slip over a flange retainer and float freely in place for bolt
       alignment. Similar to a lap joint flange except with a very small radius on the face side of the
       inside diameter to mate with a machined flange retainer. May have a flat or raised face.

       Lap Joint Flange - a flange designed to float freely on the flange retainer for bolt alignment. Made
       with a flat face and having a large radius on the I.D. to mate with a flared pipe style flange
       retainer.

       Threaded Flange - a flange, the inside diameter of which is threaded to attach to a male pipe
       fitting. A leak proof seal, made with thread sealant, usually does not allow for bolt hole alignment.
       Inverted Flare Fitting - a fitting consisting of a male or female nut, trapped on a tube by flaring the
       end of the tube material to either 37° or 45°.
       JIC Fittings - joint Industrial Council (no longer in existence). An engineering group that
       established an industry standard fitting design incorporating a 37° mating surface, male and
       female styles. These standards now governed by SAE.

       Lined Fitting - any fitting of which the wetted surface or entire fitting is covered with a protective
       material. The covering process may be by spray coating, molding or by inserting hose liner
       through the I.D. of fitting and anchoring.

       O-ring Fittings - a fitting that seals by means of an elastomeric ring of a specified material.

       Pipe Thread Fittings -

              NPT- National Pipe Taper. Pipe thread per ANSI B1.20.1

              NPTF- National Pipe Tapered for Fuels. Same as above except dry-seal per ANSI
              B1.20.3

              NPSH- National Pipe Straight Hose per ANSI B1.20.7

              NPSM- National Pipe Straight Mechanical. Straight thread per ANSI B1.20.1

              NPSL- National Pipe Straight Loosefit per ANSI B1.20.1

             BSPP, BSPT- British Standard Pipe Parallel, British Standard Pipe Taper. BS21.
       Quick Connect Fitting - a fitting designed to quickly connect and disconnect. These fittings come
       in many styles and types.

       Reusable Fitting - a fitting designed to be attached and unattached to a hose, allowing all or most
       of the fitting to be reused.

       Sanitary Fittings - a fitting whose seal is accomplished by means of a round gasket in a groove on
       the face of the fitting. The design eliminates the need for a male and female, since the fitting
       mates to itself. A re-attachable clamp is also used for coupling.

       Bevel Seat - a type of sanitary fitting incorporating a 45° beveled sealing surface. Used in the food
       and pharmaceutical industries.

       Split Flange Fitting - a fitting consisting of a flange retainer and a flange of two halves. This design
       allows the flanges to be installed after the retainer has been attached to the hose, making the
       flange reusable. SAE Code 61 and 62.

       Tube Fitting - a hose fitting of which the mating end conforms to a tube diameter. The mate or
       male end of a compression fitting.

       2-Bolt Flange Fitting - an elliptical flange with two bolt holes. Typically used in steam applications
       such as laundry and tire presses.

flammable gases/liquid/media: a flammable gas, including liquefied gas, is one having a closed cup flash
point below +100ºF (+37.8ºC) and a vapor pressure greater than 25 psi. (174.2 KPa).

flat spots: flat areas on the surface of cured hose caused by deformation during vulcanization.

flex cracking: a surface cracking induced by repeated bending and straightening.

flex life: the relative ability of an article to withstand bending stresses.
flex life test: a laboratory method used to determine the life of a rubber product when subjected to dynamic
bending stresses.

flow rate: a volume of media being conveyed in a given time period.

fluid: a gas or liquid medium.

fluid velocity: the speed of fluid through a cross section expressed in length divided by time.

fluorocarbon: an organic compound containing fluorine directly bonded to carbon. The ability of the carbon
atom to form a large variety of structural chains gives rise to many fluorocarbons and fluorocarbon derivatives.

Fluron®: a registered trademark of ICI. A term descriptive of the family of fluorocarbons and fluorocarbon
derivatives in general commercial use. See PTFE.

fluoropolymer: a high molecular weight (long chain) chemical containing fluorine as a major element.

free length: the lineal measurement of hose between fittings or couplings.

frequency: the rate of vibration or flexure in a given time period.

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-G-

galvanic corrosion: corrosion that occurs on the less noble of two dissimilar metals in direct contact with each
other in an electrolyte, such as water, sodium chloride in solution, sulfuric acid, etc.

GMAW: Gas Metal Arc Weld.

GPM: gallons per minute.

GTAW: see Tig Weld/GTAW.

guide (for piping): a device that supports a pipe radially in all directions, but directs movement.

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-H-

Halar®: Ausimont USA registered trademark. See ECTFE.

hand built hose: a hose made by hand on a mandrel, reinforced by textile or wire or combination of both.

hardness: resistance to indentation. See durometer hardness.

heat resistance: the property or ability to resist the deteriorating effects of elevated temperatures.

heat-shrink sleeving: tubular thermoplastic sleeve used for chafe protection or identification. The sleeve is
slipped over the hose and shrunk down by the application of heat to fit tightly on the hose.

helical wire armor/spring guard: an abrasion resistance device.

helical: used to describe a type of corrugated hose having one continuous convolution resembling a screw
thread.

helix: a shape formed by spiraling a wire or other reinforcement around the cylindrical body of a hose; typically
used in suction hose.
higbee: the thread of a hose coupling, the outermost convolution of which has been removed to such an extent
that a full cross section of the thread is exposed, this exposed end being beveled.

hoop strength: the relative measure of a hose’s resistance to collapse of the diameter perpendicular to the
hose axis.

hose: a flexible conduit consisting of a tube, reinforcement, and usually an outer cover.

hose assembly: see assembly.

hose clamp: a device used to hold a hose onto a fitting.

Hostaflon®: a registered trademark of Dyneon. See PFA.

hydrostatic testing: the use of liquid pressure to test a hose or hose assembly for leakage, twisting, and/or
hose change-in-length.

Hypalon®: a DuPont registered trademark. See CSM.

Hytrel®: a DuPont registered trademark.

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-I-

I.D.: the abbreviation for inside diameter.

identification yarn: a yarn of single or multiple colors, usually embedded in the hose wall, used to identify the
manufacturer.

impression: a design formed during vulcanization in the surface of a hose by a method of transfer, such as
fabric impression or molded impression.

impulse service: an application parameter characterized by continuous cyclical pressure changes from low to
high.

impulse: an application of force in a manner to produce sudden strain or motion, such as hydraulic pressure
applied in a hose.

indentation: 1) the extent of deformation by the indentor point of any one of a number of standard hardness
testing instruments; 2) a recess in the surface of a hose.

innercore: the innermost layer of a hose; the hose material in contact with the medium.

insert: optional term for nipple. See nipple.

interlocked hose: formed from profiled strip and wound into flexible metal tubing with no subsequent welding,
brazing, or soldering; may be made pressure-tight by winding in strands of packing.

interlocking clamp: a clamp which engages the fitting in a manner which prevents the clamp from sliding off
the fitting, typically a bolt or U-bolt style with interlocking fingers which engage an interlock ring on the fitting.

interlocking ferrule: a ferrule, which physically attaches to the fitting preventing the ferrule from sliding off the
fitting.

interstice: a small opening, such as between fibers in a cord or threads in a woven or braided fabric.

IPT: iron pipe threads; a reference to NPT or NPTF.
ISO: International Organization for Standardization.

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-J-

jacket: a seamless tubular braided or woven ply generally on the outside of a hose.

JIC: see fitting/coupling-JIC.

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-K-

kinking: a temporary or permanent distortion of the hose induced by bending beyond the minimum bend
radius.

Kynar®: ELF Atochem registered trademark. See PVDF.

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-L-

lap seam: a seam made by placing the edge of one piece of material extending flat over the edge of the
second piece of material.

lap weld (LW): type of weld in which the ends or edges of the metal overlap each other.

lay: 1) the direction of advance of any point in a strand for one complete turn; (2) the amount of advance of any
point in a strand for one complete turn. See pitch.

layer: a single thickness of rubber or fabric between adjacent parts.

leaker: 1) a crack or hole in the tube which allows fluids to escape; 2) a hose assembly which allows fluids to
escape at the fittings or couplings.

life test: a laboratory procedure used to determine the resistance of a hose to a specific set of destructive
forces or conditions. See accelerated life test.
light resistance: the ability to retard the deleterious action of light.

lined bolt holes: the bolt holes, which have been given a protective coating to cover the internal structure.

liner: flexible sleeve used to line the inside diameter of hose when conveying a high velocity media, also
prevents erosion.

live length: see free length.

LJF (lap joint flange): see fitting/coupling - Lap Joint Flange.

long shank: a shank length greater than the nominal diameter, typically two diameters in length, which allows
more than a single clamp.

loop installation: the assembly is installed in a loop or “U” shape, and is most often used when frequent
and/or large amounts of motion are involved.

low temperature flexibility: the ability of a hose to be flexed, bent or bowed at low temperatures without loss
of serviceability.
LPG, LP Gas: the abbreviation for liquefied petroleum gas.

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-M-

MAWP: see pressure, maximum allowable working.

mandrel: 1) a form, generally of elongated round section used for size and to support hose during fabrications
and/or vulcanization. It may be rigid or flexible; 2) a tapered expanding device, fixed in diameter, which is pulled
through a shank of a fitting thus expanding the diameter to exert force on the hose between the shank and
ferrule.

mandrel built: a hose fabricated and/or vulcanized on a mandrel.

mandrel, flexible: a long, round, smooth rod capable of being coiled in a small diameter. It is used for support
during the manufacture of certain types of hose. (The mandrel is made of rubber or plastic material and may
have a core of flexible wire to prevent stretching.)

mandrel, rigid: a non-flexible cylindrical form on which a hose may be manufactured.

manufacturer’s identification: a code symbol used on or in some hose to indicate the manufacturer.

mass flow rate: the mass of fluid per unit of time passing through a given cross-section of a flow passage in a
given direction.

mean diameter: the midpoint between the inside diameter and the outside diameter of a corrugated/convoluted
hose.

mechanical fitting/reusable fitting: a fitting attached to a hose, which can be disassembled and used again.

media, medium: the substance(s) being conveyed through a system.

mender: a fitting or device used to join two sections of hose.

metal hose: thin wall metal tubing formed into flexible hose with helical or annular ridges and grooves, often
braided with stainless steel to increase the operating pressure capability. With fittings welded on, assemblies
are used in applications outside temperature range of rubber, thermoplastic and fluoroplastic.

misalignment: a condition where two parts do not meet true.

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-N-

NAHAD: the abbreviation for the National Association of Hose & Accessories Distributors.

necking down: a localized decrease in the cross-sectional area of a hose resulting from tension.

Neoflon®: a registered trademark of Daikin USA.

Neoprene®: a registered trademark of DuPont.

nipple: the internal member or portion of a hose fitting.

nitrile rubber (NB/Buna-N): a family of acrylonitrile elastomers used extensively for industrial hose.

nominal: a size indicator for reference only.
nomograph: a chart used to compare hose size to flow rate to recommended velocity.

non-conductive: the inability to transfer an electrical charge.

non-interlocking ferrule: see sleeve.

nozzle end: an end of hose in which both the inside and outside diameters are reduced.

NPT/NPTF: abbreviation for national pipe threads. See fitting/coupling - Pipe Thread Fittings.

nylon: a family of polyamide materials.

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-O-

OAL: see overall length

O.D.: the abbreviation for outside diameter.

OE/OEM: original equipment manufacturer.

off-center: see eccentricity.

offset-lateral, parallel: the distance that the ends of a hose assembly are displaced in relation to each other as
the result of connecting two misaligned terminations in a system, or intermittent flexure required in a hose
application.

oil resistance: the ability of the materials to withstand exposure to oil.

oil swell: the change in volume of a rubber article resulting from contact with oil.

open steam cure: a method of vulcanizing in which steam comes in direct contact with the product being
cured.

operating conditions: the pressure, temperature, motion, and environment to which a hose assembly is
subjected.

o-ring fitting: see fitting/coupling, O-Ring.

OS & D hose: the abbreviation for oil suction and discharge hose.

overall length (OAL): the total length of a hose assembly, which consists of the free hose length plus the
length of the coupling(s).

oxidation: the reaction of oxygen on a material, usually evidenced by a change in the appearance or feel of the
surface or by a change in physical properties.

ozone cracking: the surface cracks, checks or crazing caused by exposure to an atmosphere containing
ozone.

ozone resistance: the ability to withstand the deteriorating effects of ozone (generally cracking).

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-P-

PFA: perfluoralkoxy
penetration (weld): the percentage of wall thickness of the two parts to be joined that is fused into the weld
pool in making a joint.

performance test (service test): a test in which the product is used under actual service conditions.

permanent fitting: the type of fitting which, once installed, may not be removed for re-use.

permeation: the process of migration of a substance into and through another, usually the movement of a gas
into and through a hose material; the rate of permeation is specific to the substance, temperature, pressure and
the material being permeated.

Pharmacopeia Class VI: a standard for sanitary fittings, designating the form, fit, function and finish.

pick: the distance across a group of braid wires from a single carrier, measured along the axis of the hose.

pig: a mechanical projectile used for cleaning hose.

pin pricked: perforations through the cover of a hose to vent permeating gases.

pitch: 1) the distance from one point on a helix to the corresponding point on the next turn of the helix,
measured parallel to the axis; 2) the distance between the two peaks of adjacent corrugation or convolution.

pitted tube: surface depressions on the inner tube of a hose.

plain ends: fitting ends without threads, groove, or a bevel typically used for welding, as in a flange.

plaits: an individual group of reinforcing braid wires/strands.

plating: a material, usually metal, applied to another metal by electroplating, for the purpose of reducing
corrosion; typically a more noble metal such a zinc is applied to steel.

ply: an individual layer in hose construction.

pneumatic testing: the use of compressed air to test a hose or hose assembly for leakage, twisting, and/or
hose change-in-length. NOTE: Use of high pressure air is extremely hazardous.

Polyflon®: a registered trademark of Daikin USA. See PTFE.

polymer: a macromolecular material formed by the chemical combination of monomers, having either the
same or different chemical compositions.

post-sinter: the technique of re-heating PTFE innercore to process temperature in order to reduce
permeability.

preform: the compressed cylinder of PTFE resin that is used to extrude into raw tubing. Also called a billet.

pre-production inspection or test: the examination of samples from a trial run of hose to determine
adherence to a given specification, for approval to produce.

preset: the process of pressurizing a hose to set the braid and minimize length change in final product.

pressure: force ÷ unit area. For purposes of this document, refers to PSIG (pounds per square inch gauge).

pressure drop: the measure of pressure reduction or loss over a specific length of hose.

pressure, burst: the pressure at which rupture occurs.

pressure, deformation: the pressure at which the convolutions of a metal hose become permanently
deformed.
pressure, gauge: relative pressure between inside and outside of an assembly.

pressure, maximum allowable working: the maximum pressure at which a hose or hose assembly is
designed to be used.

pressure, operating: see pressure, working.

pressure, proof test: a non-destructive pressure test applied to hose assemblies.

pressure, pulsating: a rapid change in pressure above and below the normal base pressure, usually
associated with reciprocating type pumps.

pressure, rated working: see pressure, maximum allowable working.

pressure, service: see working pressure.

pressure, shock/spike: the peak value of a sudden increase of pressure in a hydraulic or pneumatic system
producing a shock wave.

pressure, working: the maximum pressure to which a hose will be subjected, including the momentary surges
in pressure, which can occur during service. Abbreviated as WP.

printed brand: see brand.

profile: used in reference to the contour rolled into strip during the process of manufacturing strip wound hose,
or the finished shape of a corrugation/convolution.

propane: see LPG, LP Gas.

psi: pounds per square inch.

PTFE: polytetrafluoroethylene, a high molecular weight fluoroplastic polymer with carbon atoms shielded by
fluorine atoms having very strong inter atomic bonds, giving it chemical inertness.

pull off force: the force required to pull the hose from its attachment not generated by the internal pressure.

PVC: polyvinyl chloride. A low cost thermoplastic material typically used in the manufacture of industrial hoses.
The operating temperature range is -500ºF to +1750ºF (-295.5ºC to +954.4ºC).

PVDF: polyvinylidene fluoride.

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-Q-

quality conformance inspection or test: the examination of samples from a production run of hose to
determine adherence to given specifications, for acceptance of that production.
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-R-

RAC: Rubber Association of Canada.

random motion: the uncontrolled motion of a metal hose, such as occurs in manual handling.

reinforcement: the strengthening members, consisting of either fabric, cord, and/or metal, of a hose. See ply.

reusable fitting/coupling: see fitting/coupling, reusable.
RMA: The Rubber Manufacturers Association, Inc.

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-S-

SAE: Society of Automotive Engineers.

safety factor: see design factor.

sampling: a process of selecting a portion of a quantity for testing or inspection, selected without regard to
quality.

Santoprene®: a registered trademark of Monsanto.

scale: the oxide in a hose assembly brought about by surface conditions or welding.

serrations: bumps, barbs, corrugations, or other features that increase the holding power of the device.

service temperature: see working temperature.

shank: that portion of a fitting, which is inserted into the bore of a hose.

shelf/storage life: the period of time prior to use during which a product retains its intended performance
capability.

shell: see ferrule.

shock load: a stress created by a sudden force.

short shank: shank length, approximately equal to the nominal diameter, but long enough to allow a single
clamp at minimum.

simulated service test: see bench test.

skive: the removal of a short length of cover and/or tube to permit the attachment of a fitting directly over the
hose reinforcement.

sleeve: a metal cylinder, which is not physically attached to the fitting, for the purpose of forcing the hose into
the serrations of the fitting.

smooth bore: a term used to describe the type of innercore in a hose.

socket: the external member or portion of a hose fitting, commonly used in describing screw-together reusable
fittings.

soft end: a hose end in which the rigid reinforcement of the body, usually wire, is omitted.

specification: a document setting forth pertinent details of a product.

spiral: a method of applying reinforcement in which there is not interlacing between individual strands of the
reinforcement.

spiral angle: the angle developed by the intersection of the helical strand and a line parallel to the axis of a
hose. See braid angle.

splice: a method of joining two sections of hose.

splicer: a fitting or device used to join two sections of hose.
spring guard: a helically wound component applied internally or externally to a hose assembly, used for strain
relief, abrasion resistance, collapse resistance.

squirm: a form of failure where the hose is deformed into an “S” or “U” bend, as the result of excessive internal
pressure being applied to unbraided corrugated hose while its ends are restrained or in a braided corrugated
hose which has been axially compressed.

standard: a document, or an object for physical comparison, for defining product characteristics, products, or
processes, prepared by a consensus of a properly constituted group of those substantially affected and having
the qualifications to prepare the standard for use.

static bonding: use of a grounded conductive material between fittings to eliminate static electrical charges.

static conductive: having the capability of furnishing a path for a flow of static electricity.

static discharge: see electrostatic discharge.

static wire: wire incorporated in a hose to conduct static electricity.

stem: see nipple.

stress corrosion: a form of corrosion in metal.

strip wound: see interlocked hose.

surge (spike): a rapid and transient rise in pressure.

swage: the method of fitting attachment that incorporates a set of die halves designed to progressively reduce
the collar or ferrule diameter to the required finish dimension by mechanically forcing the fitting into the mating
die.

swelling: an increase in volume or linear dimension of a specimen immersed in liquid or exposed to a vapor.

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-T-

tape wrapped convoluted: a type of flexible hose incorporating layers of tape to form helical ridges and
grooves.

tear resistance: the property of a rubber tube or cover of a hose to resist tearing forces.

Teflon®: a registered trademark of E.I. DuPont. See PTFE, FEP and PFA.

TFE: Polytetrafluoroethylene. See PTFE.

tig weld/GTAW: the gas tungsten arc welding process sometimes referred to a “shielded arc” or “heliarc.”

traveling loop, Class A Loop: an application wherein the radius remains constant and one end of the hose
moves parallel to the other end.

traveling loop, Class B Loop: a condition wherein a hose is installed in a U-shaped configuration and the
ends move perpendicular to each other so as to enlarge or decrease the width of the loop.

tube: the innermost continuous all-rubber or plastic element of a hose.

tube fitting: see fitting/coupling-Tube.
tubing: a non-reinforced, homogeneous conduit, generally of circular cross-section.

twist: (1) the turns about the axis, per unit of length, of a fiber, roving yarn, cord, etc. Twist is usually expressed
as turns per inch; (2) the turn about the axis of a hose subjected to internal pressure.

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-U-

unsintered: material that has not undergone primary heat processing.

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-V-

vacuum formed convoluted: smooth bore hose that is made flexible by the formation of ridges and grooves
during a process that utilizes heat and vacuum to mechanically form convolutions.

vacuum resistance: the measure of a hoses ability to resist negative gauge pressure.

velocity resonance: vibration due to the buffeting of a high velocity gas or liquid flow.

vibration: amplitude motion occurring at a given frequency.

viscosity: the resistance of a material to flow.

volume change: a change in dimensions of a specimen due to exposure to a liquid or vapor.

volume swell: see swelling.

volumetric expansion: the volume increase of hose when subjected to internal pressure.

vulcanization: a process during which a rubber compound, through a change in its chemical structure,
improves or extends elastic properties over a greater range of temperature.
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-W-

weathering: the surface deterioration of a hose cover during outdoor exposure, as shown by checking,
cracking, crazing and chalking.

wire reinforced: a hose containing wires to give added strength, increased dimensional stability; crush
resistance. See reinforcement.

working temperature: the temperature range of the application, may include the temperature of the fluid
conveyed or the environmental conditions the assembly is exposed to in use.

WP: the abbreviation for working pressure.

wrapped cure: a vulcanizing process using a tensioned wrapper (usually of fabric) to apply external pressure.

The preceding Glossary of Terms, as utilized in the hose industry, includes some definitions from The Hose
Handbook, published by the Rubber Manufacturers Association.

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>> continue to Section 3
Section 3 Application Requirements - Stamped

3.1 Purpose

3.2 General

3.3 Directions

3.1   Purpose

The purpose of this section is to provide a simple to use guide to assist in determining the correct hose,
coupling and attachment method that will satisfy your customers needs.
3.2   General

The guide uses the STAMPED process. STAMPED is an acronym and stands for the 7 major information areas
required to provide a quality hose assembly for your customer, as follows:

       S stands for SIZE; I.D., O.D. and length
       T stands for TEMPERATURE of the material conveyed and environmental
       A stands for the APPLICATION, the conditions of use
       M stands for the MATERIAL being conveyed, type and concentration
       P stands for the PRESSURE to which the assembly will be exposed
       E stands for ENDS; style, type, orientation, attachment methods, etc.
       D stands for DELIVERY; testing, quality, packaging, and delivery requirements
3.3   Directions

Using the form:

       1. Inform the customer you will be using an application format called STAMPED.

       2. Ask your customer the pertinent questions outlined on the form, in sequence.

       3. After completing the form, ask your customer to confirm their answers as you repeat them, in
       sequence.

       4. Provide the completed format to your assembly area or order entry as required

The following list of special considerations may help to clarify application parameters:

       1. Abrasion
       2. Electrical conductivity
       3. Environment
       4. Flammability
       5. Flow rate
       6. Fluid velocity
      7. Movement (type, distance, frequency)
      8. Ozone
      9. Permeation (vapor conveying hose)
      10. Routing
      11. Salt water
      12. Static electricity
      13. Ultraviolet light
      14. Vibration (frequency rate – Hz, amplitude – "G" load)

Click here to the STAMPED Form

>> continue to Section 4
Customer Information:
Company: ______________________________                        Fax: _____________________________
Contact: _______________________________                       E-mail: ___________________________
Address: _______________________________                       P.O. #: ___________________________
Phone: ________________________________                        Terms: ___________________________


                  I.D.                O.D.          Overall Length          Tolerance
Size
                      in./mm             in./mm             ft, in./mm                  -


                               Material Conveyed         Environmental Temperature
Temperature                     Min         Max             Min            Max
                                   ºF/ºC       ºF/ºC            ºF/ºC          ºF/ºC


Application            Type:



Material/                                          Material Conveyed
Media                 Internal Media -                 External Environment        -


                  Max Working Pressure             Spikes                 Vacuum
Pressure
                               PSI /kPa              PSI/kPa             Inches of Hg/kPa


                           Style/          Threads/ Bolt               Attachment
                End                Size                  Orien-tation               Capped
                          Material        Hole Alignment                Methods
Ends
            1           -          -    -                -            -           Yes No
            2           -          -    -                -            -           Yes No


                  Quantity Required:                       Date Required:
                  Package Type:
Delivery          Pick Up Date:                           Ship Via:
                  Testing Required:          Yes       No Type:
                  Certification Required:    Yes       No Type:

Special Requirements:
Section 4     Composite Hose

4.1 Scope

4.2 Hose Data Sheet

4.3 Hose Materials and Construction

      4.3.1 Purpose
      4.3.2 Materials
      4.3.3 Pressure Ratings

4.4 Composite Hose Customer Information

      4.4.1 Purpose
      4.4.2 Method for Application Qualification

4.5 Common Hose Assembly Techniques

      4.5.1   Purpose
      4.5.2   Overview
      4.5.3   Preparation for Swaging or Crimping
      4.5.4   End Connections Used

4.6 Finished Assembly Dimension Tolerances

      4.6.1 Purpose
      4.6.2 Size
      4.6.3 Length

4.7 Testing Procedures

      4.7.1   Purpose
      4.7.2   Hydrostatic Pressure Tests
      4.7.3   Electrical Continuity Test
      4.7.4   Electrical Resistance Test
      4.7.5   Test Documentation

4. 8 Hose Assembly Markings

      4.8.1 Purpose
      4.8.2 Method of Marking
      4.8.3 Information to be Included

4.9 Installation and Handling

      4.9.1   Purpose
      4.9.2   Cleaning
      4.9.3   Storage
      4.9.4   Packaging and Transportation
      4.9.5   Installation and Usage
      4.9.6   Transfer Hose Handling Guidelines while in Service
      4.9.7   Inspection of Hose/Troubleshooting
      4.9.8 Field Testing of Composite Hose

4.1   Scope

This section specifies the methods and requirements necessary for the fabrication and testing of composite
hose assemblies, and pertains to multi-layered, non-vulcanized, thermoplastic hose assemblies suitable for
hydrocarbons products, aromatic hydrocarbons, solvents and chemicals with nominal diameters from 1 to 10
inches (25 mm to 254 mm).
4.2   Hose Data Sheet
General Uses:

Composite hose, consisting of thermoplastics and wire reinforcement, can be used in selective petroleum and
chemical service where flexibility combined with strength is required.
Limitations:

The type of hose selected is dependent on application. The hose supplier or manufacturer should be consulted
to determine the style of hose needed.
Warnings:

Composite hose should not be used for the conveyance of gaseous products, solids or abrasive slurries.

Special attention needs to be given to the following:

      a) It is important that any media be thoroughly drained prior to cleaning to avoid chemical or
      exothermic reactions when the hose is returned to service.

      b) Pigging of lines should not be used with composite hose.
      c) Compressed air may be used but hose must be open ended.

      d) Consult with the manufacturer for temperature limitations as composite is constructed with
      thermoplastics, which tend to weaken at elevated temperatures. Care must be taken when
      cleaning with hot water so as not to exceed the maximum working temperature of the hose. If
      steam is to be used contact the manufacturer for any recommended practices.

      e) During any cleaning operation, the assembly must be electrically grounded to avoid build up of
      static charge.
4.3   Hose Materials and Construction

      4.3.1    Purpose

      The purpose of this section is to provide a general description of composite hose construction and
      pressure rating requirements.
      4.3.2    Materials

      A. An internal metal wire helix. This may be stainless steel, galvanized carbon steel, aluminum, or
      carbon steel sheathed in a polymeric material resistant to the materials of service.

               1. Stainless steel wire as specified and agreed between purchaser and
               manufacturer.

               2. Galvanized carbon steel wire as specified and agreed between purchaser and
               manufacturer.
              3. Aluminum wire as specified and agreed between purchaser and manufacturer.

              4. Carbon wire sheathed in a polymeric material should be coated as required with
              material resistant to liquid hydrocarbon, aromatic hydrocarbon or liquid chemicals as
              specified and agreed between the purchaser and manufacturer.

      B. A multi-ply wall of thermoplastic films and reinforcing fabrics in proportions that give the
      required physical properties and provide a complete seal. The films may be a flat film, tube,
      and/or fabric.

      C. A fabric cover with an abrasion and ozone resistant polymeric coating.

      D. An external metal wire helix. Wire material should be as outlined above.
      4.3.3   Pressure Ratings

      The maximum working pressure of a composite hose should be equal to the Nominal Burst
      pressure divided by four as a minimum. This may change dependent upon customer
      requirements.
4.4   Composite Hose Customer Information

      4.4.1   Purpose

      The purpose and intent of this section is to obtain all information necessary to satisfy the
      requirements of the customer, and reduce the risk of premature failure of hose assemblies in
      application.
      4.4.2   Method for Application Qualification

              4.4.2.1   Parameters of Applications

              The following should be defined and considered in the design, recommendation
              and/or quotation of hose and/or hose assemblies:
              4.4.2.2   Configurations Parameters

              Information should include:

                    a) Size (nominal diameter).

                    b) Length of assembly (e.g., end to end) Length tolerances (+5% /
                    -2%)

                    c) Fittings –

                           1. end fitting adaptor at both ends (NPT,”C”,”E”, flange,
                           etc.)

                           2. material type: stem

                           3. ferrule

                           4. end adaptor

                           5. gasket material on female end adaptor

                    d) Definition of value scale (e.g., inches, millimeters, etc.).
              4.4.2.3   Physical Parameters
              Information should include:

                    a) Material conveyed: media and percent concentration of media.

                    b) Product temperature (min / normal operating / max),

                    c) External environment temperature (min / max) and definition of
                    value scale (e.g., Fahrenheit, Celsius, etc.)

                    d) Specify any environmental conditions.

                    e) Installation parameters: Horizontal installation, Vertical installation
                    self supported, End load, Minimum Bend Radius, etc. .

                    f) Maximum working pressure required for the installation (including
                    surges), vacuum rating.
              4.4.2.4   Control Parameters

              Information should include:

                    a) Drawing or print if applicable and proper revision of drawing or
                    print.

                    b) Agency standard(s) applicable.

                    c) Test requirements, customer.

                    d) Documentation requirements, customer.

                    e) Special branding requirement and cover color.

                    f) Information of past performance of present hose in place.

                    g) Flame resistance.

                    h) Special cleaning procedure in use.
              4.4.2.5   Contract Parameters

              Information should include:

                    a) Quantity

                    b) Delivery schedule

                    c) Cleaning requirements

                    d) Packaging requirements

                    e) Other items per manufacturer guidelines
4.5   Common Hose Assembly Techniques

      4.5.1   Purpose

      The purpose of this section is to provide common techniques for coupling of composite hose
      assemblies.
      4.5.2   Overview
      The technique of attaching fittings onto composite style hose may be accomplished in a number
      of ways. The early methods used included wire binding, hose clamps and bands. The more recent
      methods include external swaging or crimping. The latest methods of hydraulically crimping and
      swaging are now the most popular and are considered more secure for higher pressures.
      4.5.3   Preparation for Swaging or Crimping

      The preparation of composite hose for the attachment of fittings when the swaging or crimping
      method is to be used can be described as follows:

              A. Follow the manufacturer’s recommendations to prepare the end of the hose to
              accept the fitting components.

              B. The next stage of assembly is accomplished through varying methods. One
              method used by some assemblers forms an epoxy seal around the end of the hose
              once the fitting is attached. This is done by pouring resin into the bowl formed by the
              ferrule that had been first welded to the fitting. Following the manufacturer’s
              procedures, the fitting is then turned on tightly and swaged or crimped to the proper
              dimensions.

              C. An alternative method for this stage of assembly involves the installation of a seal
              supplied by the manufacturer that covers the end of the hose and extends inside
              and over the hose. The sizes and lengths of these seals vary with the manufacturers
              and with the diameter of the hose. Install the seal, ferrule and fitting following the
              manufacturer’s recommendations and swage or crimp to the proper dimensions.
      4.5.4   End Connections Used

      For all types of end connections used, the part of the fitting which enters the hose, and forms the
      means by which the fitting is connected to the hose, should be provided with scrolls or protrusions
      on the surface that correspond to the pitch of the inner reinforcing wire of the hose. In all cases,
      they should be connected to the construction wire or bonding wire to provide electrical continuity.
4.6   Finished Assembly Dimension Tolerances

      4.6.1   Purpose

      The purpose of this section is to provide dimension and tolerance guide lines for composite
      assemblies.
      4.6.2   Size

      The bore and bend radius of the hose should comply with the nominal dimensions given by the
      manufacturer.
      4.6.3   Length

      The length of hose ordered should be the OAL including the end fittings. OAL measurements
      should be from flange face to flange face, seat to seat, end of threads to end of threads, etc. If in
      question, this data should be added to the purchase order.

      In the as fabricated condition, after testing, the overall length, (OAL), should be within +5%/-2% of
      the OAL.

      The maximum change in length at the maximum test pressure should not exceed 12% of initial
      length as measured in 4.7.2.2B.

      Because of the elongation under pressure, the distributor may need to seek the advice of the
      manufacturer for applications where length in use is critical.
4.7   Testing Procedures

      4.7.1   Purpose

      The purpose of this section is to define minimum test requirements, which should be routinely
      carried out on all new hose assemblies before use.
      4.7.2   Hydrostatic Pressure Tests

      All fitted hose assemblies should be pressure tested to establish that the end fittings have been
      correctly fitted and the assembly is leak free.

      The following criteria should apply when pressure testing hose assemblies:

              A. Hose assemblies with 1 inch to 4 inches (25 mm to 100 mm) nominal bore
              standard duty oil and chemical hose should be tested to a minimum of one and a
              half times the rated working pressure of the assembly for a minimum period of five
              minutes.

              B. Hose assemblies with 4 inch (100 mm) nominal bore heavy duty and 6 inches to
              10 inches (150 mm to 250 mm) nominal bore composite hose should be tested to
              one and a half times the rated working pressure of the assembly for a minimum
              period of 30 minutes.

              C. Unless otherwise stated by the purchaser, the test medium should be water.
              4.7.2.1   Recommended Testing Procedure

              The following testing procedure is recommended:

                    a) Lay the hose out straight, allowing space for elongation under
                    pressure, preferably on supports to allow free movement under
                    pressure.

                    b) Blank off one end and fill hose with water, taking particular care to
                    ensure that all trapped air is released from the hose.

                    c) Pressurize hose assembly to one and a half times rated working
                    pressure and sustain at that pressure for the time appropriate to the
                    grade of hose under test. (See Section 4.7.2)

                    d) While pressure is maintained, examine the assembly for leaks and
                    any unusual appearance and test for electrical continuity between the
                    end fittings. (See Sections 4.7.3 and 4.7.4)

                    e) When tested in accordance with the above, the assembly under test
                    should be totally leak free for the duration of the test.
              4.7.2.2   Elongation Length Measurement

              A characteristic of composite hose is elongation. This characteristic should not be
              used solely as an assessment of the condition of the hose or an indication of failure.
              Consult manufacturer for more information. (See Section 4.6.3)

              In the event that elongation length measurement is required, the following is an
              accepted process and may be incorporated into your test procedure.
                     a) Pressurize the hose to one time working pressure, hold for 30
                     seconds, release pressure to 10 psi and take the initial length
                     measurement at 10 psi. Lo=____.

                     b) Measure the hose length under pressure (Test Pressure Length),
                     Lt=_____. Calculate the temporary elongation as follows:

                     Lt - Lo x 100 = ____% Lo.

                     c) Release the pressure, wait 30 seconds, measure and record the
                     Over All Final Length, and drain hose.
      4.7.3 Electrical Continuity Test

              All lengths of composite hose that have been fitted with electrically conductive end
              fittings must be tested from end fitting to end fitting with a calibrated multi-meter to
              ensure that the hose is electrically continuous.
      4.7.4   Electrical Resistance Test

      Unless otherwise specified, all lengths of composite hose that have been fitted with electrically
      conductive end fittings must have an electrical resistance not exceeding 10 ohms. The test should
      be made from end fitting to end fitting using a calibrated multi-meter to ensure that the hose is
      electrically continuous.
      4.7.5   Test Documentation

      If required by the customer, a test certificate may be issued to provide written confirmation that
      the assembly has been tested, and conforms to certain performance criteria. If a test certificate is
      not supplied, test results should be maintained and kept on file for five years.

      Each test certificate should bear a unique number for traceability.

      Test certificates should include the following information as a minimum:

              A. Test Certificate Number
              B. Customers Name and Purchase Order Number
              C. Suppliers Name and Job Number
              D. Hose Serial Number(s)
              E. Hose details including length, type of hose and diameter
              F. End fitting details with types of ferrules and seals used
              G. Test Date
              H. Test Pressure
              I. Electrical Continuity Conformance
              J. Suppliers Authorization Signature
4.8   Hose Assembly Markings

      4.8.1   Purpose

      The purpose of this section is to establish a method and content of hose assembly marking.
      4.8.2   Method of Marking

      The marking of hose assemblies may be achieved in two ways:

              A. Information pre-stamped in legible characters on metal tag or band affixed to the
              assembly by approved durable method.
               B. Information in legible characters stamped directly onto the ferrule or fitting.
       4.8.3   Information to be Included

       Information to be included on the tag, band or by stamp:

               A. the manufacturers name, trademark or other identification
               B. the hose serial number
               C. the nominal bore size
               D. the month and year of manufacture
               E. the maximum working pressure

       Example: Manname/CH12/3"/Aug97/150psi
4.9   Installation and Handling

       4.9.1   Purpose

       The purpose of this section is to serve as a guide for the proper and safe installation, and
       subsequent handling and use of composite hose in service.
       4.9.2   Cleaning

       It is important that any media be thoroughly drained prior to cleaning to avoid chemical or
       exothermic reactions when the hose is returned into service.

               A. Typically, composite hose assemblies are cleaned by flushing thoroughly with
               clean water.

               B. Other media which can be used, depending on the media that has been passing
               through the hose, include hot water, sea water, detergents and common solvents at
               ambient temperature. If sea water is used the hose must be well drained after
               cleaning to minimize corrosion.

               C. Due to the inherent nature of the hose internally, any form of mechanical method
               of cleaning such as pigging should not be used under any circumstances.

               D. Also, due to the fact that the hose is constructed using plastics which tend to
               weaken at elevated temperatures, care must be taken when cleaning with hot water
               so as not to exceed the maximum working temperature of the hose. If steam is to be
               used, contact the manufacturer for any recommended practices.

               E. Compressed air may be used but the hose must be open-ended.

               F. During any cleaning operation, the assembly must be electrically grounded to
               avoid build up of static charge.
       4.9.3   Storage

       After service, hose assemblies should be flushed out and drained. Ideally, stored hoses should be
       dry and kept off the ground in a straight line out of direct sunlight.
       4.9.4   Packaging and Transportation

       Hose and hose assemblies may be transported in coiled form on pallets, in crates or loose within
       containers. Care should be taken to prevent impact damage.
       4.9.5   Installation and Usage
Hoses must be correctly supported during use. These supports should be arranged so that the
hoses are never bent beyond the minimum bend radius. Hoses should never be supported along
their live length by a single rope. Slings, saddles or some other means of proper support must be
used. The support must be wide enough to spread the load sufficiently so that the hose is not
deformed in the area of support. Incorrect installation can unduly stress hose assemblies leading
to a shortened working life or premature failure.

        A. Flanged hose assemblies should ideally have one end secured with a floating
        flange.

        B. Hose assemblies must not be twisted either on installation or in use.

        C. Hose assemblies subject to movement while operating should be installed in
        such a way that flexing occurs in the same plane.

        D. When installing hose assemblies, careful attention should be paid to minimum
        bend radii specifications.
4.9.6   Transfer Hose Handling Guidelines while in Service

        4.9.6.1   DO'S

        a) Support the hose within 3 to 4 feet of flange connections always maintaining
        horizontal plane.

        b) Support the hose using recommended hose supports throughout the balance of
        the length.

        c) Cushion the hose against sharp edges, dock edge, ships rail, etc.

        d) Cushion the hose when the application demands use of reciprocating machinery.
        It is recommended that all points of contact be cushioned to avoid potential damage
        due to the pulsating effect of reciprocating machinery. (See Figure 4.9.6.1)
        4.9.6.2   DON’TS

        a) Do not use the hose unsupported.

        b) Do not support the hose with a single rope.
        c) Do not allow the hose to hang unsupported between ship and quay. (See Figure
        4.9.6.1)
Figure 4.9.6.1 Transfer Hose Handling Guide
4.9.7   Inspection of Hose/Troubleshooting
      Before each operation, hose assemblies should be visually examined paying attention to the
      following points:

              A. Displacement of reinforcing wires from their normal pitch.
              B. Abrasion or corrosion of the hose outer wire
              C. Abrasion of the reinforcing fabrics beneath the outer cover.
              D. Dents or kinks.
              E. Damage or displacement of end fittings.
              F. Evidence of leakage from end fittings.

      Assemblies with any of the above significant defects or any other abnormal feature should be
      withdrawn from service immediately.
      4.9.8   Field Testing of Composite Hose

      It is recommended that hose assemblies be tested regularly depending on service. Consult
      manufacturers for more information.

>> continue to Section 5
Section 5     Hydraulic Hose

5.1 Scope

5.2 Hydraulic Hose Assembly Component Selection

5.3 Fabrication

       5.3.1 Purpose
       5.3.2 Scope
       5.3.3 Material Verification, Order Requirements
       5.3.4 Hose
       5.3.5 Skiving or Buffing (As required)
       5.3.6 Coupling Assembly (First end)
       5.3.7 Crimping (First end)
       5.3.8 External Accessories (As required)
       5.3.9 Crimping (Second end)
       5.3.10 Final Assembly Inspection
       5.3.11 Shipping

5.4 Quality Plan

       5.4.1 Purpose
       5.4.2 Scope
       5.4.3 Sampling Plan
       5.4.4 Material Receiving Inspection
       5.4.5 Storage (Labeling, Environment, Time)
       5.4.6 Retrieval (Pulling Stock)
       5.4.7 In-Process
       5.4.8 Final Assembly Inspection
       5.4.9 Calibrations
       5.4.10 Tolerances
       5.4.11 Documentation
       5.4.12 Recommended Inspection Equipment

5.5 SAE J517 Hose Working Pressures

5.6 Hose Assembly Orientation for Offset Elbow Fittings

5.7 Overall Length -- Pictorial Views

5.8 Flow Chart

5.1   Scope

Hydraulics can be simply defined as the science of using fluid, under pressure, to do work. Hydraulic hose assemblies are flexible, fluid
power connectors used to convey and direct these fluids. Today, hydraulics has progressed to where it is used in farming, construction,
metal working, marine, forestry, mining and practically any other industry you can name.
This section recommends the methods and requirements necessary for the selection, fabrication and testing of hydraulic hose
assemblies and pertains to nominal internal diameters 1/8 inch through 4 inch (3.2 mm through 101.6 mm).
It is extremely important that the specific instructions of the hose and coupling manufacturers be followed! Therefore, the practice of
“mixing and matching” hose and couplings is strictly prohibited. In no instance should the information printed in this section
supercede manufacturer’s instructions.

This document is not intended to prohibit either fabricator or end user from including additional requirements for hydraulic hose,
couplings or hydraulic hose assemblies, if necessary, to satisfy the application. It is the responsibility of each fabricator and user to
define these applications and their requirements to ensure performance capability.

Note: Aerospace and hydraulic brake hose assemblies are excluded from the scope of this section
5.2   Hydraulic Hose Assembly Component Selection

After careful consideration and analysis of the application requirements described in Section 3 - STAMPED of this document, it is time for
the assembler to select the proper hose and couplings to satisfy the application.
Many hydraulic hose styles and couplings are available and are described in detail in the component manufacturer’s catalogs. The most
common and popular hose styles in use today are the SAE 100R series which are listed in the Section 5.5 - SAE J517 Hose Working
Pressures.
However, in addition to these 18 SAE hose types, there are a great many new styles and constructions that have been developed in the
last 20 years to meet almost every possible condition imaginable.
The most common coupling termination end styles are illustrated in Appendix B – Hose Ends.

When in doubt, don’t hesitate to contact your hose and coupling supplier for advice.
5.3   Fabrication

       5.3.1   Purpose

       This section is intended as a guideline for hydraulic hose assembly fabrication.
       5.3.2   Scope

       The scope of this section is to outline the general steps recommended in fabricating hydraulic hose assemblies. This
       includes material identification, manufacturing, quality, packaging and shipping.
       5.3.3 Material Verification, Order Requirements
               5.3.3.1   Fabrication Order (Work Order)

               Whether it is one hose assembly from an over the counter request or a written work order for multiple hose
               assemblies from an OEM, it is recommended that the components to be assembled be verified against the
               requirements of the fabrication order.
               5.3.3.2   Material Quality

               All customers deserve a quality product. Initial visual inspection of hose assembly components, as well as the
               completed assembly must be performed.

               Documented validation may be required by the customer. It is recommended the assembly fabricator keep
               inspection records on incoming material, as well as document assembly testing and packaging processes.
               (See Section 5.4 – Quality Plan)
       5.3.4   Hose
               5.3.4.1   Calculate Cut Length

               The hose cut length for a hose assembly is calculated by subtracting the cut off factor (distance from the
               bottom of the ferrule or collar to the end of the fitting) from the actual assembly length required. Typical length
               tolerance for an assembly is +/- 1% or less.
               5.3.4.2   Cutting

               Wire reinforced hydraulic hose should be cut with either a circular steel cutting wheel or a circular abrasive
               cutoff wheel. The preferred choice would be the steel wheel with a cooling agent. Overheating the hose as
               you cut can cause deformation of the hose creating difficulty when assembling the hose fittings. For textile
               reinforced hose, a guillotine style cutter may be used.
               5.3.4.3   Cleanliness

               Contaminated oil may reduce the service life of hydraulic systems. Therefore, hose cleanliness is an
               important part of the fabrication of a hydraulic hose assembly. If contamination is left in the hose after cutting,
               it is very likely that these particles will work their way into the hydraulic system. Always clean the hose after
               cutting.

               If a guillotine cutter is used with textile hose, it is unlikely that any particles exist. If a circular saw with a
               abrasive cutoff wheel is used, a significant amount of rubber and steel is forced into the end of the hose.
               Always run a brush into at least the first 6” (152.4 mm) of both ends of the hose, then blow out with shop air.
               Hose cut on an air or water cooled cutter may only require blowing out after cutting.

               Some customers may require flushing after cutting or crimping. Check customer requirements.
       5.3.5   Skiving or Buffing (As required)

       Some component manufacturers design the fitting in a manner that skiving or buffing is required.
               5.3.5.1   Skiving

               Skiving is the process of removing the portion of hose cover that lies directly under the coupling collar or
        ferrule. This allows the metal fitting shell to be coupled directly onto the hose reinforcement. Some fitting
        designs also may require a section of the tube to be removed before coupling.
        Use caution not to cut or burn the hose reinforcement. Burnt wire will appear blue. Review the hose and
        coupling manufacturer’s recommendations prior to performing this operation
        5.3.5.2   Buffing

        Buffing is also a process of removing rubber cover from the hose. Unlike skiving, the rubber would not be
        removed to the reinforcement, but to a specific diameter. This process could apply to either wire or textile
        reinforced hose.
        5.3.5.3   Cleaning

        When skiving or buffing applies, always blow or vacuum off the rubber particles created from this process.
5.3.6   Coupling Assembly (First end)
        5.3.6.1   Insertion Depth

        To determine the insertion depth of a hose coupling, first measure the distance from the bottom of the fitting
        to the end of the ferrule where the hose is to be inserted. Mark a line on the hose cover at the distance from
        the end of the hose that equals the insertion depth. This becomes a visual check to determine if the hose was
        fully bottomed in the fitting.
        5.3.6.2   Lubrication (As needed)

        It is sometimes difficult to insert a fitting into hydraulic hose. When this occurs, it is recommended that an
        SAE 10 W oil or other compatible lubricants be used to lubricate the hose.

        Never dip the end of the hose into a container of oil or use a squirt can. Instead, put a thick sponge or other
        soft material in the bottom of a small tray (anything large enough to handle all sizes of hose in the work area).
        Before inserting the coupling into the hose, push approximately 1/2" (12.7 mm) of the end of the hose into the
        sponge in the tray of lubricant.
        5.3.6.3   Verification of Fitting Bottoming

        After lubricating the hose, grip firmly and push into the fitting. Fittings with an elbow configuration should point
        toward the curvature of the hose, unless otherwise specified. If the insertion mark was applied correctly, you
        should now be able to determine if the coupling has been completely assembled. The depth mark will be
        aligned with the end of the ferrule.
5.3.7   Crimping (First end)

        5.3.7.1   Verification of Set Up (Tooling)

        The first step in verifying the tooling set up is to review the manufacturers’ recommendations. Read the set up
        chart and follow the instructions. If instructions are not available, consult your supervisor or contact the
        manufacturers of the hose, coupling and crimping equipment.

        Note: Some crimping equipment may be generic, but with tooling packages supplied or manufactured by the
        coupling supplier. In these instances, contact the coupling manufacturer for crimping recommendations.
        5.3.7.2   Verify Crimp Dimensions (First piece only)

        Insert the hose and fitting into the crimp machine, and perform the crimping operation as specified. Remove
        the crimped assembly and with the appropriate gauging tools, check the first part for proper crimp diameter
        and location. If the crimp diameter and location are correct, proceed to the next steps in assembly. It is
        recommended that a log of these crimp measurements be kept for future reference.
        If there is an error, verify tooling and set up. Make the needed adjustments and proceed. Any crimped part
        that cannot be brought within specification must be discarded.
5.3.8   External Accessories (As required)

Some applications require the addition of protective outer sleeving or strain reliefs. If this is a requirement, the most
appropriate time to assemble is before the second end fitting is applied. Choose the appropriate product for the specific
application. When cutting to length, allow for flexing and bending of the hose.
5.3.9   Crimping (Second end)

At this point, the second end should be ready for assembly and crimping. Follow instructions in 5.3.6 and 5.3.7. If the
second end fitting is also a bent tube configuration, orientate the coupling before the crimping operation. After the first part
       has been examined, and approved, proceed with the balance of the order. (See Section 5.6 - Hose Assembly Orientation)
       5.3.10     Final Assembly Inspection

       Some customers require a quality plan that has a final audit program. Even if the hose assemblies fabricated are not for
       such a customer, it is good business practice to examine (audit) the product before delivery to the customer. Records
       should be maintained per quality plan. An “audit” program is not 100% inspection. Assembly fabricators should work with
       customers to define the degree of inspection. (See Section 5.4 - Quality Plan)
                5.3.10.1   Inspection & Testing

                Visual inspection, dimensional inspection and proof pressure testing shall be in accordance with quality plan
                paragraphs 5.4.8.1, 5.4.8.2, and 5.4.8.3, respectively.
                5.3.10.2   Cleaning

                Air shall be blown through the assembly to remove the loose particles that may have contaminated the hose
                (plating chips, rubber dust, etc.). Some customers have stringent cleanliness requirements that may require
                flushing the assembly. Consult specific customer documents for requirements.
                5.3.10.3   Capping

                Closures or caps are designed to protect threads and to keep out contamination. Consult your customer for
                specific requirements. This also includes “over-the-counter” sales.
                5.3.10.4   Identification (Labeling and Marking)

                Some customers require specific markings be applied to the hose assemblies for identification purposes.
                Consult the customer for labeling and marking requirements.
                5.3.10.5   Packaging

                Unless otherwise specified by the customer, packaging should afford adequate protection during shipping.
                Packaging requirements will vary from handing a completed hose to a customer, to capping, bagging and bar
                coding. Individual customers will each have different requirements. What they all have in common is
                adequate protection until usage. Check with your customer for specific details.
       5.3.11     Shipping

       Check labeling to ensure all information is correct and ship in an appropriate manner.
5.4   Quality Plan

       5.4.1    Purpose

       The purpose of this section is to outline a quality plan for fabricating hose assemblies. The assurance of an acceptable
       hose assembly reaching the customer depends upon the quality of the components and the workmanship of the fabricator.
       5.4.2    Scope

       An effective quality control plan is based on statistical sampling principles. Responsibility for supervising the quality plan
       must be designated. Corrective action procedures must be formalized to deal with nonconformance.
       5.4.3    Sampling Plan

       An effective sampling plan is based on the statistical history of a design that demonstrates quality performance and sets
       confidence levels.
       Sampling is performed in an effort to statistically evaluate a product or process against tolerances that are considered
       acceptable as determined by national standards, customer requirements, etc. This monitoring of product or process with an
       adequate sampling plan is done in an effort to provide 100% acceptable product to the customer. In an ideal world, if
       inspection capability is 100% effective, then the only way to assure 100% acceptable product is to inspect everything
       100%. Due to practical considerations of time and resources (both manpower and financial), 100% inspection will probably
       not occur as a standard method of operation.

       Many areas or processes may be sampled. These may vary from operation to operation. However, some constants should
       apply no matter what the operation.
                A. Inspection of incoming material – You cannot guarantee the quality of the outgoing product, if the quality of
                incoming materials has not been verified.
                B. In process inspection – This may be as simple as inspection of the first assembly produced. Or it may be
                quite complicated, such as doing a complete dimensional audit on so many pieces per production run and
        plotting these results on Statistical Process Control (SPC) charts in order to track trends and potential
        problems.
        C. Final Inspection – This may be relatively simple, such as verifying piece counts before shipping to the
        customer, or as complicated as checking specific criteria to ensure compliance with the customer’s
        requirements.
Inspection characteristics, the corresponding documentation, and the personnel responsible must be defined, regardless of
what is being sampled.
When establishing the frequency of sampling, many factors need to be considered. These include but are not limited to:

        1. Cost
        2. Complexity of process

        3. Application
        4. Liability
        5. Stability of procedure

If a process is very stable as indicated by past performance, the frequency of sampling can be decreased.
There is no specific sampling plan that can be considered best suited to all applications.
5.4.4   Material Receiving Inspection

        5.4.4.1    Couplings

        Upon receipt of a shipment of couplings, the assembly fabricator should perform, at a minimum, the following
        inspection steps:

                a) Compare the couplings received with the purchase order by making sure part numbers agree
                between order and packing slip.

                b) Check the count between packing slip and actual quantity received.

                c) Check the product in the package to make sure it agrees with the part number on the
                package. Supplier catalogs are a good reference.

                d) When possible, leave the couplings in the original container with the original date code. If a
                coupling problem arises later, all the couplings of that size and date code can be separated out
                for 100% inspection purposes.
        5.4.4.2    Hose

        Upon the receipt of a shipment of hose, the assembly fabricator should perform, at a minimum, the following
        inspection steps:
                a) Check product numbers on the packing list with numbers on the packages of the actual
                merchandise.
                b) Check total footage against the packing slip, making sure they agree.
                c) Check the product, making sure it agrees with the label on the packaging.

                d) Check the hose inside diameter, outside diameter and reinforcement, and verify against the
                manufacturer’s product information.
5.4.5   Storage (Labeling, Environment, Time)

Proper storage will maximize hose shelf life.

        A. Store components in a cool, dry area. If stored below freezing, pre-warming may be required prior to
        handling, testing and placing into service.
        B. Store components in original date-coded containers.

        C. Care should be taken when stacking hose, as its weight can crush hose at the bottom of the stack. The
        stack could also become unstable, creating a safety hazard.
        D. Avoid exposure to direct sunlight, rain, heaters or proximity to electrical equipment.
5.4.6   Retrieval (Pulling Stock)

Keep inventory current. Use the oldest product first.
Check product numbers to ensure that the proper product is being used.
5.4.7   In-Process

Quality cannot be inspected into a finished product. Therefore, an in-process inspection procedure will insure the best
quality hose assembly.
        5.4.7.1   Hose Cutting

              a) Check that correct hose is being cut for the order being processed.

              b) Check for any cover imperfections.
              c) Cut must be square.

              d) Check the cut length of the hose to make sure it will produce the proper overall length of the
              required assembly.

              e) Check that foreign particles have been removed from hose bore.
        5.4.7.2   Hose Skiving or Buffing (When applicable)

              a) Check length of skive against proper specification.

              b) Check for burned, damaged or disoriented wires in the reinforcement caused by skiving tool
              or brush being set too close to hose. Overheated wires (blue in color) and frayed wires are not
              acceptable.

              c) On fiber braided hoses, the outside diameter of the buffed area must be measured against
              the specification. No fiber braid should be visible.
        5.4.7.3   Coupling Assembly

              a) Check that correct couplings are being used for the order being processed.

              b) Make sure couplings are pushed all the way on the hose (bottomed).

              c) Check that no skive shows and couplings are on straight.

              d) Verify coupling orientation.
        5.4.7.4   Crimping Hose Assemblies

              a) At the start of an order, verify crimped diameter against the proper specification furnished by
              manufacturer. The crimp diameter should be measured in the center of the ferrule between two
              opposite die faces using a micrometer or caliper.
              b) Check the first and last assembly of the order for proper crimp diameter and location, as well
              as periodically during the order.

              c) Visually check for cracked, cocked or damaged couplings.
        5.4.7.5   Cleaning and Packaging

              a) The inside bore of all hose assemblies shall be free of all cuttings, rubber dust, etc.
              b) Capping of assemblies is recommended.

              c) Assemblies will be packaged in such a manner as to prevent damage during shipment.
              d) Follow special customer packaging and labeling requirements.
5.4.8   Final Assembly Inspection

        5.4.8.1   Visual Inspection

        All sample assemblies should be visually inspected for substandard quality conditions in the hose or
        couplings. Visual inspection checkpoints should include but are not limited to the following:
              a) Hose Identification - Size and type must correspond to the fabrication order (work order).
               b) Coupling Identification - Coupling size, type, and product number must correspond to
               information on the fabrication order (work order) and specifications. Identified with date code,
               part number, etc. when required.

               c) Inspection Items -
                       Bulge behind the coupling.

                       Cocked couplings.
                       Cracked couplings .

                       Exposed reinforcement.
                       Freedom of swivels.
                       General appearance of the assembly.

                       Hose cover pricked if required.
                       Internal contaminants.

                       Protective caps or plugs.
                       Restriction in the tube.

                       Rusted couplings.
         5.4.8.2    Dimensional Inspection

               a) Length - Measure the length of a coupled assembly laid out on a flat surface. Unless
               otherwise shown on the fabrication order (work order), hose assembly length includes the
               couplings. Length tolerances on coupled assemblies are listed in Section 5.4.10.2 or in special
               customer specifications.
               b) Crimped Outside Diameter – With a micrometer or caliper, measure the diameter of the
               crimped ferrule, in the center between two opposite die faces.

               c) Coupling Orientation - Coupling orientation should be as specified on customer blueprints or
               fabrication order (work order). (See Section 5.6 - Coupling Orientation.)
         5.4.8.3    Physical Testing

         Coupled hose assembly lots should be sampled and tested utilizing an acceptable burst and proof pressure
         procedure. It is recommended that proof and burst testing be performed in accordance with SAE J517 and
         SAE J343, as shown below, or an applicable industry standard or customer specification.

               a) Proof Pressure Test – This proof test is conducted at twice the working pressure of the hose
               unless otherwise specified by the customer.

               The test pressure shall be maintained for a period of not less than 30 seconds or more than 60
               seconds. There shall be no indication of failure or leakage.

               b) Burst Test - Hose assemblies on which the end fittings have been attached less than 30 days
               shall be subjected to a hydrostatic pressure increased at a constant rate so as to attain the
               specified minimum burst pressure within a period of not less than 15 seconds nor more than 30
               seconds.

               There shall be no leakage, hose burst, or indication of failure below the specified minimum burst
               pressure.
5.4.9    Calibrations

Inspection and testing equipment used in the production or testing of coupled hose assemblies should be calibrated at
prescribed intervals according to written procedures. All gauging equipment shall be calibrated regularly by means
traceable to NIST (National Institute of Standards and Technology). The tag giving date of last calibration, next calibration
due date and signature of the inspector shall be attached to the gauge and a record filed for future reference.
5.4.10     Tolerances
         5.4.10.1    Orientation of Offset Elbow Ends

         Unless otherwise specified by the customer, a tolerance of ± 3 degrees is acceptable for assembly lengths up
               to and including 24” (609.6 mm), and ± 5 degrees for assembly lengths over 24” (609.6 mm). (See Section
               5.6 - Coupling Orientation.)
               5.4.10.2      Assembly Length

               Unless otherwise specified by the customer, assembly length shall be the overall assembly length measured
               from the extreme end of one fitting to the extreme end of the other; except for O-ring face seal fittings which
               shall be measured from the sealing face. Where elbow fittings are used, measurement shall be to the
               centerline of the sealing surface of the elbow end. The sealing surface of female flared elbow fittings shall be
               the centerline of the outer end of the cone seat. (See Section 5.7 - Overall Length Pictorial Views.)
      5.4.11     Documentation

      Inspection records should be maintained to verify product inspection, testing, and equipment calibration. Records are
      required for certification of quality, government orders, special orders or OEM customers. Inspection records should be
      retained a minimum of five years.
      5.4.12     Recommended Inspection Equipment

               A. Worktable suitable for inspection of hose assemblies.
               B. Linear measurement devices. (Tape measure).
               C. Direct reading jaw type calipers reading to .001” or .01 mm.

               D. Pi tape.

               E. Plug gauges for measuring hose inside diameter 1/8” through 4” (3.2 mm through 101.6 mm). (Dumb-bell
               Type or Telescoping).
               F. Protractor device for measuring angle of orientation between bent tube coupling ends.

               G. Magnifying glass.

               H. Light probe for viewing inside of assemblies.
               I. Burst and proof tester capable of 30,000 psi (207 Mpa).
5.5   SAE J517 Hose Working Pressures

Portions of the following table have been reprinted with Permission SAE Standard J517 Copyright, Society of Automotive Engineers, Inc.

  SAE                                                                       NOMINAL HOSE I.D.
 HOSE
 STYLE CONSTRUCTION                     1/8       3/16            1/4     5/16       3/8       13/32      1/2      5/8       3/4        7/8
 100R1           1 WIRE BR.                          3000         2750    2500        2250       2250     2000     1500       1250      1125

 100R2           2 WIRE BR.                          5000         5000    4250        4000                3500     2750       2250      2000

 100R3         2 FABRIC BR.                          1500         1250    1200        1125                1000       875          750
 100R4            SUCTION                                                                                                         300
 100R5      FABRIC COVER                             3000         3000    2250                   2000     1750     1500                  800
 100R6         1 FABRIC BR.                           500          400      400        400                 400       350          300
 100R7 THERMOPLASTIC                                 3000         2750    2500        2250                2000     1500       1250
 100R8 THERMOPLASTIC                                 5000         5000                4000                3500     2750       2250
 100R9            SP. WIRE                                                            4500                4000                3000
100R10            SP. WIRE                         10,000         8750                7500                6250                5000
100R11            SP. WIRE                         12,500     11,250                10,000                7500                6250
100R12            SP. WIRE                                                            4000                4000     4000       4000
100R13            SP. WIRE                                                                                                    5000
100R14             TEFLON               1500         1500         1500    1500        1500       1000      800       800          800    800
100R15           SP. WIRE                                                          6000             6000                 6000
100R16           WIRE BR.                                    5000     4250         4000             3500     2750        2250
             COMPACT WIRE
100R17                                                       3000     3000         3000             3000     3000        3000
                 BR.
100R18 THERMOPLASTIC                               3000      3000     3000         3000             3000     3000        3000
  SAE       -                                                             NOMINAL HOSE SIZE
 HOSE
 STYLE CONSTRUCTION                  1     1-1/8     1-1/4      1-3/8      1-1/2    1-13/16     2      2-3/8     2-1/2     3     4
 100R1          1 WIRE BR.          1000                  625                500                 375
 100R2          2 WIRE BR.          2000              1625                  1250                1125             1000
 100R3        2 FABRIC BR.           565                  375
 100R4           SUCTION             250                  200                150                 100                62      56   35
 100R5       FABRIC COVER                   625                     500                   350              350             200
 100R6        1 FABRIC BR.
 100R7 THERMOPLASTIC 1000
 100R8 THERMOPLASTIC 2000
 100R9           SP. WIRE           3000              2500                  2000                2000
100R10           SP. WIRE           4000              3000                  2500                2500
100R11           SP. WIRE           5000              3500                  3000                3000             2500
100R12           SP. WIRE           4000              3000                  2500                2500
100R13           SP. WIRE           5000              5000                  5000                5000
100R14            TEFLON             800    600
100R15           SP. WIRE           6000              6000                  6000
100R16           WIRE BR.           2000              1625
             COMPACT WIRE
100R17                              3000
                 BR.
100R18 THERMOPLASTIC 3000


5.6   Hose Assembly Orientation For Offset Elbow Fittings

      Figure 5.6.1. Offset Angles
How to Measure

The offset angle is determined by the number of degrees measured in a counter-clockwise direction between the fitting nearest the
viewer and the farthest end fitting.
Offset Angle Tolerances

± 3 degrees on lengths up to 24 inches (609.6 mm).
± 5 degrees on lengths 24 inches (609.6 mm) and longer
Figure 5.6.2. Far End Reference – Measured Clockwise




      As shown in Figure 5.6.2, with the centerline of the far end as a base reference, angular displacement is measured
       clockwise to the centerline of the near end.
Figure 5.6.3 Far End Reference – Measure Counter Clockwise




       As shown in Figure 5.6.3, with the centerline of the near end as a base reference, angular displacement is measured
       counterclockwise to the centerline of the far end.
5.7   Overall Length – Pictorial Views

Assembly Length Measurement
                                                            Tolerance    Tolerance          Tolerance
                           Assembly Length
                                                             ± inches     ± inches            ± mm
       Up through 12 inches (304.8 mm)                            0.13                1/8         3.2
       Over 12 through 18 inches (304.8 through 457.2 mm)         0.19               3/16         4.8
       Over 18 through 36 inches (457.2 through 914.4 mm)         0.25                1/4         6.4
       Over 36 inches (914.4 mm)                                   1%                 1%          1%

>> continue to Section 6
5.8   Flow Chart
>> continue to Section 6
Section 6 Industrial Hose

6.1 Scope

6.2 Selection Chart

6.3 Hose Data Sheets

      6.3.1 Air Hose
      6.3.2 Asphalt and Hot Tar Hose
      6.3.3 Chemical Hose -- Plastic Lined
      6.3.4 Chemical Hose -- Rubber Lined
      6.3.5 Food Handling Hose, Regulated
      6.3.6 Food Handling Hose -- Non-regulated
      6.3.7 Lay Flat Hose
      6.3.8 Material Handling Hose --Bulk Transfer
      6.3.9 Material Handling Hose -- High Pressure Cement Handling
      6.3.10 Petroleum -- Fuel Oil Hose
      6.3.11 Petroleum Drop Hose
      6.3.12 Petroleum Vapor Recovery Hose
      6.3.13 Petroleum Discharge Hose
      6.3.14 Petroleum Suction and Discharge Hose
      6.3.15 Push On Hose
      6.3.16 Sandblast Hose
      6.3.17 Steam Hose
      6.3.18 Water/Multi-Purpose Hose

6.4 Fitting Data Sheets

      6.4.1 Cam and Groove -- Metallic Only
      6.4.2 Universal Coupling (Chicago, Claw, Crowsfoot)
      6.4.3 Short Shank Machined Fittings
      6.4.4 Medium Shank Machined Fittings
      6.4.5 Long Shank Machined Fittings
      6.4.6 Cast Shank Fittings
      6.4.7 Interlocking
      6.4.8 Ground Joint Fittings
      6.4.9 Sanitary
      6.4.10 Sandblast
      6.4.11 Push-on
      6.4.12 Internal Expansion Stems
      6.4.13 Internal Expanded Short Brass

6.5 Attachment Data Sheets

      6.5.1   Clamp, Bolt
      6.5.2   Band & Buckles
      6.5.3   Crimp and Swage
      6.5.4   Clamp, Interlocking
      6.5.5   Internal Expansion Ferrule
      6.5.6   Clamp, Pinch
      6.5.7 Clamp, Preformed
      6.5.8 Internal Expansion Short Brass / Stainless Ferrule

6.6 General Fabrication Methods

      6.6.1   Overall Length (OAL)
      6.6.2   Hose Cut Length
      6.6.3   Hose Cutting
      6.6.4   How to Make the Assembly Static (Electrically) Conductive
      6.6.5   Coupling Insertion

6.7 Assembly Data Sheets

      6.7.1 Air Hose (soft wall) / Universal / Crimp
      6.7.2 Air Hose (soft wall) / Universals / Interlocking Clamp
      6.7.3 Air Hose (soft wall) / Universal / Preformed
      6.7.4 Air Hose (soft wall) / Machined, Short Shank / Crimp
      6.7.5 Air Hose (soft wall) / Machined, Short Shank / Pinch Clamp
      6.7.6 Air Hose (soft wall) / Machined, Short / Preformed
      6.7.7 Air Hose (soft wall) / Machined, Medium Shank / Pinch Clamp
      6.7.8 Air Hose (soft wall) / Machined, Medium / Preformed
      6.7.9 Air Hose (soft wall) / Machined, Medium Shank / Band & Buckle
      6.7.10 Air Hose (soft wall) / Machined, Long Shank / Pinch Clamp
      6.7.11 Air Hose (soft wall) / Machined, Long Shank / Preformed
      6.7.12 Air Hose (soft wall) / Machined, Long Stem / Band & Buckle
      6.7.13 Air Hose (soft wall) / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.14 Air Hose/ Interlocking Swage-Crimp / Crimp
      6.7.15 Air Hose/ Interlocking Swage-Crimp / Swaged
      6.7.16 Asphalt Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.17 Chemical, Plastic / Cam & Groove / Crimp
      6.7.18 Chemical Plastic / Cam & Groove / Swaged
      6.7.19 Chemical Plastic / Cam & Groove / Preformed
      6.7.20 Chemical Plastic / Cam & Groove / Band & Buckle
      6.7.21 Chemical Plastic / Interlocking Crimp-Swage / Crimp
      6.7.22 Chemical Plastic / Interlocking Swage-Crimp / Swaged
      6.7.23 Chemical, Plastic / Machined, Medium Shank / Preformed
      6.7.24 Chemical Plastic / Machined, Medium Shank / Band & Buckle
      6.7.25 Chemical, Plastic / Machined, Long Shank / Preformed
      6.7.26 Chemical Plastic / Machined Shank, Long / Band & Buckle
      6.7.27 Chemical Rubber / Cam & Groove / Crimp
      6.7.28 Chemical Rubber / Cam & Groove / Swaged
      6.7.29 Chemical Rubber / Cam & Groove / Preformed Banded
      6.7.30 Chemical Rubber / Cam & Groove / Band & Buckle
      6.7.31 Chemical Rubber / Interlocking Crimp-Swage / Crimp
      6.7.32 Chemical Rubber / Interlocking Crimp-Swage / Swaged
      6.7.33 Chemical Rubber / Machined, Medium Shank / Preformed
      6.7.34 Chemical Rubber / Machined, Medium Shank / Band & Buckle
      6.7.35 Chemical Rubber / Machined, Long Shank / Preformed
      6.7.36 Chemical Rubber / Machined, Long Shank / Band & Buckle
      6.7.37 Chemical Rubber / Internal Expanded Stem / Internal Expanded Ferrule
6.7.38 Food Grade, Regulated / Sanitary / Internal Expanded
6.7.39 Food Grade, Unregulated / Cam & Groove / Crimp
6.7.40 Food Grade Unregulated / Cam & Groove / Swage
6.7.41 Food Grade Unregulated / Cam & Groove / Preformed
6.7.42 Food Grade Unregulated / Cam & Groove / Band & Buckle
6.7.43 Food Grade Unregulated / Machined, Medium Shank / Preformed
6.7.44 Food Grade Unregulated / Machined, Medium Shank / Band & Buckle
6.7.45 Food Grade Unregulated / Interlocking Crimp-Swage / Crimp
6.7.46 Food Grade Unregulated / Interlocking Crimp-Swage / Swage
6.7.47 Food Unregulated / Internal Expansion Stem / Internal Expansion Ferrule
6.7.48 Lay Flat / Cam & Groove / Crimp
6.7.49 Lay Flat / Cam & Groove / Preformed
6.7.50 Lay Flat or Mill / Machined, Medium Shank / Preformed
6.7.51 Lay Flat / Machined. Long Shank / Preformed
6.7.52 Lay Flat / Cast / Preformed
6.7.53 Material Handling/Cam & Groove/Crimp
6.7.54 Material Handling / Cam & Groove / Swaged
6.7.55 Material Handling / Cam & Groove / Preformed
6.7.56 Material Handling / Cam & Groove / Band & Buckle
6.7.57 Material Handling (soft wall only) / Machined, Medium Shank / Bolt Clamp
6.7.58 Material Handling / Machined, Medium Shank / Preformed
6.7.59 Material Handling / Machined, Medium Shank / Band & Buckle
6.7.60 Material Handling (soft wall only) / Machined, Long Shank / Bolt Clamp
6.7.61 Material Handling / Machined, Long Shank / Preformed
6.7.62 Material Handling / Machined, Long Shank / Band & Buckle
6.7.63 Material Handling (soft wall only) / Cast / Bolt Clamp
6.7.64 Material Handling / Cast / Preformed
6.7.65 Material Handling / Cast / Band & Buckle
6.7.66 Material Handling / Interlocking Crimp-Swage / Crimp
6.7.67 Material Handling / Interlocking Crimp-Swage / Swage
6.7.68 Material Handling / Internal Expanded Stem / Internal Expanded Ferrule
6.7.69 Material Handling Cement / Interlocking Crimp-Swage / Crimp
6.7.70 Material Handling Cement / Interlocking Crimp-Swage / Swage
6.7.71 Material Handling, Cement / Ground Joint or Interlocking Male Stem /Interlocking Clamp
6.7.72 Material Handling, Cement / Internal Expanded Stem/ Internal Expanded Ferrule
6.7.73 Petroleum Transfer /Cam & Groove / Crimp
6.7.74 Petroleum Transfer / Cam & Groove / Swaged
6.7.75 Petroleum Transfer / Cam & Groove / Preformed
6.7.76 Petroleum Transfer / Cam & Groove / Band & Buckle
6.7.77 Petroleum Transfer / Machined, Medium Shank / Preformed
6.7.78 Petroleum Transfer / Machined, Medium Shank / Band & Buckle
6.7.79 Petroleum Transfer / Machined, Long Shank / Preformed
6.7.80 Petroleum Transfer / Machined, Long Shank / Band & Buckle
6.7.81 Petroleum Transfer / Interlocking Crimp-Swage / Crimp
6.7.82 Petroleum Transfer / Interlocking Crimp-Swage / Swaged
6.7.83 Petroleum Transfer / Internal Expanded Stem/ Internal Expanded Ferrule
6.7.84 Petroleum Transfer / Internal Expanded Short Brass / Internal Expansion Short Brass or
Stainless Ferrule
6.7.85 Push On / Push On
      6.7.86 Sand Blast / Sand Blast
      6.7.87 Steam Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.88 Water Hose / Cam & Groove / Crimp
      6.7.89 Water Hose / Cam & Groove / Swaged
      6.7.90 Water Hose / Cam & Groove / Preformed
      6.7.91 Water Hose / Cam & Groove / Band & Buckle
      6.7.92 Water Hose / Universals / Preformed
      6.7.93 Water Hose / Universals / Interlocking Clamp
      6.7.94 Water Hose / Machined, Short Shank / Crimp
      6.7.95 Water Hose / Machined, Short Shank / Preformed
      6.7.96 Water Hose / Machined, Short Shank / Clamp, Pinch
      6.7.97 Water Hose (soft wall only) / Machined, Medium Shank / Bolt Clamp
      6.7.98 Water Hose / Machined, Medium Shank / Preformed
      6.7.99 Water Hose / Machined, Medium Shank / Pinch Clamp
      6.7.100 Water Hose (soft wall only) / Machined, Long Shank / Bolt Clamp
      6.7.101 Water Hose / Machined, Long Shank / Preformed
      6.7.102 Water Hose (soft wall only) / Cast / Bolt Clamp
      6.7.103 Water Hose / Cast / Preformed
      6.7.104 Water Hose / Cast / Band & Buckle
      6.7.105 Water Hose / Interlocking Crimp-Swage / Crimp
      6.7.106 Water Hose / Interlocking Crimp-Swage / Swaged
      6.7.107 Water Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

6.8 Pressure Ratings Chart
Section 6 Industrial Hose - 6.1 to 6.3

6.1 Scope

6.2 Selection Chart

6.3 Hose Data Sheets

        6.3.1 Air Hose
        6.3.2 Asphalt and Hot Tar Hose
        6.3.3 Chemical Hose -- Plastic Lined
        6.3.4 Chemical Hose -- Rubber Lined
        6.3.5 Food Handling Hose, Regulated
        6.3.6 Food Handling Hose -- Non-regulated
        6.3.7 Lay Flat Hose
        6.3.8 Material Handling Hose --Bulk Transfer
        6.3.9 Material Handling Hose -- High Pressure Cement Handling
        6.3.10 Petroleum -- Fuel Oil Hose
        6.3.11 Petroleum Drop Hose
        6.3.12 Petroleum Vapor Recovery Hose
        6.3.13 Petroleum Discharge Hose
        6.3.14 Petroleum Suction and Discharge Hose
        6.3.15 Push On Hose
        6.3.16 Sandblast Hose
        6.3.17 Steam Hose
        6.3.18 Water/Multi-Purpose Hose
>> continue to next section

6.1   Scope

The sections pertaining to industrial hose assemblies has been compiled to provide authoritative information on
assembly applications; hose, coupling and attachment selection; procedures to fabricate the assembly. This
information is intended to help those that are responsible for making assemblies as well as those responsible
for selecting the components.

The user of this document is cautioned that the information contained herein is for general guidance only. The
document reflects the most commonly used equipment and procedures to make assemblies. It does not reflect
new developments. The user is encouraged to contact the manufacturers of products in order to obtain the
latest information.
Note:

Because there are many combinations of hose, coupling and attachment methods, the user should not assume
that all combinations listed in the guide have been tested for acceptability. The information that is provided is
based on an environment of +72°F (+22.2°C). The reader is cautioned to contact the component manufacturers
when dealing with temperature extremes.

The industrial hose sections are designed to guide the user through selection of the components, fabrication of
the assembly and verification that the assembly will meet the application requirements.
6.2   Selection Chart - The Attachment Method based on Fitting Type and Hose type
                          Chart I                                        Chart II
       Fitting Types:                            Fitting Types:
            q Cam and Grove                           q Interlocking Swage/Crimp
            q Universal-Chicago, Crowsfoot, Claw      q Ground Joint
            q Machined-Short Shank                    q Sanitary
            q Machined-Medium Shank                   q Sandblast
            q Machined-Long Shank                     q Push-on
            q Cast Shank-Pin Lug Water Hose           q Internal Expansion
               Cplg, Suction Cplg, Shank Cplg         q Internal Expansion Short Brass Cplg


6.3   Hose Data Sheets

      6.3.1   Air Hose

      General Uses:

      There are typically three categories of air hose: oil resistant, non-oil resistant, and
      non-conductive. The lower pressure hoses are generally used for applications such as air guns,
      service stations, industrial air lines in plants, and many other air services. High pressure air hoses
      which are considered to be hoses with working pressures above 300 psi (2069 kPa) are generally
      used in construction and mining where large volumes of air service are required. The
      non-conductive air hose is specifically made to meet one megohm resistance per inch when 1000
      volts DC is applied.
      Limitations:

      Hoses that are non-oil resistant rubber should not be used in an oil environment. The
      non-conductive hoses have an electrical resistance of one megohm per inch when subjected to
      1000 volts DC. Consult hose manufacturer for recommendations. Air hoses with a helical wire will
      reduce the working pressure of the assembly, consult manufacturer for assembly
      recommendations.
      Warnings:

      Do not use non-oil resistant hoses in an oil environment. Non-conductive hoses should be used in
      high voltage areas. Use extreme caution with high pressure air applications.

      Refer to Selection Chart for fitting and attachment recommendations:

      6.3.2   Asphalt and Hot Tar Hose
      General Uses:

      This hose is designed for the bulk transfer and delivery of hot petroleum products, such as tar,
      asphalt, and oil. This hose is generally designed for suction and discharge. Consult hose
      manufacturer for vacuum rating.
      Limitations:

      Generally, the hoses are recommended for a maximum of +350° (+176.66°C) service. Consult
      hose manufacturer for specific temperature ratings.
      Warnings:

      Consult the hose, coupling, and/or attachment manufacturer if the application temperature is
      above +350°F (+176.66°C).
Refer to Selection Chart for fitting and attachment recommendations.

6.3.3   Chemical Hose – Plastic Lined
General Uses:

This section covers Chemical hoses manufactured from plastic liners such as Cross-Linked
Polyethylene (XLPE) or Ultra-High Molecular Weight Polyethylene (UHMWPE). Chemical hose
should be inspected, tested and maintained per the guidelines of RMA/IP-11-7.
Limitations:

The hose and couplings selected for use must be compatible with the chemical(s) to be conveyed
under the stated service conditions. Refer to RMA Hose Handbook, Chapter 8, “Chemical
Recommendations”, for general information and/or consult with your hose and coupling suppliers
for specific product recommendations.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.4   Chemical Hose – Rubber Lined
General Uses:

This section covers Chemical hoses manufactured from various types of thermoset rubber
polymers such as Natural Rubber (NR), Chlorosulfonated Polyethylene Rubber (CSM), and
Fluorocarbon Rubber (FKM). Chemical hose should be inspected, tested and maintained per the
guidelines of RMA/IP-11-7.
Limitations:

The hose and couplings selected for use must be compatible with the chemical(s) to be conveyed
under the stated service conditions. Refer to RMA Hose Handbook - Chapter 8 - Chemical
Recommendations for general information and/or consult with your hose and coupling suppliers
for specific product recommendations.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.5   Food Handling Hose, Regulated
General Uses:

These requirements cover hose assemblies designed to convey food products – dry foods, liquid
foods and fatty foods. The governing specifications are controlled by the FDA, 3A, NSF, and
USDA. This application covers sizes up to and including nominal inside diameter of 6 inches
(152.4 mm). There are four classes of hose in the 3A standard. These include:

        Class 1 – +300ºF (+148.8°C)

        Class 2 – +250ºF (+121.11°C)

        Class 3 – +120ºF (+48.88°C)

        Class 4 – +100ºF (+37.77°C)

This standard would also encompass hose assemblies addressed by other agencies such as
NSF, which cover hot food oil hose that is used at +300ºF (+148.88°C) and intermittent to +350ºF
(+176.66°C).
Refer to Selection Chart for fitting and attachment recommendations.

6.3.6   Food Handling Hose – Non-regulated
General Uses:

These requirements cover hose assemblies designed to convey food products – dry foods, liquid
foods and fatty foods. This application covers sizes up to and including nominal inside diameter 6
inches (152.4 mm).
Limitations:

The type of food hose is dependent upon the application. Contact the hose supplier to determine
the type of hose needed for the application.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.7   Lay Flat Hose
General Uses:

This section covers General Purpose Lay Flat hose, i.e. hose that when empty, may be rolled
onto itself, providing a neat compact package. Hoses of this type may be manufactured using
various types of thermoplastics and or thermoset rubber polymers that provide some minor
degree of oil resistance. However, they are not intended for use as a fuel delivery hose.

Polymers that may be used are, but not limited to, Polyvinyl Chloride, Natural Rubber, (NR),
Styrene Butadiene Rubber, (SBR), Acrylonitrile Butadiene Rubber, (NBR), or Ethylene Propylene
Diene Monomer, (EPDM), alone or in combination. Hoses of this type normally consist of a tube,
a layer of reinforcement, and a cover.

Hoses of this type are normally used as discharge hoses in construction, agriculture, mining and
marine industries. It is used to transport water or water based material from point of supply to
point of discharge. This includes but not limited to, sump or bilge drainage, stock pond water,
flood drainage, process water, etc.
Limitations:

Lay Flat hoses must not be connected to the suction side of a pump system. General Purpose
Lay Flat hoses are NOT intended to be used to transport water intended for human consumption,
nor should they be used to transport steam or super hot water, such as a condensate collection
line, above +140ºF (+60°C). GP Lay Flat hoses should not be used to transport oil or
solvent-based liquids and should not be used to transport materials at temperatures below –20°F
(-28.88)°C.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.8   Material Handling Hose – Bulk Transfer
General Uses:

This section covers hoses intended to convey products such as dust, limestone, wood chips,
ores, coal, sand, gravel, grains, ground slate, asphalt roofing chips, metal shavings, flour, fish or
shells, and/or slurries by means of suction, gravity feed, or pneumatic conveyance. Most products
contain a means for static charge dissipation by incorporating a ground wire(s) in the hose wall
and/or the use of a static-conducting black rubber in the tube.
Limitations:
The hose and couplings selected for use must be compatible with the product(s) to be conveyed
under the stated service conditions. For example, use a black static conductive SBR tube for
extremely abrasive materials. Use a black static conductive CR tube for oil and abrasion
resistance, and a white Food Grade CR tube for conveyance of oily foods. The thickness of the
tubes may vary from 1/16 inch (3.17 mm) to 1/2 inch (12.7 mm) depending on the severity of wear
and service life expected.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.9    Material Handling Hose – High Pressure Cement Handling
General Uses:

This Hose is intended for use in plaster, grout, shotcrete and cement applications, handling a
multitude of materials being pumped to concrete structures, tunnel faces, swimming pools, etc. at
pressures from 700 to 1000 psi (4826 kPa to 6890 kPa). For use as a flexible connection between
pumping equipment and hard piping or as discharge hose on the delivery end of high pressure
concrete pumps
Limitations:

Typical operating temperature is –25ºF (-32ºC) to +150ºF (65ºC) in sizes 1 to 6 inches (25.4 to
152.4 mm).

Refer to Selection Chart for fitting and attachment recommendations.

6.3.10    Petroleum – Fuel Oil Hose
General Uses:

This hose should be used for transfer of fuel oil and other petroleum based products in home
delivery, commercial and industrial service.
Limitations:

This hose is designed for fuel oil service. If the hose is used for transferring non-petroleum based
materials, then consult the hose manufacturer for chemical compatibility of the transferred
material with the hose tube.

Hose usually ranges in inside diameters of 1 to 1½ inches (25.4 mm to 38.1 mm). The normal
application temperature range is -20ºF (-29ºC) to +180ºF (+82ºC).

Hose is NOT to be used in a vacuum application.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.11    Petroleum Drop Hose
General Uses:

This hose should be used for transfer of gasoline and other petroleum based products under
pressure, gravity flow or suction.
Limitations:

This hose is designed for petroleum based products. If the hose is used for transferring
non-petroleum based materials, then consult the hose manufacturer for chemical compatibility of
the transferred material with the hose tube.
Hose is usually designed for a maximum of 150 psi (1034.24 kPa) working pressure.

Hose can be used in a vacuum if the hose is constructed with a helical wire or reinforcement that
will support a vacuum.

Hose usually ranges in inside diameters of 1 to 6 inches (25.4 mm to 152.4 mm). The normal
application temperature range is -20ºF to +180ºF (-29ºC to +82ºC).

Refer to Selection Chart for fitting and attachment recommendations.

6.3.12   Petroleum Vapor Recovery Hose
General Uses:

This hose is used for recovering gasoline vapors in tank truck loading at bulk terminals and in
tank truck unloading at service stations.
Limitations:

This hose is designed for petroleum based products. If the hose is used for transferring
non-petroleum based materials, then consult the hose manufacturer for chemical compatibility of
the transferred material with the hose tube.

Hose usually ranges in inside diameters of 2 to 4 inches (50.8 mm to 101.6 mm). The normal
application temperature range is -20ºF (-29ºC) to +180ºF (+82ºC).
Warnings:

Hose is for VAPOR RECOVERY ONLY!

Refer to Selection Chart for fitting and attachment recommendations.

6.3.13   Petroleum Discharge Hose
General Uses:

This hose should be used for transfer of gasoline and other petroleum based products under
pressure or gravity flow.
Limitations:

This hose is designed for petroleum based products. If the hose is used for transferring
non-petroleum based materials, then consult the hose manufacturer for chemical compatibility of
the transferred material with the hose tube.

Hose is usually designed for a maximum of 150 psi (1034.24 kPa) working pressure. Hose should
NOT be used in a vacuum application.

Hose usually ranges in inside diameters of 1 to 6 inches (25.4 to 152.4 mm). The normal
application temperature range is -20ºF (-29ºC) to +180ºF (+82ºC).

Refer to Selection Chart for fitting and attachment recommendations.

6.3.14   Petroleum Suction and Discharge Hose
General Uses:

This hose should be used for transfer of gasoline and other petroleum based products under
pressure, gravity flow or suction.
Limitations:

This hose is designed for petroleum based products. If the hose is used for transferring
non-petroleum based materials, then consult the hose manufacturer for chemical compatibility of
the transferred material with the hose tube.

Hose is usually designed for a maximum of 150 psi (1034.24 kPa) working pressure.

Hose can be used in a vacuum application, if the hose is constructed with a helical wire or
reinforcement that will support a vacuum.

Hose usually ranges in inside diameters of 1 to 6 inches(25.4 to 152.4 mm). The normal
application temperature range is -20ºF (-29°C) to +180ºF (+82 °C).

Refer to Selection Chart for fitting and attachment recommendations.

6.3.15   Push On Hose
General Uses:

These hoses are typically used for air tools, to convey water, mild chemicals, and various
petroleum products. These hoses are generally used for air applications up to a maximum of 350
psi (2413.25 kPa). The size range is typically ¼ inch (6.35 mm) to 1 inch (25.4 mm).
Limitations:

These hoses are used with push on couplings. Service temperature range is normally -40°F (4°C)
to +212°F (+100°C), but check with the hose manufacture for temperatures above +120°F
(+49°C) and compatibility with various chemicals.
Warnings:

Due to the risk of tube damage, external clamp should never be used in combination with push on
style fittings.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.16   Sandblast Hose
General Uses:

This hose is designed for sandblasting of metal castings, steel, stone, and cement - wherever
abrasive materials are carried at a high velocity.
Limitations:

Hose is designed with materials that do not have a high temperature rating. The usual
temperature range is -40ºF (4.0°C) to +160ºF (+71.1°C). This hose requires special couplings for
the application.
Warnings:

This hose requires special couplings for the application. Sandblasting hoses do not have a long
service life due to extreme application. Hoses should be inspected periodically to insure integrity
of the assembly.

Refer to Selection Chart for fitting and attachment recommendations.

6.3.17   Steam Hose
      General Uses:

      The transport of pressurized saturated steam, pressurized super-heated steam, or pressurized
      hot water from point of supply to point of use.
      Limitations:

      Steam hoses must not be used for service above their rated working pressures or temperatures.

      Steam hoses should not be used to transport any material other than those listed in the General
      Use section above. Steam or hot water contaminated with hydrocarbons or chemicals may
      shorten service life.

      These hoses are NOT intended to connect a steam supply point and a pressurized steam vessel
      or autoclave.

      Refer to Selection Chart for fitting and attachment recommendations.

      6.3.18   Water/Multi-Purpose Hose
      General Uses:

      There are typically two categories of water hose: multiple purpose, which is oil resistant, and
      general purpose, which is non-oil resistant.

      The lower pressure hoses are generally used to transport water, petroleum based fluids, or water
      based materials from point of supply to point of use.

      High pressure water hoses which are considered to be hoses with working pressures above 300
      psi (2069 kPa) are generally used in construction and mining where large volume or high
      pressure water service is required.
      Limitations:

      Hoses used to transport hot water MUST NOT be used to transport pressurized steam. General
      and Multiple purpose hoses are NOT intended to transport water for human consumption. Hoses
      that are constructed of non-oil resistant rubber should not be used in oil environments. Water
      hoses with a helical wire will reduce the working pressure of the assembly, consult manufacturer
      for assembly recommendations.
      Warnings:

      Do not use non-oil resistant hoses in an oil environment. Use extreme caution with high pressure
      water applications.

      Refer to Selection Chart for fitting and attachment recommendations.

>> continue to next Section
Section 6 Industrial Hose - 6.4 to 6.6

6.4 Fitting Data Sheets

       6.4.1 Cam and Groove -- Metallic Only
       6.4.2 Universal Coupling (Chicago, Claw, Crowsfoot)
       6.4.3 Short Shank Machined Fittings
       6.4.4 Medium Shank Machined Fittings
       6.4.5 Long Shank Machined Fittings
       6.4.6 Cast Shank Fittings
       6.4.7 Interlocking
       6.4.8 Ground Joint Fittings
       6.4.9 Sanitary
       6.4.10 Sandblast
       6.4.11 Push-on
       6.4.12 Internal Expansion Stems
       6.4.13 Internal Expanded Short Brass

6.5 Attachment Data Sheets

       6.5.1   Clamp, Bolt
       6.5.2   Band & Buckles
       6.5.3   Crimp and Swage
       6.5.4   Clamp, Interlocking
       6.5.5   Internal Expansion Ferrule
       6.5.6   Clamp, Pinch
       6.5.7   Clamp, Preformed
       6.5.8   Internal Expansion Short Brass / Stainless Ferrule

6.6 General Fabrication Methods

       6.6.1   Overall Length (OAL)
       6.6.2   Hose Cut Length
       6.6.3   Hose Cutting
       6.6.4   How to Make the Assembly Static (Electrically) Conductive
       6.6.5   Coupling Insertion

>> continue to next section

6.4   Fitting Data Sheets

       6.4.1    Cam and Groove – Metallic Only




                              Old Designs
                                New Designs
General Uses:

Cam and Groove couplers and adapters are used as a means of coupling hose assemblies to connect hose to
hose or hose to pipe manifold for the purpose of transferring liquids or dry bulk products.

Cam and Groove couplings are available in both locking and non-locking designs.
Limitations:

Care must be used to select a body material, arm material and gasket material that is compatible with the
material being transferred through the coupling. Contact coupler manufacturer for more information.
Shanks to old Standard MIL-C-27487 with large serrations are not designed to be attached with a ferrule or
sleeve. Damage to the tube can result if they are swaged or crimped. A shank that is specifically designed for
swaging or crimping is recommended if the assembly is to be swaged or crimped. For maximum coupling
retention, an interlocking collar must be used.
Cam and Groove fittings are interchangeable among manufacturers, with the exception of ½ inch (12.7 mm), 5
inch (127 mm) or 8 inch (203.2 mm), which may not be interchangeable. Contact coupling manufacturer for
interchange information.
Pressure ratings of cam and groove fittings vary from manufacturer to manufacturer. Be sure to select a Cam and
Groove fitting that will meet the application requirements.
Warnings:

Cam and Groove couplings must never be used for steam service.
When replacement of cam arms is necessary, use only original manufacturer’s replacement arms.

Refer to Selection Chart for hose and attachment recommendations.

6.4.2   Universal Coupling (Chicago, Claw, Crowsfoot)




General Uses:

This fitting is designed for air and water service and provides a quick connection between two lengths of hose; or
length of hose and a male or female NPT outlet. In sizes ¼ inch (6.35 mm) to 1 inch (25.4 mm), all heads are the
same and are interchangeable regardless of the hose shank or NPT thread size. Connections made by pressing
the two heads together and applying a quarter-turn. The locking pin is placed in the holes to provide a safe
connection.
Limitations:

The universal fittings have a maximum pressure rating of 110 psi (758.45 kPa).
Warnings:

Safety pins, clips or wires should always be installed in couplings. The universal fitting should never be used for
steam service.

Refer to Selection Chart for hose and attachment recommendations.

6.4.3   Short Shank Machined Fittings




General Uses:

Low-pressure fluid transfer, suction, and discharge. Fitting styles include brass inserts, barbed quick disconnects,
single bump nipples and small bore barbed inserts of other metallic materials.
Limitations:

A. Pressure ratings only apply to non-toxic and non-combustible fluids; careful consideration must be given to
dangerous or volatile fluids. (Ref. Section 6.7 - Assembly Data Sheets)

B. Unusual ends other than NPT threaded parts may also effect pressure ratings, consult manufacturers of those
connections and/or accessories for pressure ratings.
C. The following pressure tables apply to fittings made with the outside diameter of the serrations 1/16 inch (1.59
mm) larger than the nominal hose size with a tolerance of ±1/32 inch (.79 mm). Minimum shank lengths are as
specified in the table. Parts shall have multiple serrations. (Ref. Section 6.7 - Assembly Data Sheets)

D. The pressure tables also apply to fittings with a single large bump; the bump being 3/32" (2.38 mm) larger than
the nominal hose size, with a tolerance of ±1/32" (.79 mm). The area behind the bump shall be sized in diameter
to the nominal size of the hose ±1/32" (.79 mm) and shall be wide enough to permit at least a 3/4" (19 mm) wide
band clamp. Shank lengths and serration depths as specified in the table do not apply to this style.

E. Materials used in the manufacture of these fittings shall be pipe or other solid billet. Pipe used shall be
intended for pressure applications, shall be hydrostatically tested and certified. Recommended pipe materials
include: steel pipe to ASTM A53 or better, stainless pipe to ASTM A312 or better, brass pipe to ASTM B43 or
better, and aluminum pipe to ASTM B243 or better.

 Nominal Size               Shank Length

 1/4" (6.35 mm)             15/16" (23.8 mm)

 3/8" (9.53 mm)             15/16" (23.8 mm)

 1/2" (12.7 mm)             15/16" (23.8 mm)

 5/8" (15.9 mm)             15/16" (23.8 mm)

 3/4" (19 mm)               15/16" (23.8 mm)

 1" (25.4 mm)               1-1/4" (31.8 mm)

Refer to Selection Chart for hose and attachment recommendations.
6.4.4    Medium Shank Machined Fittings




General Uses:

Low pressure fluid transfer, suction, and discharge. Fitting styles include: combination nipples, double bump
(grooved) nipples, menders, turned back nipples and Bowes & Thor style.
Limitations:

A. Pressure ratings only apply to non-toxic and non-combustible liquids; careful consideration must be given to
dangerous or volatile liquids. (Ref. Section 6.7 - Assembly Data Sheets)

B. Unusual ends other than NPT threaded parts may also effect pressure ratings, consult manufacturers of those
connections and/or accessories for pressure ratings. Other suitable ends include grooved, turned back lapped
joint style, British threaded, or other threads.
C. The pressure tables apply to fittings made with the outside diameter of the serrations 1/32 inch (.79 mm) larger
than the nominal hose size with a tolerance of ±1/32 inch (.79 mm). Serration tips shall have a radius not
exceeding .015 inch (.38 mm). All shanks shall be machined with multiple serrations or grooves. Minimum shank
lengths and serration depths are as specified in the table. (Ref. Section 6.7 - Assembly Data Sheets)

D. The pressure tables also apply to fittings with a minimum of 2 large bumps, each bump being 3/32 inch (2.38
mm) larger than the nominal hose size with a tolerance of ±1/32 (.79 mm). The areas between the large bumps
shall be sized in diameter to the nominal size of the hose ±1/32 inch (.79 mm) and shall be wide enough to permit
at least a 3/4 inch (19 mm) wide band clamp each. Shank lengths and serration depths as specified in the table
do not apply to this style. (Ref. Section 6.7 - Assembly Data Sheets)

E. Materials used in the manufacture of these fittings shall be pipe or other solid billet. Pipe used shall be
intended for pressure applications, shall be hydrostatically tested and certified. Recommended pipe materials
include: steel pipe to ASTM A53 or better, stainless pipe to ASTM A312 or better, brass pipe to ASTM B43 or
better, and aluminum pipe to ASTM B243 or better.

        Nominal Size          Shank Length                 Depth
 1/4" (6.35 mm)          1-3/8" (34.9 mm)          .025" (.64 mm)
 3/8" (9.53 mm)          1-3/8" (34.9 mm)          .025" (.64 mm)
 1/2" (12.7 mm)          1-3/8" (34.9 mm)          .030" (.76 mm)
 5/8" (15.9 mm)          1-3/8" (34.9 mm)          .030" (.76 mm)
 3/4" (19 mm)            1-3/8" (34.9 mm)          .030" (.76 mm)
 1" (25.4 mm)            1-3/8" (34.9 mm)          .030" (.76 mm)
 1-1/4" (31.8 mm)        1-11/16" (42.9 mm)        .035" (.89 mm)
 1-1/2" (38.1 mm)        1-11/16" (42.9 mm)        .035" (.89 mm)
 2" (50.8 mm)            2-1/4" (57.2 mm)          .045" (1.14 mm)
 2-1/2" (63.5 mm)        2-7/16" (61.9 mm)         .045" (1.14 mm)
 3" (76.2 mm)            2-7/8" (73 mm)            .045" (1.14 mm)
 4" (102 mm)             3-11/16" (93.7 mm)        .045" (1.14 mm)
 5" (127 mm)             4-13/16" (122 mm)         .055" (1.4 mm)
 6" (152 mm)             6" (152 mm)               .055" (1.4 mm)
 8" (203 mm)             7" (178 mm)               .055" (1.4 mm)

Refer to Selection Chart for hose and attachment recommendations.

6.4.5   Long Shank Machined Fittings




General Uses:

Low pressure fluid transfer, suction, and discharge. Fitting styles include: long shank combination nipples and
long shank menders.
Limitations:

A. Pressure ratings only apply to non-toxic and non-combustible liquids; careful consideration must be given to
dangerous or volatile liquids. (Ref. Section 6.7 - Assembly Data Sheets)

B. Unusual ends other than NPT threaded parts may also effect pressure ratings, consult manufacturers of those
connections and/or accessories for pressure ratings. Other suitable ends include grooved, turned back lapped
joint style, British threaded, or other threads.
C. The following pressure tables apply to fittings made with the outside diameter of the serrations 1/32 inch (.79
mm) larger than the nominal hose size with a tolerance of ±1/32 inch (.79 mm). Serration tips shall have a radius
not exceeding .015 inch (.38 mm). All shanks shall be machined with multiple serrations. Minimum shank lengths
and serration depths are as specified in the table. (Ref. Section 6.7 - Assembly Data Sheets)

D. Materials used in the manufacture of these fittings shall be pipe or other solid billet. Pipe used shall be
intended for pressure applications, shall be hydrostatically tested and certified. Recommended pipe materials
include: steel pipe to ASTM A53 or better, stainless pipe to ASTM A312 or better, brass pipe to ASTM B43 or
better, and aluminum pipe to ASTM B243 or better.

Refer to Selection Chart for hose and attachment recommendations.

6.4.6   Cast Shank Fittings
General Uses:

Low pressure liquid transfer, suction, and discharge. Fitting styles include: shank couplings, suction couplings,
pin lug couplings, garden hose couplings, and other shank fittings not meeting the specific requirements of the
other categories. This category does not include cam & Groove, ground joint or universal fittings.
Limitations:

A. Pressure ratings only apply to non-toxic and non-combustible liquids; careful consideration must be given to
dangerous or volatile liquids. (Ref. Section 6.7 - Assembly Data Sheets)

B. Unusual ends other than NPT, NPSM or NPSH threaded parts may also effect pressure ratings, consult
manufacturers of those connections and/or accessories for pressure ratings. This section may also apply to
menders or other shank style fittings not meeting the criteria for machined shank fittings as stated in this
document.
C. The following pressure tables apply to fittings made with the outside diameter of the serrations 1/16 inch (1.59
mm) larger than the nominal hose size with a tolerance of ±1/16 inch (1.59 mm). Minimum shank lengths are as
specified in the table. Parts shall have multiple serrations. (Ref. Section 6.7 - Assembly Data Sheets)

        Nominal Size                 Shank Length
 1/4" (6.35 mm)                1" (25.4 mm)
 3/8" (9.53 mm)                1" (25.4 mm)
 1/2" (12.7 mm)                1" (25.4 mm)
 5/8" (15.9 mm)                1" (25.4 mm)
 3/4" (19 mm)                  1" (25.4 mm)
 1" (25.4 mm)                  1-1/4" (31.8 mm)
 1-1/4" (31.8 mm)              1-1/4" (31.8 mm)
 1-1/2" (38.1 mm)              1-1/2" (38.1 mm)
 2" (50.8 mm)                  1-1/2" (38.1 mm)
 2-1/2" (63.5 mm)              2" (50.8 mm)
 3" (76.2 mm)                  2" (50.8 mm)
 4" (102 mm)                   3" (76.2 mm)
 5" (127 mm)                   3" (76.2 mm)
 6" (152 mm)                   4" (102 mm)
 8" (203 mm)                   4" (102 mm)

Refer to Selection Chart for hose and attachment recommendations.

6.4.7   Interlocking
        6.4.7.1 Interlocking Swaged Stem




        General Uses:

        A swaged coupling that provides a connection between coupling and hose allowing for
        higher-pressure assemblies. These fittings include an interlocking collar that is specifically designed
      to be used with a ferrule.
      Limitation:

      Special swaging equipment is necessary to attach fittings to hose.

      Refer to Selection Chart for hose and attachment recommendations.

      6.4.7.2 Interlocking Crimp Stem




      General Uses:

      A. crimped coupling that provides a connection between coupling and hose allowing for
      higher-pressure assemblies. These fittings include an interlocking collar that is specifically designed
      to be used with a ferrule.
      Limitation:

      Special crimping equipment is necessary to attach fittings to hose.

      Refer to Selection Chart for hose and attachment recommendations.

6.4.8 Ground Joint Fittings




General Uses:

High pressure air, water; steam; other high pressure, elevated temperature applications. Fitting styles include:
tapered seat and washer seal ground joints, interlocking male stems, and interlocking hose menders.
Limitations:

For ASME B31.1 applications:
A. Ground joints, malleable or ductile interlocking male stems not to be used for toxic fluids or flammable gases.

B. Steel interlocking male stems limited to +775ºF (+412.8ºC). Malleable or ductile ground joints or interlocking
male stems limited to 350 psi (2413 kPa) and +450ºF (+232.2ºC).
C. Steel or ductile ground joints or interlocking male stems limited to 400ºF (204.4ºC) for flammable or
combustible liquids. Malleable ground joints or interlocking male stems may not be suitable for flammable or
combustible fluids.

D. Further code consultation is recommended.
For ASME B31.3 applications:
A. Steel ground joints or interlocking male stems are not suitable.
B. Malleable or ductile ground joints or interlocking male stems limited to -20ºF (-28.9ºC) to +650ºF (+343ºC)
temperature range.

C. Malleable ground joints or interlocking male stems not suitable for severe cyclic conditions.
D. Malleable ground joints or interlocking male stems not suitable for flammable fluid service above +300ºF
(+148.9ºC) or 400 psi. (2758 kPa).
E. Ground joints or interlocking male stems not suitable for category K fluid service. Category K fluid service is
defined by the owner of the piping system as high pressure, typically above 2500 psi (17237 kPa).
F. Further code consultation is recommended.
For general service applications:

A. Clamps other than interlocking style may be used; however, pressure and temperature rating charts will not
apply. Generally, use of non-interlocking clamps result in similar pressure ratings as other similar shank style
fittings.
B. Use of ground joints or interlocking male stems of unknown or untraceable origin are not recommended for
critical applications such as toxic, flammable, combustible fluids, or cyclic conditions involving either temperature
or pressure.
C. The following table shows minimum shank lengths of ground joints or interlocking male stems which the
assembly pressure rating tables are based. This table also shows the working pressure of the ground joint or
interlocking male stem at a temperature range of -20ºF (-28.9ºC) to +450ºF (+232ºC). Materials of manufacture
for these tables to be applicable are: steel billet, ductile iron castings to ASTM A395 or malleable iron castings to
ASTM A47. Use of materials which can not be certified to these requirements preclude the use of the pressure
ratings.

       Nominal Size                  Shank Length
 1/4" (6.35 mm)               1 1/8” (28.6 mm)
 3/8” (9.5 mm)                1 1/4" (31.8 mm)
 1/2" (12.7 mm)               1-5/8" (41.2 mm)
 3/4" (19 mm)                 2-3/8" (60 mm)
 1" (25.4 mm)                 2-3/8" (60 mm)
 1-1/4" (31.8 mm)             3-1/4" (82.6 mm)
 1-1/2" (38.1 mm)             3-3/8" (85.7 mm)
 2" (50.8 mm)                 3-7/8" (98.4 mm)
 2-1/2" (63.5 mm)             4-5/8" (117 mm)
 3" (76.2 mm)                 5" (127 mm)
 4" (102 mm)                  5-3/4" (146 mm)
 6” (152.4 mm)                6” (152.4 mm)

Refer to Selection Chart for hose and attachment recommendations.

6.4.9 Sanitary
General Uses:

Sanitary stainless steel food grade fittings are designed for various food hose applications, including the
processing of wine, beer, juice, vegetables and dairy products.
Limitations:

Fittings should meet the 3-A Standards for food service if required.
Special equipment is required to attach fittings to hose.
The fittings and the ferrules must be from the same manufacturer.

Refer to Selection Chart for hose and attachment recommendations.

6.4.10 Sandblast




General Uses:

Designed for use on sandblast hose.
Limitations:

Since these fittings attach to the outside of the hose, they are to be used only with Sand Blast hose.
Special care must be taken not to let the screws penetrate the hose tube.
Warnings:

These fittings are designed to be used with sandblast hose only.

Refer to Selection Chart for hose and attachment recommendations.

6.4.11 Push-on




General Uses:

Push-on fittings are specifically designed for push-on style hose. These fittings are commonly used for air, water,
petroleum based fluids, etc.
Limitations:

Fittings are designed to be used without hose ferrules or clamps.
Warnings:

These fittings are designed for Push-on hose only. The barbs of the fitting are larger in diameter and may cut the
tube if used on other hoses.
Refer to Selection Chart for hose and attachment recommendations.

6.4.12 Internal Expansion Stems




General Uses:

An internally expanded coupling provides a permanent connection between coupling and hose where full flow is
desired.
Limitation:

Special expanding equipment is necessary to attach fittings to hose.

It is important that stems and ferrules come from the same manufacturer, since there is no standardization in the
industry.
Warnings:

Not intended for Cross-Linked Polyethylene or Ultra High Molecular Weight Polyethylene hoses.
Proper ferrule selection is critical for the fabrication of a safe assembly.

These do not include brass short shank (Scovill-style) internal expanded fittings.

Refer to Selection Chart for hose and attachment recommendations.

6.4.13 Internal Expanded Short Brass




General Uses:

Brass, internally expanded permanent coupling. Recommended for low-pressure discharge and suction service.
Commonly used in the transfer of fuel in industry to homes, airplanes, ships, etc. The working pressure of these
fittings varies with the size of the fitting, the size and construction of the hose and the media being conveyed.
Consult the Factory for recommendations. Not intended for air service.
Limitations:

Care must be used to select a body material and gasket material that is compatible with the material being
transferred through the coupling.
Special coupling machinery is required to properly install these fittings.
Where the final hose assembly must comply with API 1529 specifications the couplings must be manufactured to
comply with API 1529.
Warnings:
     Internally expanded brass short couplings are not intended for air service.

     Refer to Selection Chart for hose and attachment recommendations.

6.5 Attachment Data Sheets
     6.5.1 Clamp, Bolt




     General Uses:

     These clamps provide a means to secure fittings in heavy or light wall hose. For use with low pressure couplings
     for suction and discharge service.

     Clamp Recommendations by Hose Size (for combination nipple style shanks)

                                   No. of
      I.D.
                                   Clamps
      Below 2" (50.8 mm)            1
      2" to 4" (50.8 mm to 101.6
                                    2
      mm)
      5" to 6" (127 mm to 152.4
                                    3
      mm)
      8" (203.2 mm) and above       4

     Limitations:

     Hose outside diameter determines the proper size clamp to use.
     Single bolt clamps have hose range of 7/8 inch (22.22 mm) to 5-1/4 inches (133.35 mm).
     Double bolt clamps have hose range of 3-1/2 inches (88.9 mm) to 17-1/2 inches (444.5 mm).
     Malleable iron construction restricts use under certain conditions. Check compatibility with media used as well as
     the environment.
     Warnings:

     Do not use Bolt Clamps on hoses that are constructed with a helix wire.
     Refer to Selection Chart for hose and fitting recommendations.
     6.5.2 Band & Buckles
General Uses:

To secure medium and heavy wall hose to grooved or serrated fitting shanks. Band and buckle is applied with
manual tools only, and therefore may be too time consuming for high volume production. On the other hand, the
band & buckle method gives complete diameter versatility. This versatility makes this attachment method
especially suitable for field installation and repairs.
Limitations:

Not suited for extreme thin wall and lay flat hose, or very small diameters, due to the possibility of leakage under
the buckle.
Warnings:

Improperly tightened bands or an insufficient number of bands used per fitting may result in a potentially
dangerous hose assembly. A tighter band keeps the fitting more secure, but excess tension could damage the
hose.
Refer to Selection Chart for hose and fitting recommendations.
6.5.3   Crimp and Swage

        6.5.3.1 Crimped, Ferrule/Sleeve




                  Ferrule                                   Sleeve

        General Uses:

        Crimped Sleeves may be used on virtually any metallic shank fitting that is designed for crimping.
        These sleeves do not interlock with the fittings.
        Limitations:
      For purposes of this document, Crimped Ferrules are limited to ferrules with a minimum wall of
      .085" (2.16 mm).
      The material of the ferrule/sleeve must be compatible with all materials to which it may be exposed.
      This includes both the material being transferred as well as external materials.
      Proper equipment is required to crimp the ferrule/sleeve onto the assembly. For maximum coupling
      retention, the ferrule must lock into the hose shank locking collar.
      Warnings:

      The use of crimped ferrule/sleeve on a cam & groove fitting to old MIL-C-27487 may result in
      damage to the hose assembly.

      Refer to Selection Chart for hose and fitting recommendations.
      6.5.3.2 Swaged Ferrule




                Ferrule                                    Sleeve

      General Uses:

      Swaged ferrules are designed to be used with fittings with a collar to provide a high pressure hose
      assembly where an interlocked connection is required between fitting and ferrule.
      Limitations:

      For purposes of this document, Swaged Ferrules are limited to ferrules with a minimum wall of .085"
      (2.16 mm).
      Special equipment is required to assemble these ferrules.
      Proper swage die and ferrule selection are critical for the fabrication of a safe assembly.
      Refer to Selection Chart for hose and fitting recommendations.
6.5.4 Clamp, Interlocking




General Uses:
High pressure and/or high temperature clamping on ground joint coupling, interlocking male stems and other
fittings with an interlocking collar.
Limitations:

Not recommended for fittings without an interlocking collar. Materials used must meet manufacturer’s
specifications. Clamp halves or yokes to be from malleable iron to ASTM A47 or ductile iron to ASTM A536 or
better, bolts or U-bolts made from carbon steel; all parts zinc plated.
Warnings:

Re-tightening of clamps may be necessary. Regular inspection of the assembly is recommended.
Refer to Selection Chart for hose and fitting recommendations.
6.5.5 Internal Expansion Ferrule




General Uses:

See Internal Expansion Fitting.
Limitations:

Special equipment is required to assemble these ferrules.
Refer to Selection Chart for hose and fitting recommendations.
6.5.6 Clamp, Pinch




General Uses:

Metal pinch clamps are manufactured in a variety of styles. These styles include: 1-ear, 2-ear and stepless.
The two-ear clamps discussed in this document are manufactured out of 1008 carbon steel which is zinc plated.
Depending upon the size of the clamps, the physical dimensions of these clamps may vary.
This document deals specifically with 2-ear Pinch clamps.
These clamps are used to secure various types of industrial hose to a variety of fittings. they are designed to
attach machined or cast barbed fittings to low pressure, small bore soft wall hose.
Limitations:

Pinch clamps should not be used for service on high pressure applications.
Proper tools are required for installation and removal of pinch clamps.




Warnings:

Sizing of the materials to be clamped is of utmost importance. Proper sizing is achieved by measuring the outside
diameter (OD) of the hose after the appropriate fitting (coupling) is inserted firmly and squarely into the hose.
Refer to Selection Chart for hose and fitting recommendations.
6.5.7 Clamp, Performed




General Uses:

To secure hose to grooved or serrated fitting shanks.
Limitations:

Do not use for steam or other applications where clamp re-tightening is required.
Warnings:

Improperly tightened clamps or an insufficient number of clamps used per fitting may result in a potentially
dangerous hose assembly. A tighter clamp keeps the fitting more secure, but excess tension could damage the
hose.
      Refer to Selection Chart for hose and fitting recommendations.
      6.5.8 Internal Expansion Short Brass/Stainless Ferrule




      General Uses:

      Brass or Stainless Steel Ferrules are used exclusively on, internally expanded permanent coupling.
      Recommended for low pressure discharge and suction service. Commonly used in the transfer of fuel in industry
      such as homes, airplanes, ships, etc. The working pressure of these fittings varies with the size of the fitting, the
      size and construction of the hose and the media being conveyed. Consult the Factory for recommendations. Not
      intended for air service.
      Limitations:

      Special equipment is required to assemble these ferrules
      Warnings:

      These internally expanded short brass or stainless ferrules are not intended for air service.
      Refer to Selection Chart for hose and fitting recommendations.
6.6 General Fabrication Methods
      The following general fabrication methods may or may not be required. Refer to the appropriate data sheets for
      any special fabrication requirements.
      6.6.1 Overall Length (OAL)

      The overall hose assembly length is measured from the end of the coupling on one end of the hose to the end of
      the coupling on the other end of the hose.




      6.6.2 Hose Cut Length

      The cut length of the hose shall be determined from the overall hose assembly length. The hose cut length shall
      be determined from the following formula:
      Hose cut length = overall assembly length – (coupling no. 1 – hose insertion depth) – (coupling no. 2 – hose
      insertion depth)
6.6.3 Hose Cutting

The hose should be cut in such a manner to ensure a straight cut that is perpendicular to the hose axis. Angular
cuts should not be used because this causes poor assembly characteristics. The cut angle should be
perpendicular to the centerline of the hose.

Hoses shall be cut to the following tolerances:

                         Hose I.D.                                         Maximum Variation
 ¾” (.75”) (19.05 mm) and under                               1/16” (0.063”) (1.6 mm)
 over ¾”(.75”) (19.05 mm) through 2” (50.4 mm)                1/8” (0.125”) (3.2 mm)
 over 2” (50.4 mm) through 6” (152.4 mm)                      ¼” (0.250”) (6.35 mm)


Textile reinforced hose can be cut to proper length using a power driven circular knife edge blade or a guillotine
cutter. Hose with a metallic reinforcement should be cut with a power driven circular knife edge blade. An
alternate style of blade is the scalloped knife edge blade. Abrasive blades are acceptable for cutting wire
reinforced hose. The inside diameter of the hose must be cleaned after cutting.

6.6.4 How to Make the Assembly Static (Electrically) Conductive
After the hose has been squarely cut, pull the helical wire(s), static wire(s) approximately a ½ inch, or expose the
wire reinforcement enough to insure complete contact with the insert of the fitting. Bend the wire(s) towards the
inside of the tube so that the wire(s) lay parallel to the axis of the hose to insure full contact with the insert of the
fitting. The same procedure needs to be completed on both ends of the assembly to make the assembly
electrically conductive. It is important to bend the wire(s) to make sure that they do not back out of the end of the
hose.

When utilizing a staple, place the staple in direct contact with the static wire or wire reinforcement of the hose.
Make certain the staple has the opposing leg towards the inside diameter of the hose to insure full contact with
the insert of the fitting. The same procedure needs to be completed on both ends of the assembly to make the
assembly electrically conductive.
             6.6.4.1 Keeping the helical wires from backing out of the assembly

             After the hose has been squarely cut, pull the helical wire(s) out of the end of the hose
             approximately a 1/2 inch. Bend the wire(s) towards the inside of the tube so that the wire(s) lay
             parallel to the axis of the hose to ensure that the wires are trapped during assembling. This is very
             important to keep the wire(s) from backing out of the end of the hose.
             Note: The helical wires should be bent over for assemblies except for the hoses that are to be
             insulated.
      6.6.5 Coupling Insertion

      After cutting the hose squarely and determining if the hose needs to be grounded:
      1. To ensure proper alignment, the coupling or hose should be held by means necessary to prevent movement
      during insertion. This will prevent damaging the tube.
      2. Insert the coupling into the hose. If the shank is too large, try inserting the coupling at an angle. Do not modify
      the inner tube to allow for clearance to insert the coupling shank into the tube.
      3. If necessary, lubricate the inner tube and/or hose shank to help the coupling go into the tube. Use soap and
      water for lubrication. Consult hose or coupling manufacturer before using other lubricants.
      4. Do not alter the shank of the coupling. This might alter the coupling integrity or create sharp edges that could
      puncture the hose tube.
      5. After insertion, inspect the hose end for cuts and bulges, and verify that the coupling was inserted to the
      correct depth.

>> continue to next section
Section 6 Industrial Hose - 6.7.1 to 6.7.19

6.7 Assembly Data Sheets

      6.7.1 Air Hose (soft wall) / Universal / Crimp
      6.7.2 Air Hose (soft wall) / Universals / Interlocking Clamp
      6.7.3 Air Hose (soft wall) / Universal / Preformed
      6.7.4 Air Hose (soft wall) / Machined, Short Shank / Crimp
      6.7.5 Air Hose (soft wall) / Machined, Short Shank / Pinch Clamp
      6.7.6 Air Hose (soft wall) / Machined, Short / Preformed
      6.7.7 Air Hose (soft wall) / Machined, Medium Shank / Pinch Clamp
      6.7.8 Air Hose (soft wall) / Machined, Medium / Preformed
      6.7.9 Air Hose (soft wall) / Machined, Medium Shank / Band & Buckle
      6.7.10 Air Hose (soft wall) / Machined, Long Shank / Pinch Clamp
      6.7.11 Air Hose (soft wall) / Machined, Long Shank / Preformed
      6.7.12 Air Hose (soft wall) / Machined, Long Stem / Band & Buckle
      6.7.13 Air Hose (soft wall) / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.14 Air Hose/ Interlocking Swage-Crimp / Crimp
      6.7.15 Air Hose/ Interlocking Swage-Crimp / Swaged
      6.7.16 Asphalt Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.17 Chemical, Plastic / Cam & Groove / Crimp
      6.7.18 Chemical Plastic / Cam & Groove / Swaged
      6.7.19 Chemical Plastic / Cam & Groove / Preformed

>> continue to next section

6.7   Assembly Data Sheets

      6.7.1   Air Hose (soft wall) / Universal / Crimp

                     I.D.                            Working Pressure                                  Test Pressure
       inch                        mm                               psi     (kPa)                                   psi       (kPa)
       3/8”                    (9.5 mm)       lesser of hose or    110       ( 758 )       lesser of 2X hose or 220            ( 1517 )
       1/2”                   (12.7 mm)       lesser of hose or    110       ( 758 )       lesser of 2X hose or 220            ( 1517 )
       5/8”                   (15.9 mm)       lesser of hose or    110       ( 758 )       lesser of 2X hose or 220            ( 1517 )
       3/4”                    (19 mm)        lesser of hose or    110       ( 758 )       lesser of 2X hose or 220            ( 1517 )
       1”                     (25.4 mm)       lesser of hose or    110       ( 758 )       lesser of 2X hose or 220            ( 1517 )


      Fabrication Procedures:

      1. Cut hose end square and clean any debris from tube interior.

      2. Measure the outer diameter of the hose, preferably with a pi tape.

      3. Based on the hose outer diameter, select the proper ferrule.

      4. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

      5. Insert the stem into the hose squarely without causing damage to the tube.
      6. Lubrication should only be used if necessary.

      7. Select the desired crimp length and crimp OD using manufacturer’s recommendations.

      8. Based on #7, select the proper die set using the crimp machine manufacturer’s recommendations.

      9. Place the hose assembly in the die opening.

      10. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are lined up properly to achieve
      the desired crimp length.
      11. Crimp the ferrule to the desired diameter.

      12. Retract the dies and remove the hose assembly.
13. Measure the crimp diameter across the flats to ensure it meets manufacturer’s specifications.

14. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

15. Repeat steps 1 through 14 for the other end.
Testing:

Hydrostatic testing as required.
6.7.2   Air Hose (soft wall) / Universals / Interlocking Clamp

           I.D.                         Working Pressure                                  Test Pressure
 inch                mm                                 psi       (kPa)                               psi           (kPa)

 3/8”         (9.5 mm)          lesser of hose or         110    ( 758 )      lesser of 2X hose or 220           ( 1517 )
 1/2”        (12.7 mm)          lesser of hose or         110    ( 758 )      lesser of 2X hose or 220           ( 1517 )
 5/8”        (15.9 mm)          lesser of hose or         110    ( 758 )      lesser of 2X hose or 220           ( 1517 )
 3/4”             (19 mm)       lesser of hose or         110    ( 758 )      lesser of 2X hose or 220           ( 1517 )
 1”          (25.4 mm)          lesser of hose or         110    ( 758 )      lesser of 2X hose or 220           ( 1517 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.
2. Cut the hose square per general fabrication methods.

3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.

4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting may help
insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:

Assembly Procedure for Two Bolt Clamps:

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of coupling head. Snug the
bolts equally by hand.
7. Snug the bolts equally by hand again.

8. Using a torque wrench, begin tightening the bolts as follows:

9. First bolt (nut facing assembler) 1 full turn,

10. Second bolt (opposite first bolt) 1 full turn.

11. Repeat procedure “9” and “10” until both bolts have reached recommended published torque.
Assembly Procedure of Four Bolt Clamps:

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of coupling head. Snug the
bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be necessary to put the
stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the bolts equally (thread
engagement between bolt and nut is equal on all 4 bolts).

7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) 1 full turn,

9. Front bolt (close to gripping finger) 1 full turn,

10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,
11. Opposite side back bolt 1 full turn,
12. Opposite side front bolt 1 full turn,

13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torque.

14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published torque.
Assembly procedure for U-bolt clamps:

 Clamp Size                                             Nut Torque

 1/2” (12.7 mm)                                         15 ft.-lbs.

 3/4” (19.05 mm) through 1" (31.75 mm)                  25 ft.-lbs.

Testing:

Hydrostatic testing as required.
6.7.3   Air Hose (soft wall) / Universal / Preformed

           I.D.                         Working Pressure                                   Test Pressure
 inch                 mm                          psi                  (kPa)                        psi          (kPa)

 3/8”             (9.5 mm)    lesser of hose or      110              ( 758 )   lesser of 2X hose or 220       ( 1517 )
 1/2”         (12.7 mm)       lesser of hose or      110              ( 758 )   lesser of 2X hose or 220       ( 1517 )
 5/8”         (15.9 mm)       lesser of hose or      110              ( 758 )   lesser of 2X hose or 220       ( 1517 )
 3/4”             (19 mm)     lesser of hose or      110              ( 758 )   lesser of 2X hose or 220       ( 1517 )
 1”           (25.4 mm)       lesser of hose or      110              ( 758 )   lesser of 2X hose or 220       ( 1517 )

Note:

Use 2 bands on ¾” and larger.
        6.7.3.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.

        2. Place fitting along side hose and mark positions of clamps on hose cover. Place as many clamps over the
        serration as will comfortably fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or
        9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
        clamps. For 3/4 to 1inch (19 to 25.4 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
        pressure settings that correspond to clamp width and material used.
        6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

        7. Activate tool to tighten clamp.
        8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        9. Roll hose up until shear hook engages buckle
        10.Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
        finish the clamp.
        11.Reset tool and remove scrap end of clamp.
12.Repeat steps 5 to 11 with each clamp, staggering the buckle position.

Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.3.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. Place as many clamps over the
serrations as will comfortably fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm)
wide clamps. For 3/4 to 1 inch (19 to 25.4 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle position.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.3.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
        it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
        machine until it can go no further and then slip assembled hose and fitting through the clamp.
        6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
        button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
        band off while maintaining correct tension. Due to many different types of hose and fitting construction and
        styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
        application and making a note of this on the included chart for future uniformity.
        7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

        8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle position.

        9. Make sure that the manufacturer’s marking is obliterated after punching on all clamps.

        Testing:

        Hydrostatic testing as required.
        6.7.3.4 Center Punch Clamp applied with Hand Tool
        Special Tools Required:

        Hand Tool & Mallet
        Fabrication Procedures:

        1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
        suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
        This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
        is inserted and select a clamp that is the closet to, but not less than that outside diameter.

        2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
        be applied. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
        be located on the shank somewhere.
        3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
        enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
        want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
        4. Insert fitting into hose until the entire shank is covered.

        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
        lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
        smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
        tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
        surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
        amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
        ultimate tension has been attained, hold the ball handle in the down position with one hand.
        7.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
        blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
        obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
        lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
        prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
        lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
        by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.

        Testing:

        Hydrostatic testing as required.
6.7.4   Air Hose (soft wall) / Machined, Short Shank / Crimp

           I.D.                         Working Pressure                                       Test Pressure
 inch               mm                                psi         (kPa)                                      psi        (kPa)
 1/4”        (6.4 mm)        lesser of hose or         200        (1379 )         lesser of 2X hose or 400               ( 2758 )
 3/8”        (9.5 mm)        lesser of hose or         150        (1034 )         lesser of 2X hose or 300               ( 2069 )
 1/2”       (12.7 mm)        lesser of hose or         150        ( 1034)         lesser of 2X hose or 300               ( 2069 )
 5/8”       (15.9 mm)        lesser of hose or         100         ( 690 )        lesser of 2X hose or 200               ( 1379 )
 3/4”         (19 mm)        lesser of hose or         100         ( 690 )        lesser of 2X hose or 200               ( 1379 )
 1”         (25.4 mm)        lesser of hose or         100         ( 690 )        lesser of 2X hose or 200               ( 1379 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. Measure the outer diameter of the hose, preferably with a pi tape.

3. Based on the hose outer diameter, select the proper ferrule.

4. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

5. Insert the stem into the hose squarely without causing damage to the tube.

6. Lubrication should only be used if necessary.

7. Select the desired crimp length and crimp O.D. using manufacturer’s recommendations.

8. Based on #7, select the proper die set using the crimp machine manufacturer’s recommendations.

9. Place the hose assembly in the die opening.

10. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.

11. Crimp the ferrule to the desired diameter.

12. Retract the dies and remove the hose assembly.

13. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

14. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

15. Repeat steps 1 through 14 for the other end.
Testing:

Hydrostatic testing as required.
6.7.5   Air Hose (soft wall) / Machined, Short Shank / Pinch Clamp

           I.D.                           Working Pressure                                      Test Pressure
 inch                 mm                               psi            (kPa)                                 psi            (KPa)

 1/4”             (6.4 mm)         lesser of hose or     300         (2069)          lesser of 2X hose or 600             (4137)
 3/8”             (9.5 mm)         lesser of hose or     300         (2069)          lesser of 2X hose or 600             (4137)
 1/2”         (12.7 mm)            lesser of hose or     250         (1724)          lesser of 2X hose or 500             (3448)
 5/8”         (15.9 mm)            lesser of hose or     200         (1379)          lesser of 2X hose or 400             (2758)
 3/4”             (19 mm)          lesser of hose or     200         (1379)          lesser of 2X hose or 400             (2758)
 1”           (25.4 mm)            lesser of hose or     150         (1034)          lesser of 2X hose or 300             (2069)

Note:

Bandwidth for 1/4” = 7.5mm, for 3/8” 8.0 mm, for 1/2”, 5/8”, 3/4” and 1” = 10.mm.
Special Tools Required:
Pincer (Manual pinching tool)




Fabrication Procedures:

1. Place fitting along side of hose end and mark the hose for location of clamp or clamps.

2. On short shank fittings locate clamp directly over the machined barbs.

3. Insert fitting into hose until hose meets shoulder of fitting.
4. Place clamp over assembly. Holding clamp directly over barbed area of fitting, pinch one ear of the clamp down
completely, then go to the second ear and pinch it down completely.

Testing:

Hydrostatic testing as required.




Illustration 1. When installing Ear Type Clamps, please note that each ear must be crimped as recommended to obtain a
proper seal. An installation made incorrectly may impair the best connection. If a clamp ear can be closed all the way, the
clamp size selected is probably too big and the next smaller clamp size should be used.

How to Apply
Illustration 2. Position Clamp as illustrated.

Illustration 3. Give each ear a firm squeeze with pincers.

6.7.6   Air Hose (soft wall) / Machined, Short / Preformed

            I.D.                          Working Pressure                               Test Pressure
 inch                  mm                               psi         (kPa)                             psi       (kPa)

 1/4”              (6.4 mm)        lesser of hose or    200         ( 1379 )   lesser of 2X hose or 400          ( 2758 )
 3/8”              (9.5 mm)        lesser of hose or    150         ( 1034 )   lesser of 2X hose or 300          ( 2069 )
1/2”           (12.7 mm)         lesser of hose or    150        ( 1034 )         lesser of 2X hose or 300           ( 2069 )
5/8”           (15.9 mm)         lesser of hose or    100         ( 690 )         lesser of 2X hose or 200           ( 1379 )
3/4”              (19 mm)        lesser of hose or    100         ( 690 )         lesser of 2X hose or 200           ( 1379 )
1”             (25.4 mm)         lesser of hose or    100         ( 690 )         lesser of 2X hose or 200           ( 1379 )

       6.7.6.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
       Special Tools Required:

       Pneumatic Roll-over Tool
       Fabrication Procedures:

       1. Select smallest clamp, which slides over hose with fitting inserted.

       2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
       barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
       large bards. If all barbs or serrations are the same, place as many clamps over the serration as will
       comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
       clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
       3/4 to 1inch (19 to 25.4 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.

       3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

       4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

       5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
       pressure settings that correspond to clamp width and material used.
       6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

       7. Activate tool to tighten clamp.

       8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

       9. Roll hose up until shear hook engages buckle
       10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
       finish the clamp.
       11. Reset tool and remove scrap end of clamp, staggering the buckle positions.

       12. Repeat steps 5 to 11 with each clamp
       Special Considerations:

       Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
       Testing:

       Hydrostatic testing as required.
       6.7.6.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
       Special Tools Required:

       Spinner type Hand Tool and Adapter
       Fabrication Procedures:

       1. Select smallest clamps, which slides over hose with fitting inserted

       2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
       barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
       large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
       comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
       clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
       3/4 to 1 inch (19 to 25.4 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
       3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.6.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

9. Make sure that the manufacturer’s marking are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.6.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:
        1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
        suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
        This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
        is inserted and select a clamp that is the closet to, but not less than that outside diameter.
        2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
        be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
        the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
        be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
        the fitting is grooved.
        3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
        enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
        want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

        4. Insert fitting into hose until the entire shank is covered.

        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
        lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.
        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
        smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
        tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
        surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
        amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
        ultimate tension has been attained, hold the ball handle in the down position with one hand.
        7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
        hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
        once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center
        of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly
        to prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
        lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
        by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
6.7.7   Air Hose (soft wall) / Machined, Medium Shank / Pinch Clamp

              I.D.                           Working Pressure                                     Test Pressure
 inch                     mm                                 psi         (kPa)                                  psi      (kPa)
 1/4”                 (6.4 mm)          lesser of hose or    220          (1517)       lesser of 2X hose or 440            (3034)
 3/8”                 (9.5 mm)          lesser of hose or    220          (1517)       lesser of 2X hose or 440            (3034)
 1/2”                (12.7 mm)          lesser of hose or    300          (2069)       lesser of 2X hose or 600            (4137)
 5/8”                (15.9 mm)          lesser of hose or    300          (2069)       lesser of 2X hose or 600            (4137)
 3/4”                 (19 mm)           lesser of hose or    300          (2069)       lesser of 2X hose or 600            (4137)
 1”                  (25.4 mm)          lesser of hose or    300          (2069)       lesser of 2X hose or 600            (4137)

Note:

Use 1 clamp on 1/4” and 3/4”. Use 2 clamps on 1/2” through 1”.
Special Tools Required:

Pincer (Manual pinching tool)
Fabrication Procedures:

1. Place fitting along side of hose end and mark the hose for location of clamp or clamps.

2. On medium shank fittings locate clamp directly over the machined barbs.

3. Insert fitting into hose until hose meets shoulder of fitting.
4. Place clamp over assembly. Holding clamp in position over the front barbs of the fitting, pinch one ear of the clamp down
completely. Then go to the second ear and pinch it down completely.

5. Locate the second clamp next to the first. position this clamp so that the ears are perpendicular to the first clamp’s ears.
This configuration amounts to a north, south, east west direction of the ears.

6. Fasten this clamp as described in step 4.

Testing:

Hydrostatic testing as required.




Illustration 1. When installing Ear Type Clamps, please note that each ear must be crimped as recommended to obtain a
proper seal. An installation made incorrectly may impair the best connection. If a clamp ear can be closed all the way, the
clamp size selected is probably too big and the next smaller clamp size should be used.

How to Apply
Illustration 2. Position Clamp as illustrated.

Illustration 3. Give each ear a firm squeeze with pincers.

6.7.8   Air Hose (soft wall) / Machined, Medium / Preformed

           I.D.                            Working Pressure                                  Test Pressure
 inch                 mm                               psi            (kPa)                             psi           (kPa)
 1/4”             (6.4 mm)         lesser of hose or 300            ( 2069 )     lesser of 2X hose or 600           ( 4137 )
 3/8”              (9.5 mm)        lesser of hose or 300             ( 2069 )       lesser of 2X hose or 600            ( 4137 )
 1/2”             (12.7 mm)        lesser of hose or 250             ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 5/8”             (15.9 mm)        lesser of hose or 200             ( 1379 )       lesser of 2X hose or 400            ( 2758 )
 3/4”              (19 mm)         lesser of hose or 200             ( 1379 )       lesser of 2X hose or 400            ( 2758 )
 1”               (25.4 mm)        lesser of hose or 150             ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 1 1/4"           (31.8 mm)        lesser of hose or 150             ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 1 1/2"           (38.1 mm)        lesser of hose or 150             ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 2”               (50.8 mm)        lesser of hose or 125               ( 862 )      lesser of 2X hose or 250            ( 1724 )
 2 1/2"           (63.5 mm)        lesser of hose or 125               ( 862 )      lesser of 2X hose or 250            ( 1724 )
 3”               (76.2 mm)        lesser of hose or 125               ( 862 )      lesser of 2X hose or 250            ( 1724 )
 4”           (101.6 mm)           lesser of hose or 125             ( 1034 )       lesser of 2X hose or 250            ( 1724 )
 6”           (152.4 mm)           lesser of hose or 50                ( 345 )      lesser of 2X hose or 100             ( 690 )

Note:

Use 3 bands on 3” through 6”. Use 2 bands on ¾” through 2 ½”. Use 1 bands on ¼” through 5/8”.
        6.7.8.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool

        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.

        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
        barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
        large bards. If all barbs or serrations are the same, place as many clamps over the serration as will
        comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
        clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
        3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
        over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
        manner outlined above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
        pressure settings that correspond to clamp width and material used.

        6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
        hose.

        7. Activate tool to tighten clamp.
        8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        9. Roll hose up until shear hook engages buckle
        10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
        finish the clamp.
        11. Reset tool and remove scrap end of clamp.

        12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
        Special Considerations:

        Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
        Testing:
Hydrostatic testing as required.
6.7.8.2    Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.8.3    Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and
above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.

4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
        machine until it can go no further and then slip assembled hose and fitting through the clamp.

        6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
        button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
        band off while maintaining correct tension. Due to many different types of hose and fitting construction and
        styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
        application and making a note of this on the included chart for future uniformity.

        7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

        8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.
        9. Make sure that the manufacturer’s marking is obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
        6.7.8.4    Center Punch Clamp applied with Hand Tool
        Special Tools Required:

        Hand Tool & Mallet
        Fabrication Procedures:

        1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
        suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
        This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
        is inserted and select a clamp that is the closet to, but not less than that outside diameter.
        2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
        be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
        the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
        be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
        the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and
        above.

        3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
        enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
        want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
        applied.

        4. Insert fitting into hose until the entire shank is covered.
        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
        lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
        smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
        tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
        surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
        amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
        ultimate tension has been attained, hold the ball handle in the down position with one hand.

        7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
        hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
        once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center
        of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly
        to prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
        lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
        by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
6.7.9   Air Hose (soft wall) / Machined, Medium Shank / Band & Buckle
              I.D.                          Working Pressure                                  Test Pressure
 inch                     mm                            psi            (kPa)                           psi             (kPa)

 1 1/4"              (31.8 mm)      lesser of hose or 225           ( 1551 )      lesser of 2X hose or 450          ( 3103 )
 1 1/2"              (38.1 mm)      lesser of hose or 225           ( 1551 )      lesser of 2X hose or 450          ( 3103 )
 2”                  (50.8 mm)      lesser of hose or 200           ( 1379 )      lesser of 2X hose or 400          ( 2758 )
 2 1/2"              (63.5 mm)      lesser of hose or 200           ( 1379 )      lesser of 2X hose or 400          ( 2758 )
 3”                  (76.2 mm)      lesser of hose or 175           ( 1207 )      lesser of 2X hose or 350          ( 2413 )
 4”              (101.6 mm)         lesser of hose or 175           ( 1207 )      lesser of 2X hose or 350          ( 2413 )
 6”              (152.4 mm)         lesser of hose or 75              ( 517 )     lesser of 2X hose or 150          ( 1034 )

Note:

Use 3 bands on 3” through 6”. Use 2 bands on all other sizes.

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined
above.

2. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
3. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.

4. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

5. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

6. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

7. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

8. Clinch stub by hammering down buckle ears.
9. Repeat steps 3 through 8 for each clamp, staggering the buckle positions. Special Considerations: Make sure clamp is
narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
6.7.10     Air Hose (soft wall) / Machined, Long Shank / Pinch Clamp

             I.D.                           Working Pressure                                  Test Pressure
 inch                     mm                             psi          (kPa)                                  psi    (kPa)

 1/4”                (6.4 mm)    lesser of hose or      150           ( 1034 )     lesser of 2X hose or 300         ( 2069 )
 3/8”                (9.5 mm)    lesser of hose or      150           ( 1034 )     lesser of 2X hose or 300         ( 2069 )
 1/2”               (12.7 mm)    lesser of hose or      220             (1517)     lesser of 2X hose or 440          (3034)
 5/8”               (15.9 mm)    lesser of hose or      220             (1517)     lesser of 2X hose or 440          (3034)
 3/4”              (19 mm)       lesser of hose or        300         (2069)     lesser of 2X hose or 600            (4137)
 1”              (25.4 mm)       lesser of hose or        300         (2069)     lesser of 2X hose or 600            (4137)

Note:

Use 1 clamp on 1/4” and 3/4”. Use 2 clamps on 1/2” through 1”.
Special Tools Required:

Pincer (Manual pinching tool)




Fabrication Procedures:

1. Place fitting along side of hose end and mark the hose for location of clamp or clamps.

2. On medium shank fittings locate clamp directly over the machined barbs.
3. Insert fitting into hose until hose meets shoulder of fitting.
4. Place clamp over assembly. Holding clamp in position over the front barbs of the fitting, pinch one ear of the clamp down
completely. Then go to the second ear and pinch it down completely.
5. Locate the second clamp next to the first. position this clamp so that the ears are perpendicular to the first clamp’s ears.
This configuration amounts to a north, south, east west direction of the ears.

6. Fasten this clamp as described in step 4.
Testing:

Hydrostatic testing as required.




Illustration 1. When installing Ear Type Clamps, please note that each ear must be crimped as recommended to obtain a
proper seal. An installation made incorrectly may impair the best connection. If a clamp ear can be closed all the way, the
clamp size selected is probably too big and the next smaller clamp size should be used.
How to Apply

Illustration 2. Position Clamp as illustrated.

Illustration 3. Give each ear a firm squeeze with pincers.

6.7.11     Air Hose (soft wall) / Machined, Long Shank / Preformed

                I.D.                              Working Pressure                                      Test Pressure
 inch                          mm                               psi          (kPa)                              psi              (kPa)
 1/2”                    (12.7 mm)            lesser of hose or 400        ( 2758 )        lesser of 2X hose or 800            ( 5516 )
 5/8”                    (15.9 mm)            lesser of hose or 300        ( 2069 )        lesser of 2X hose or 600            ( 4137 )
 3/4”                     (19 mm)             lesser of hose or 300        ( 2069 )        lesser of 2X hose or 600            ( 4137 )
 1”                      (25.4 mm)            lesser of hose or 300        ( 2069 )        lesser of 2X hose or 600            ( 4137 )
 1 1/4"                  (31.8 mm)            lesser of hose or 225        ( 1551 )        lesser of 2X hose or 450            ( 3103 )
 1 1/2"                  (38.1 mm) lesser of hose or            225        ( 1551 )        lesser of 2X hose or 450            ( 3103 )
 2”                      (50.8 mm)            lesser of hose or 200        ( 1379 )        lesser of 2X hose or 400            ( 2758 )
 2 1/2"                  (63.5 mm)            lesser of hose or 200        ( 1379 )        lesser of 2X hose or 400            ( 2758 )
 3”                      (76.2 mm)            lesser of hose or 175        ( 1207 )        lesser of 2X hose or 350            ( 2413 )
 4”                    (101.6 mm)             lesser of hose or 175        ( 1207 )        lesser of 2X hose or 350            ( 2413 )
 6”                    (152.4 mm) lesser of hose or             75          ( 517 )        lesser of 2X hose or 150            ( 1034 )

Note:

Use 5 bands on sizes 3” through 6’. Use 4 bands on 2” and 2 ½”. Use 3 bands on ½” through 1 ½”.
         6.7.11.1      Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will
         comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
         clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
         3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
         over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
         manner outlined above.

         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

         4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

         5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
         pressure settings that correspond to clamp width and material used.
         6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

         7. Activate tool to tighten clamp.
         8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

         9. Roll hose up until shear hook engages buckle

         10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
         finish the clamp.
         11. Reset tool and remove scrap end of clamp.
12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.11.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter

Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Test Hose Assembly to 2X working pressure
6.7.11.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool

Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and
above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

9. Make sure that the manufacturer’s marking is obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.11.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is no more than
approximately 1/4" larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp that is the closet
to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located
on the shank somewhere. It is recommended that you use as many clamps as there are grooves if the fitting is
grooved. If not, use at least one clamp up to two inch hose
and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s)
around hose according to pre marked lines.

6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
ultimate tension has been attained, hold the ball handle in the down position with one hand.

7.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
lock. This
mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
turning, then lift both handles of tool together, in an up and down motion, which will break band off at lock. You
may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool by
operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
         8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

         9. Make sure that the manufacturer’s marking is obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.12     Air Hose (soft wall) / Machined, Long Stem / Band & Buckle

              I.D.                          Working Pressure                                  Test Pressure
 inch                     mm                          psi             (kPa)                            psi           (kPa)

 1 1/4"              (31.8 mm)     lesser of hose or 300            ( 2069)        lesser of 2X hose or 600        ( 4137 )
 1 1/2"              (38.1 mm)     lesser of hose or 300            ( 2069 )       lesser of 2X hose or 600        ( 4137 )
 2”                  (50.8 mm)     lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 2 1/2"              (63.5 mm)     lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 3”                  (76.2 mm)     lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 4”             (101.6 mm)         lesser of hose or 200             (1379)        lesser of 2X hose or 400        ( 2758)
 6”             (152.4 mm)         lesser of hose or 100             ( 690 )       lesser of 2X hose or 200        ( 1379 )

Note:

Use 5 bands on sizes 3” through 6’. Use 4 bands on 2” and 2 ½”. Use 3 bands on ½” through 1 ½”.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to
2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger than 2-½ inch (63.5
mm), use as many ¾ inch (19.1 mm) wide clamps
as will fit on the shank, in the manner outlined above.
2. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.

3. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.
4. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.
5. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
6. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

7. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
8. Clinch stub by hammering down buckle ears.

9. Repeat steps 3 through 8 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
6.7.13    Air Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

             I.D.                             Working Pressure                                   Test Pressure
 inch                     mm                             psi            (kPa)                              psi             (kPa)

 1/4”                (6.4 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 3/8”                (9.5 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1/2”               (12.7 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 3/4”                (19 mm)          lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1”                 (25.4 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1 1/4"             (31.8 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1 1/2"             (38.1 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 2”                 (50.8 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 2 1/2"             (63.5 mm)         lesser of hose or 450           ( 3103 )     lesser of 2X hose or 900             ( 6206 )
 3”                 (76.2 mm)         lesser of hose or 450           ( 3103 )     lesser of 2X hose or 900             ( 6206 )
 4”              (101.6 mm)           lesser of hose or 230           ( 1586 )     lesser of 2X hose or 460             ( 3172 )
 6”                 (152 mm)          lesser of hose or 230           ( 1586 )     lesser of 2X hose or 460             ( 3172 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.
2. Cut the hose square per general fabrication methods.

3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.

4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting may help
insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:

Assembly Procedure for Two Bolt Clamps: Perform steps 1-5 above.

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the stem or the
wing nut on the stem. Snug the bolts equally
by hand.

7. Snug the bolts equally by hand again.

8. Using a torque wrench, begin tightening the bolts as follows:

9. First bolt (nut facing assembler) 1 full turn,
10. Second bolt (opposite first bolt) 1 full turn.

11. Repeat procedure “9” and “10” until both bolts have reached recommended published torque.
Assembly Procedure of Four Bolt Clamps: Perform steps 1-5 above.
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the stem. Snug
the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be necessary to put the
stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the bolts equally (thread
engagement between bolt and nut is equal on all 4 bolts).
7. Using a torque wrench, begin tightening the bolts as follows:

8. Back bolt (away from gripping finger) 1 full turn,
9. Front bolt (close to gripping finger) 1 full turn,
10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,

11. Opposite side back bolt 1 full turn,

12. Opposite side front bolt 1 full turn,
13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torque.

14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published torque.

Assembly Procedure of Six Bolt Clamps: Perform steps 1-5 above.

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar. Snug the bolts by hand equally (thread
engagement between bolt and nut is equal on all six bolts. Place a mark (X) on the clamp body of one of the segments near
the nut of the back bolt (away from gripping finger) with a magic marker or something similar.

7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) having “X” near it one full turn,

9. Front bolt (close to gripping finger) of same segment one full turn,

10. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),

11. Back bolt to one full turn,

12. Front bolt one full turn,
13. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),

14. Back bolt one full turn,

15. Front bolt one full turn.

16. Repeat above procedure “8” through “15” until all of the bolts have reached the recommended published torque.
Assembly procedure for U-bolt clamps: Perform steps 1-5 above.

6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.

7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.
8. Install U-bolts around steel liner and through clamp casting and apply nuts.

9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and interlocking fingers
engage collar of fitting.

10. Evenly tighten nuts to torque values shown on chart below.

 Clamp Size                                                   Nut Torque
 ½” (12.7 mm)                                                 15 ft.-lbs.
 ¾” (19.05 mm) through 1¼” (31.75 mm)                         25 ft.-lbs.
 1½” (38.1 mm)                                                35 ft.-lbs.
 2” (50.8 mm), 3” (76.2 mm)                                   55 ft.-lbs.
 4” (101.6 mm)                                                100 ft.-lbs.

Testing:

Hydrostatic testing as required.
6.7.14     Air Hose/ Interlocking Swage-Crimp / Crimp

              I.D.                          Working Pressure                                     Test Pressure
 inch                     mm                            psi                  (kPa)                       psi         (kPa)

 1/4”                 (6.4 mm)      lesser of hose or 600              ( 4137 )      lesser of 2X hose or 1200     ( 8274 )
 3/8”                 (9.5 mm)      lesser of hose or 600              ( 4137 )      lesser of 2X hose or 1200     ( 8274 )
 1/2”                (12.7 mm)      lesser of hose or 600              ( 4137 )      lesser of 2X hose or 1200     ( 8274 )
 5/8”             (15.9 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 3/4”                 (19 mm)       lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 1”               (25.4 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 1 1/4"           (31.8 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 1 1/2"           (38.1 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 2”               (50.8 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 2 1/2"           (63.5 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 3”               (76.2 mm)         lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 4”              (101.6 mm)         lesser of hose or 500            ( 4137 )      lesser of 2X hose or 1000             ( 6895 )
 6”              (152.4 mm)         lesser of hose or 400            ( 2758 )      lesser of 2X hose or 800              ( 5516 )

Fabrication Procedures:

1.Cut hose end square and clean any debris from tube interior.

2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Measure the outer diameter of the hose, preferably with a pi tape.

5. Based on the hose outer diameter, select the proper ferrule. Mark a line on the hose cover at the distance from the end of
the hose that equals the insertion depth. This becomes a visual check to determine if the hose is fully bottomed into the
fitting.

6. Insert the stem into the hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.
8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.

11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.

14. Crimp the ferrule to the desired diameter.

15. Retract the dies and remove the hose assembly.

16 Measure the crimp diameter to ensure it meets manufacturer’s specifications.
17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
6.7.15     Air Hose/ Interlocking Swage-Crimp / Swaged

               I.D.                           Working Pressure                                   Test Pressure
 inch                      mm                              psi            (kPa)                             psi            (kPa)

 1/4”                  (6.4 mm)        lesser of hose or 600           ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 3/8”                  (9.5 mm)        lesser of hose or 600           ( 4137 )      lesser of 2X hose or 200            ( 8274 )
 1/2”                 (12.7 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 5/8”                 (15.9 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 3/4”                   (19 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 1”                   (25.4 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 1 1/4"               (31.8 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 1 1/2"               (38.1 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 2”                   (50.8 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 2 1/2"               (63.5 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 3”                   (76.2 mm)       lesser of hose or 600        ( 4137 )     lesser of 2X hose or 1200         ( 8274 )
 4”                  (101.6 mm)       lesser of hose or 500        ( 4137 )     lesser of 2X hose or 1000         ( 6895 )
 6”                  (152.4 mm)       lesser of hose or 400        ( 2758 )     lesser of 2X hose or 800          ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).

3. For stems having a welded collar, chamfer the hose tube 1/8 inch (3.175 mm) wide by 45° angle.

4. Use a diameter tape to measure hose O.D. and select proper Ferrule. Mark a line on the hose cover at the distance from
the end of the hose that equals the insertion depth. This becomes a visual check to determine if the hose is fully bottomed
into the fitting.

5. Select proper die set and accessories using manufacturer’s recommendations.
6. Insert stem into hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.

8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.

9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes n contact with the stem
collar

10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die
and the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start the
swaging process. Depending on coupling style,
it may be necessary to put pressure against the pusher to keep the ferrule properly placed until the ferrule has been reduced
to the point that it comes in contact with the hose cover. Continue the swage until desired length has been achieved. Consult
the coupling manufacturer for the swage length needed for proper assembly.

12. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe off
lubricant from ferrule and hose.
13. Repeat above steps for other end of hose.
Testing:

Hydrostatic testing as required.
6.7.16     Asphalt Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

              I.D.                        Working Pressure                                 Test Pressure
 inch                     mm                        psi            (kPa)                             psi             (kPa)

 1”                  (25.4 mm)     lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 1 1/4"           (31.8 mm)         lesser of hose or 600           ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 1 1/2"           (38.1 mm)         lesser of hose or 600           ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 2”               (50.8 mm)         lesser of hose or 600           ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 2 1/2"           (63.5 mm)         lesser of hose or 450           ( 3103 )       lesser of 2X hose or 900             ( 6206 )
 3”               (76.2 mm)         lesser of hose or 450           ( 3103 )       lesser of 2X hose or 900             ( 6206 )
 4”              (101.6 mm)         lesser of hose or 230           ( 1586 )       lesser of 2X hose or 460             ( 3172 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.

2. Cut the hose square per general fabrication methods.

3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.

4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting may help
insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy water solution.

5. Attach clamp per manufacturer’s recommendation or the following procedures:

Assembly Procedure of Four Bolt Clamps: Perform steps 1-5 above.

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the stem. Snug
the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be necessary to put the
stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the bolts equally (thread
engagement between bolt and nut is equal on all 4 bolts).

7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) 1 full turn.

9. Front bolt (close to gripping finger) 1 full turn,
10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,

11. Opposite side back bolt 1 full turn,
12. Opposite side front bolt 1 full turn,

13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torque.
14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published torque.

Assembly Procedure of Six Bolt Clamps: Perform steps 1-5 above.
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar. Snug the bolts by hand equally (thread
engagement between bolt and nut is equal on all six bolts. Place a mark (X) on the clamp body of one of the segments near
the nut of the back bolt (away from gripping finger) with a magic marker or something similar.
7. Using a torque wrench, begin tightening the bolts as follows:

8. Back bolt (away from gripping finger) having “X” near it one full turn,
9. Front bolt (close to gripping finger) of same segment one full turn,

10. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),

11. Back bolt to one full turn,

12. Front bolt one full turn,
13. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),

14. Back bolt one full turn,

15. Front bolt one full turn.
16. Repeat above procedure “8” through “15” until all of the bolts have reached the recommended published torque.

Assembly procedure for U-bolt clamps: Perform steps 1-5 above.

6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.
7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.

8. Install U-bolts around steel liner and through clamp casting and apply nuts.

9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and interlocking fingers
engage collar of fitting.
10. Evenly tighten nuts to torque values shown on chart below.

 Clamp Size                                                   Nut Torque
 ½” (12.7 mm)                                                 15 ft.-lbs.
 ¾” (19.05 mm) through 1¼” (31.75 mm)                         25 ft.-lbs.
 1½” (38.1 mm)                                                35 ft.-lbs.
 2” (50.8 mm), 3” (76.2 mm)                                   55 ft.-lbs.
 4” (101.6 mm)                                                100 ft.-lbs.

Testing:

Hydrostatic testing as required.
6.7.17     Chemical, Plastic / Cam & Groove / Crimp

               I.D.                            Working Pressure                                      Test Pressure
 inch                        mm                             psi               (kPa)                            psi               (kPa)

 1/2”                  (12.7 mm) lesser of hose or          150             ( 1034 )   lesser of 2X hose or 300                ( 2069 )
 3/4”                   (19 mm)         lesser of hose or 250               ( 1724 )   lesser of 2X hose or 500                ( 3448 )
 1”                    (25.4 mm)        lesser of hose or 250               ( 1724 )   lesser of 2X hose or 500                ( 3448 )
 1 1/4"                (31.8 mm)        lesser of hose or 250               ( 1724 )   lesser of 2X hose or 500                ( 3448 )
 1 1/2"                (38.1 mm)        lesser of hose or 250               ( 1724 )   lesser of 2X hose or 500                ( 3448 )
 2”                    (50.8 mm)        lesser of hose or 250               ( 1724 )   lesser of 2X hose or 500                ( 3448 )
 2 1/2"                (63.5 mm)        lesser of hose or 150               ( 1034 )   lesser of 2X hose or 300                ( 2069 )
 3”                    (76.2 mm)        lesser of hose or 125                ( 862 )   lesser of 2X hose or 250                ( 1724 )
 4”                   (101.6 mm)        lesser of hose or 100                ( 690 )   lesser of 2X hose or 200                ( 1379 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

3. Measure the outer diameter of the hose, preferably with a pi tape.

4. Based on the hose outer diameter, select the proper ferrule. Mark a line on the hose cover at the distance from the end of
the hose that equals the insertion depth.
This becomes a visual check to determine if the hose is fully bottomed into the fitting.

5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

6. Lubrication should only be used if necessary.

7. Insert the stem into the hose squarely without causing damage to the tube.

8. Select the desired crimp length and crimp O.D. using manufacturer’s recommendations.
9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.
10. Place the hose assembly in the die opening.

11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.

12. Crimp the ferrule to the desired diameter.

13. Retract the dies and remove the hose assembly.

14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

15. If the O.D. is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

16. Repeat steps 1 through 15 for the other end.
Testing:

Hydrostatic testing as required. Conductivity test required.
6.7.18     Chemical Plastic / Cam & Groove / Swaged

              I.D.                           Working Pressure                                    Test Pressure
 inch                     mm                            psi             (kPa)                                psi           (kPa)

 1/2”                (12.7 mm)       lesser of hose or 150            ( 1034 )       lesser of 2X hose or 300           ( 2069 )
 3/4”                 (19 mm)        lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 1”                  (25.4 mm)       lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 1 1/4"              (31.8 mm)       lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 1 1/2"              (38.1 mm)       lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 2”                  (50.8 mm)       lesser of hose or 250            ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 2 1/2"              (63.5 mm)       lesser of hose or 150            ( 1034 )       lesser of 2X hose or 300           ( 2069 )
 3”                  (76.2 mm)       lesser of hose or 125             ( 862 )       lesser of 2X hose or 250           ( 1724 )
 4”              (101.6 mm)          lesser of hose or 100              ( 690)       lesser of 2X hose or 200           ( 1379 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1.Cut hose end square and clean any debris from tube interior.

2.Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).
3.Use a diameter tape to measure hose O.D. and select proper Ferrule. Mark a line on the hose cover at the distance from
the end of the hose that equals the insertion
depth. This becomes a visual check to determine if the hose is fully bottomed into the fitting.
4.Select proper die set and accessories using manufacturers recommendations.

5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the the hose collar.

6.Lubrication should only be used if necessary.

7.Insert stem into hose squarely without causing damage to the tube.

8.Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die
and the outside of the ferule with oil or grease.

9.Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start the
swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the ferrule
properly placed until the ferrule has been reduced to the point that it comes in contact with the
hose cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the swage
length needed for proper assembly.
10.After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe off
lubricant from ferrule and hose.
11.Repeat above steps for other end of hose.
Testing:

Hydrostatic testing as required. Conductivity test required.
6.7.19     Chemical Plastic / Cam & Groove / Preformed

                I.D.                           Working Pressure                                 Test Pressure
 inch                         mm                            psi          (kPa)                                 psi       (kPa)

 1/2”                   (12.7 mm)       lesser of hose or 125           ( 862 )       lesser of 2X hose or 250         ( 1724 )
 3/4”                     (19 mm)       lesser of hose or 125           ( 862 )       lesser of 2X hose or 250         ( 1724 )
 1”                     (25.4 mm)       lesser of hose or 125           ( 862 )       lesser of 2X hose or 250         ( 1724 )
 1 1/4"                 (31.8 mm)       lesser of hose or 125           ( 862 )       lesser of 2X hose or 250         ( 1724 )
 1 1/2"                 (38.1 mm)       lesser of hose or 125           ( 862 )       lesser of 2X hose or 250         ( 1724 )
 2”                     (50.8 mm)       lesser of hose or 100           ( 690 )       lesser of 2X hose or 200         ( 1379 )

 2 1/2"                 (63.5 mm)       lesser of hose or 75            ( 517 )       lesser of 2X hose or 150         ( 1034 )

 3”                     (76.2 mm)       lesser of hose or 75            ( 517 )       lesser of 2X hose or 150         ( 1034 )
 4”                    (101.6 mm)       lesser of hose or 50            ( 345 )       lesser of 2X hose or 100          ( 690 )

         6.7.19.1      Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will
         comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
         clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
         3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
         over 1-1/2 inch (38.1 mm)
         diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.

         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

         5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
         6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
         pressure settings that correspond to clamp width and material used.

         7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

         8. Activate tool to tighten clamp.
         9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

         10. Roll hose up until shear hook engages buckle
         11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
         finish the clamp.

         12. Reset tool and remove scrap end of clamp.
13. Repeat steps 5 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.19.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm)
diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.19.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and
above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.

6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension
and automatically punches the lock and cuts band off while maintaining correct tension. Due to many different
types of hose and fitting construction and styles, you may
alter the manufacturer’s recommended setting after determining the optimum for your application and making a
note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10.Make sure the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.19.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is no more than
approximately 1/4" larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while
the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located
on the shank somewhere. It is recommended that you use as many clamps as there are grooves if the fitting is
grooved. If not, use at least one clamp up to two inch hose
and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s)
around hose according to pre marked lines.

7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
ultimate tension has been attained, hold the ball handle in the down position with one hand.
             8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
             hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
             once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center
             of the lock. This
             mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
             turning, then lift both handles of tool together, in an up and down motion, which will break band off at lock. You
             may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool by
             operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

             9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
             10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
             Testing:

             Hydrostatic testing as required.
             Conductivity test required.

>> continue to next section
Section 6 Industrial Hose - 6.7.20 to 6.7.39

6.7 Assembly Data Sheets

      6.7.20    Chemical Plastic / Cam & Groove / Band & Buckle
      6.7.21    Chemical Plastic / Interlocking Crimp-Swage / Crimp
      6.7.22    Chemical Plastic / Interlocking Swage-Crimp / Swaged
      6.7.23    Chemical, Plastic / Machined, Medium Shank / Preformed
      6.7.24    Chemical Plastic / Machined, Medium Shank / Band & Buckle
      6.7.25    Chemical, Plastic / Machined, Long Shank / Preformed
      6.7.26    Chemical Plastic / Machined Shank, Long / Band & Buckle
      6.7.27    Chemical Rubber / Cam & Groove / Crimp
      6.7.28    Chemical Rubber / Cam & Groove / Swaged
      6.7.29    Chemical Rubber / Cam & Groove / Preformed Banded
      6.7.30    Chemical Rubber / Cam & Groove / Band & Buckle
      6.7.31    Chemical Rubber / Interlocking Crimp-Swage / Crimp
      6.7.32    Chemical Rubber / Interlocking Crimp-Swage / Swaged
      6.7.33    Chemical Rubber / Machined, Medium Shank / Preformed
      6.7.34    Chemical Rubber / Machined, Medium Shank / Band & Buckle
      6.7.35    Chemical Rubber / Machined, Long Shank / Preformed
      6.7.36    Chemical Rubber / Machined, Long Shank / Band & Buckle
      6.7.37    Chemical Rubber / Internal Expanded Stem / Internal Expanded Ferrule
      6.7.38    Food Grade, Regulated / Sanitary / Internal Expanded
      6.7.39    Food Grade, Unregulated / Cam & Groove / Crimp

>> continue to next section

6.7   Assembly Data Sheet
      6.7.20     Chemical Plastic / Cam & Groove / Band & Buckle

                     I.D.                           Working Pressure                              Test Pressure
       inch                       mm                               psi     (kPa)                             psi          (kPa)

       1 1/4"                (31.8 mm)      lesser of hose or 150        (1034 )       lesser of 2X hose or 300         (2069 )
       1 1/2"                (38.1 mm)      lesser of hose or 150        ( 1034)       lesser of 2X hose or 300         ( 2069)
       2”                    (50.8 mm)      lesser of hose or 125          ( 862)      lesser of 2X hose or 250         (1724 )
       2 1/2"                (63.5 mm)      lesser of hose or 100          (690 )      lesser of 2X hose or 200         (1379 )
       3”                    (76.2 mm)      lesser of hose or 75           ( 517)      lesser of 2X hose or 150         ( 1034)
       4”                   (101.6 mm)      lesser of hose or 50           (345 )      lesser of 2X hose or 100          ( 690)

      Special Tools Required:

      Spinner type Hand Tool
      Fabrication Procedures:

      1.Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
      large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
      barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
      than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
      wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
      diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
      manner outlined above.
      2. Pull band from container as needed. To determine length of band required, either form band roughly around hose
      twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
      with cutter in tool.

      3. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
      4. Insert fitting into hose until entire shank is covered.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

5. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

6. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
7. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
8. Clinch stub by hammering down buckle ears.

9. Repeat steps 5 through 8 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.21     Chemical Plastic / Interlocking Crimp-Swage / Crimp

              I.D.                            Working Pressure                                      Test Pressure
 inch                      mm                              psi            (kPa)                                psi              (kPa)

 1/2”                 (12.7 mm)        lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200               ( 8274)
 3/4”                  (19 mm)         lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200               ( 8274)
 1”                   (25.4 mm)        lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200               ( 8274)
 1 1/4"               (31.8 mm)        lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200               ( 8274)
 1 1/2"               (38.1 mm)        lesser of hose or 400            ( 2758 )       lesser of 2X hose or 800                (5516)
 2”                   (50.8 mm)        lesser of hose or 350            ( 2413 )       lesser of 2X hose or 700                (4826)
 2 1/2"               (63.5 mm)        lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200               ( 8274)
 3”                   (76.2 mm)        lesser of hose or 300            ( 2069 )       lesser of 2X hose or 600                (4137)
 4”                  (101.6 mm)        lesser of hose or 500            ( 3448 )       lesser of 2X hose or 1000               (6895)
 6”                  (152.4 mm)        lesser of hose or 400            ( 2758 )       lesser of 2X hose or 800                (5516)

Note:

For 1 1/2”, 2”, and 3” - Ferrules may be .065” wall
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).

3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
4. Measure the outer diameter of the hose, preferably with a pi tape.
5. Based on the hose outer diameter, select the proper ferrule.

6. Insert the stem into the hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.

8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
14. Crimp the ferrule to the desired diameter.

15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.
18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.22     Chemical Plastic / Interlocking Swage-Crimp / Swaged

               I.D.                              Working Pressure                                    Test Pressure
 inch                        mm                             psi            (kPa)                                psi                 (kPa)

 1/2”                  (12.7 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 3/4”                   (19 mm)         lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                 (8274)
 1”                    (25.4 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 1 1/4"                (31.8 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 1 1/2"                (38.1 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 2”                    (50.8 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 2 1/2"                (63.5 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 3”                    (76.2 mm)        lesser of hose or 600            ( 4137 )        lesser of 2X hose or 1200                ( 8274 )
 4”                   (101.6 mm)        lesser of hose or 500            ( 3448 )        lesser of 2X hose or 1000                ( 6895 )
 6”                   (152.4 mm)        lesser of hose or 400            ( 2758 )        lesser of 2X hose or 800                 ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).

3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Use a diameter tape to measure hose O.D. and select proper Ferrule.
5. Select proper die set and accessories using manufacturers recommendations.
6. Insert stem into hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.
8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.

9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes in contact with the
stem collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between
the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging
die and the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start
the swaging process. Depending on the coupling style, it may be necessary to put pressure against the pusher to keep
the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose cover.
Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the swage length
needed for proper assembly.

12. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe
off lubricant from ferrule and hose.
13. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.23     Chemical, Plastic / Machined, Medium Shank / Preformed

               I.D.                            Working Pressure                                    Test Pressure
 inch                       mm                             psi             (kPa)                               psi            (kPa)
 1/2”                  (12.7 mm)        lesser of hose or 125            ( 862 )        lesser of 2X hose or 250            ( 1724 )
 3/4”                   (19 mm)         lesser of hose or 125            ( 862 )        lesser of 2X hose or 250            ( 1724 )
 1”                    (25.4 mm)        lesser of hose or 125            ( 862 )        lesser of 2X hose or 250            ( 1724 )
 1 1/4"                (31.8 mm)        lesser of hose or 125            ( 862 )        lesser of 2X hose or 250            ( 1724 )
 1 1/2"                (38.1 mm)        lesser of hose or 125            ( 862 )        lesser of 2X hose or 250            ( 1724 )
 2”                    (50.8 mm)        lesser of hose or 100            ( 690 )        lesser of 2X hose or 200            ( 1379 )
 2 1/2"                (63.5 mm)        lesser of hose or 75             ( 517 )        lesser of 2X hose or 150            ( 1034 )
 3”                    (76.2 mm)        lesser of hose or 75             ( 517 )        lesser of 2X hose or 150            ( 1034 )
 4”                   (101.6 mm)        lesser of hose or 50             ( 345 )        lesser of 2X hose or 100             ( 690 )

Note:

Use 3 bands on 3” & 4”. Use 2 bands on all other sizes.
         6.7.23.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted. Clamp diameter should be within 1/2
         inch (12.7 mm) of hose outside diameter.
         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
         small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every
         space between large bards. If all barbs or serrations are the same, place as many clamps over the
         serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
         or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7
         mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19
         mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide
         clamps as fit on the shank, in the manner outlined above.

         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
         4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
hose.
8. Activate tool to tighten clamp.

9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
10. Roll hose up until shear hook engages buckle
11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam
to finish the clamp.
12. Reset tool and remove scrap end of clamp.

13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.23.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:
Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space
between large barbs. If all bards or serrations are the same, place as many clamps over the serrations as
will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5
mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on
the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at
the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.23.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.

6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine
until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot
in the machine until it can go no further and then slip assembled hose and fitting through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches the
lock and cuts band off while maintaining correct tension. Due to many different types of hose and fitting
construction and styles, you may alter the manufacturer’s recommended setting after determining the
optimum for your application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.

10. Make sure the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.23.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
         between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
         are going to be located on the shank somewhere. It is recommended that you use as many clamps as
         there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
         three on two inch and above.
         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
         applied.
         4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

         5. Insert fitting into hose until the entire shank is covered.
         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool,
         until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn
         while tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the
         clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock.
         The amount of tension is directly related to the type and style of both the hose and fitting being used. After
         proper ultimate tension has been attained, hold the ball handle in the down position with one hand.
         8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
         hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
         once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the
         center of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp
         hose firmly to prevent turning, then lift both handles of tool together, in an up and down motion, which will
         break band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool,
         work it through the tool by operating ball handle. Next, press release lever and pull waste strip out toward
         rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.

         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.24     Chemical Plastic / Machined, Medium Shank / Band & Buckle

              I.D.                           Working Pressure                                  Test Pressure
 inch                     mm                            psi                 (kPa)                         psi               (kPa)

 1 1/4"              (31.8 mm)      lesser of hose or 150                 ( 1034 )   lesser of 2X hose or 300         ( 2069 )
 1 1/2"              (38.1 mm)      lesser of hose or 150                 ( 1034 )   lesser of 2X hose or 300         ( 2069 )
 2”                  (50.8 mm)      lesser of hose or 125                  ( 862 )   lesser of 2X hose or 250         ( 1724 )
 2 1/2"              (63.5 mm)      lesser of hose or 100                  ( 690 )   lesser of 2X hose or 200         ( 1379 )
 3”                  (76.2 mm)      lesser of hose or 75                   ( 517 )   lesser of 2X hose or 150         ( 1034 )
 4”              (101.6 mm)         lesser of hose or 50                   ( 345 )   lesser of 2X hose or 100          ( 690 )

Note:

Use 3 bands on 3” & 4”. Use 2 bands on all other sizes.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.

4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
with cutter in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.25     Chemical, Plastic / Machined, Long Shank / Preformed

              I.D.                          Working Pressure                                  Test Pressure
 inch                      mm                          psi             (kPa)                            psi         (kPa)

 1/2”                 (12.7 mm)     lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 3/4”                  (19 mm)      lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 1”                   (25.4 mm)     lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 1 1/4"               (31.8 mm)     lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 1 1/2"               (38.1 mm)     lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 2”                   (50.8 mm)     lesser of hose or 125            ( 862 )       lesser of 2X hose or 250       ( 1724 )
 2 1/2"               (63.5 mm)     lesser of hose or 100            ( 690 )       lesser of 2X hose or 200       ( 1379 )
 3”                   (76.2 mm)     lesser of hose or 75             ( 517 )       lesser of 2X hose or 150       ( 1034 )
 4”                  (101.6 mm)     lesser of hose or 50             ( 345 )       lesser of 2X hose or 100        ( 690 )

Note:

Use 5 bands on 3” & 4”. Use 4 bands on 2” & 2 ½”. Use 3 bands ½” through 1 ½”.
         6.7.25.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:
1. Select smallest clamp, which slides over hose with fitting inserted. Clamp diameter should be within 1/2
inch (12.7 mm) of hose outside diameter.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every
space between large bards. If all barbs or serrations are the same, place as many clamps over the
serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7
mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19
mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide
clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
hose.
8. Activate tool to tighten clamp.

9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

10. Roll hose up until shear hook engages buckle

11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam
to finish the clamp.

12. Reset tool and remove scrap end of clamp.

13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.25.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space
between large barbs. If all bards or serrations are the same, place as many clamps over the serrations as
will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5
mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on
the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at
the same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.25.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine
until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot
in the machine until it can go no further and then slip assembled hose and fitting through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches the
lock and cuts band off while maintaining correct tension. Due to many different types of hose and fitting
construction and styles, you may alter the manufacturer’s recommended setting after determining the
optimum for your application and making a note of this on the included chart for future uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
         6.7.25.4     Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
         we suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside
         diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
         while the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.

         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
         should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
         between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
         are going to be located on the shank somewhere. It is recommended that you use as many clamps as
         there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
         three on two inch and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
         applied.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool,
         until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn
         while tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the
         clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock.
         The amount of tension is directly related to the type and style of both the hose and fitting being used. After
         proper ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
         hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
         once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the
         center of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp
         hose firmly to prevent turning, then lift both handles of tool together, in an up and down motion, which will
         break band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool,
         work it through the tool by operating ball handle. Next, press release lever and pull waste strip out toward
         rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.26     Chemical Plastic / Machined Shank, Long / Band & Buckle

              I.D.                          Working Pressure                                Test Pressure
 inch                     mm                            psi           (kPa)                             psi          (kPa)
 1 1/4"              (31.8 mm)      lesser of hose or 200          ( 1379 )      lesser of 2X hose or 400          ( 2758 )
 1 1/2"              (38.1 mm)      lesser of hose or 175          ( 1207 )      lesser of 2X hose or 350          ( 2413 )
 2”                  (50.8 mm)      lesser of hose or 150          ( 1034 )      lesser of 2X hose or 300          ( 2069 )
 2 1/2"              (63.5 mm)      lesser of hose or 125            ( 862 )     lesser of 2X hose or 250          ( 1724 )
 3”                 (76.2 mm)      lesser of hose or 100          ( 690 )       lesser of 2X hose or 200       ( 1379 )
 4”             (101.6 mm)         lesser of hose or 75           ( 517 )       lesser of 2X hose or 150       ( 1034 )

Note:

Use 5 bands on 3” & 4”. Use 4 bands on 2” & 2 ½”. Use 3 bands all other sizes.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
with cutter in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.27     Chemical Rubber / Cam & Groove / Crimp

             I.D.                        Working Pressure                                 Test Pressure
 inch                    mm                         psi           (kPa)                            psi            (kPa)
 1/2”           (12.7 mm)       lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300         ( 2069 )
 3/4”                (19 mm)    lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500         ( 3448 )
 1”             (25.4 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500         ( 3448 )
 1 1/4"         (31.8 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500         ( 3448 )
 1 1/2"         (38.1 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500         ( 3448 )
 2”             (50.8 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500         ( 3448 )
 2 1/2"         (63.5 mm)       lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300         ( 2069 )
 3”             (76.2 mm)        lesser of hose or 125            ( 862 )      lesser of 2X hose or 250            ( 1724 )
 4”            (101.6 mm)        lesser of hose or 100            ( 690 )      lesser of 2X hose or 200            ( 1379 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

3. Measure the outer diameter of the hose, preferably with a pi tape.
4. Based on the hose outer diameter, select the proper ferrule. Mark a line on the hose covering at the distance from the
end of the hose that equals the insertion depth. This becomes a visual check to determine if the hose was fully bottomed
into the fitting.

5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.
7. Insert the stem into the hose squarely without causing damage to the tube.

8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.

10. Place the hose assembly in the die opening.

11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
12. Crimp the ferrule to the desired diameter.

13. Retract the dies and remove the hose assembly.

14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

16. Repeat steps 1 through 15 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.28     Chemical Rubber / Cam & Groove / Swaged

             I.D.                          Working Pressure                                   Test Pressure
 inch                    mm                           psi             (kPa)                               psi           (kPa)
 1/2”               (12.7 mm)      lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 3/4”                (19 mm)       lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 1”                 (25.4 mm)      lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 1 1/4"             (31.8 mm)      lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 1 1/2"             (38.1 mm)      lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 2”                 (50.8 mm)      lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 2 1/2"             (63.5 mm)      lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 3”                 (76.2 mm)      lesser of hose or 125             ( 862 )      lesser of 2X hose or 250            ( 1724 )
 4”            (101.6 mm)          lesser of hose or 100             ( 690 )      lesser of 2X hose or 200            ( 1379 )

Special Tools Required:
Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

3. Use a diameter tape to measure hose O.D. and select proper Ferrule. Mark a line on the hose cover at the distance
from the end of the hose that equals the insertion depth. This will serve as a visual check to determine that the hose was
fully bottomed into the fitting.
4. Select proper die set and accessories using manufacturers recommendations.

5. Slide the ferrule over the stem collar . If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.
7. Insert stem into hose squarely without causing damage to the tube.

8. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die
and the outside of the ferrule with oil or grease.
9. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start
the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the
ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose cover.
Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the swage length
needed for proper assembly.

10. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe
off lubricant from ferrule and hose.
11. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.29     Chemical Rubber / Cam & Groove / Preformed Banded

             I.D.                         Working Pressure                                    Test Pressure
 inch                  mm                              psi            (kPa)                               psi            (kPa)

 1/2”            (12.7 mm)          lesser of hose or 150          ( 1034 )        lesser of 2X hose or 300           ( 2069 )
 3/4”               (19 mm)         lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500           ( 3448 )
 1”              (25.4 mm)          lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500           ( 3448 )
 1 1/4"          (31.8 mm)          lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500           ( 3448 )
 1 1/2"          (38.1 mm)          lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500           ( 3448 )
 2”              (50.8 mm)          lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500           ( 3448 )
 2 1/2"          (63.5 mm)          lesser of hose or 150          ( 1034 )        lesser of 2X hose or 300           ( 2069 )
 3”              (76.2 mm)          lesser of hose or 125           ( 862 )        lesser of 2X hose or 250           ( 1724 )
 4”            (101.6 mm)           lesser of hose or 100           ( 690 )        lesser of 2X hose or 200           ( 1379 )

         6.7.29.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every
space between large bards. If all barbs or serrations are the same, place as many clamps over the
serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7
mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19
mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide
clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.

7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
hose.

8. Activate tool to tighten clamp.
9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

10. Roll hose up until shear hook engages buckle

11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam
to finish the clamp.

12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.

Conductivity test required.
6.7.29.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space
between large barbs. If all bards or serrations are the same, place as many clamps over the serrations as
will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5
mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on
the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at
the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.29.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.

6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine
until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot
in the machine until it can go no further and then slip assembled hose and fitting through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches the
lock and cuts band off while maintaining correct tension. Due to many different types of hose and fitting
construction and styles, you may alter the manufacturer’s recommended setting after determining the
optimum for your application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
         6.7.29.4 Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
         we suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside
         diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
         while the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.

         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
         should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
         between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
         are going to be located on the shank somewhere. It is recommended that you use as many clamps as
         there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
         three on two inch and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
         applied.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool,
         until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn
         while tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the
         clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock.
         The amount of tension is directly related to the type and style of both the hose and fitting being used. After
         proper ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
         hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
         once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the
         center of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp
         hose firmly to prevent turning, then lift both handles of tool together, in an up and down motion, which will
         break band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool,
         work it through the tool by operating ball handle. Next, press release lever and pull waste strip out toward
         rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.

         Conductivity test required.
6.7.30     Chemical Rubber / Cam & Groove / Band & Buckle

                 I.D.                              Working Pressure                                   Test Pressure
 inch                          mm                              psi           (kPa)                                psi         (kPa)
 1 1/4"                 (31.8 mm)           lesser of hose or 250         ( 1724 )         lesser of 2X hose or 500         ( 3448 )
 1 1/2"                 (38.1 mm)           lesser of hose or 250         ( 1724 )         lesser of 2X hose or 500         ( 3448 )
 2”                     (50.8 mm)           lesser of hose or 250         ( 1724 )         lesser of 2X hose or 500         ( 3448 )
 2 1/2"                 (63.5 mm)           lesser of hose or 150         ( 1034 )         lesser of 2X hose or 300         ( 2069 )
 3”                     (76.2 mm)        lesser of hose or 125             ( 862 )        lesser of 2X hose or 250        ( 1724 )
 4”                    (101.6 mm)        lesser of hose or 100             ( 690 )        lesser of 2X hose or 200        ( 1369 )

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
with cutter in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.31     Chemical Rubber / Interlocking Crimp-Swage / Crimp

             I.D.                           Working Pressure                                    Test Pressure
 inch                    mm                           psi               (kPa)                               psi         (kPa)

 1/2”               (12.7 mm)       lesser of hose or 600             ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 3/4”                (19 mm)        lesser of hose or 600             ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1”                 (25.4 mm)       lesser of hose or 600             ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1 1/4"             (31.8 mm)       lesser of hose or 600             ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1 1/2"             (38.1 mm)       lesser of hose or 400             ( 2758 )       lesser of 2X hose or    800      ( 5516 )
 2”                 (50.8 mm)       lesser of hose or 350              (2413)        lesser of 2X hose or    700       (4826)
 2 1/2"             (63.5 mm)       lesser of hose or 600             ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 3”                 (76.2 mm)       lesser of hose or 300             ( 2069 )       lesser of 2X hose or    600      ( 4137 )
 4”             (101.6 mm)          lesser of hose or 500             ( 3448 )       lesser of 2X hose or 1000        ( 6895 )
 6”             (152.4 mm)         lesser of hose or 400               ( 2758 )       lesser of 2X hose or 800            ( 5516 )

For 1 1/2”, 2” and 3” ferrules may be .065” wall.
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).

3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
4. Measure the outer diameter of the hose, preferably with a pi tape.
5. Based on the hose outer diameter, select the proper ferrule.

6. Insert the stem into the hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.

8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.

11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.

14. Crimp the ferrule to the desired diameter.
15. Retract the dies and remove the hose assembly.

16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.32     Chemical Rubber / Interlocking Crimp-Swage / Swaged

             I.D.                           Working Pressure                                      Test Pressure
 inch                    mm                               psi          (kPa)                                 psi               (kPa)

 1/2”               (12.7 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 3/4”                (19 mm)          lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 1”                 (25.4 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 1 1/4"             (31.8 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 1 1/2"             (38.1 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 2”                 (50.8 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 2 1/2"             (63.5 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 3”                 (76.2 mm)         lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200            ( 8274 )
 4”             (101.6 mm)            lesser of hose or 500          ( 3448 )         lesser of 2X hose or 1000            ( 6895 )
 6”             (152.4 mm)            lesser of hose or 400          ( 2758 )         lesser of 2X hose or 800             ( 5516 )
Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Use a diameter tape to measure hose O.D. and select proper ferrule.
5. Select proper die set and accessories using manufacturers recommendations.

6. Insert stem into hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.

8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.
9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes n contact with the
stem collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between
the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging
die and the outside of the ferule with oil or grease.

11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start
the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the
ferrule properly placed until the ferrule has been reduced to the point that iv comes in contact with the hose cover.
Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the swage length
needed for proper assembly.

12. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the machine. Wipe
off lubricant from ferrule and hose.

13. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.33 Chemical Rubber / Machined, Medium Shank / Preformed

            I.D.                          Working Pressure                                Test Pressure
 inch                   mm                           psi           (kPa)                             psi          (kPa)

 1/2”              (12.7 mm)       lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500          ( 3448 )
 3/4”               (19 mm)        lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500          ( 3448 )
 1”                (25.4 mm)       lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500          ( 3448 )
 1 1/4"            (31.8 mm)       lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500          ( 3448 )
 1 1/2"            (38.1 mm)       lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500          ( 3448 )
 2”                (50.8 mm)       lesser of hose or 200        ( 1379 )      lesser of 2X hose or 400          ( 2758 )
 2 1/2"            (63.5 mm)       lesser of hose or 150        ( 1034 )      lesser of 2X hose or 300          ( 2069 )
 3”                (76.2 mm)       lesser of hose or 125          ( 862 )     lesser of 2X hose or 250          ( 1724 )
 4”             (101.6 mm)         lesser of hose or 100          ( 690 )     lesser of 2X hose or 200          ( 1379 )

Note:

Use 3 bands on 3” & 4”. Use 2 bands on all other sizes.
6.7.33.1   Preformed Clamps, applied with Roll-Over Pneumatic Tool
Special Tools Required:

Pneumatic Roll-over Tool
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every
space between large bards. If all barbs or serrations are the same, place as many clamps over the
serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7
mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19
mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide
clamps as fit on the shank, in the manner outlined above.

3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.

7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
hose.
8. Activate tool to tighten clamp.

9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

10. Roll hose up until shear hook engages buckle

11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam
to finish the clamp.

12. Reset tool and remove scrap end of clamp.

13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.33.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space
between large barbs. If all bards or serrations are the same, place as many clamps over the serrations as
will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5
mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on
the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at
the same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.33.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine
until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot
in the machine until it can go no further and then slip assembled hose and fitting through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches the
lock and cuts band off while maintaining correct tension. Due to many different types of hose and fitting
construction and styles, you may alter the manufacturer’s recommended setting after determining the
optimum for your application and making a note of this on the included chart for future uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
         6.7.33.4     Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
         we suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside
         diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
         while the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.

         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
         should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
         between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
         are going to be located on the shank somewhere. It is recommended that you use as many clamps as
         there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
         three on two inch and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
         applied.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool,
         until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn
         while tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the
         clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock.
         The amount of tension is directly related to the type and style of both the hose and fitting being used. After
         proper ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
         hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
         once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the
         center of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp
         hose firmly to prevent turning, then lift both handles of tool together, in an up and down motion, which will
         break band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool,
         work it through the tool by operating ball handle. Next, press release lever and pull waste strip out toward
         rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.34     Chemical Rubber / Machined, Medium Shank / Band & Buckle

              I.D.                          Working Pressure                                 Test Pressure
 inch                     mm                             psi              (kPa)                          psi          (kPa)

 1 1/4"              (31.8 mm)       lesser of hose or 300           ( 2069 )     lesser of 2X hose or 600          ( 4137 )
 1 1/2"             (38.1 mm)      lesser of hose or 300          ( 2069 )       lesser of 2X hose or 600       ( 4137 )
 2”                 (50.8 mm)      lesser of hose or 250          ( 1724 )       lesser of 2X hose or 500       ( 3448 )
 2 1/2"             (63.5 mm)      lesser of hose or 175          ( 1207 )       lesser of 2X hose or 350       ( 2413 )
 3”                 (76.2 mm)      lesser of hose or 150          ( 1034 )       lesser of 2X hose or 300       ( 2069 )
 4”            (101.6 mm)          lesser of hose or 125           ( 862 )       lesser of 2X hose or 250       ( 1724 )

Note:

Use 3 bands on 3” & 4”. Use 2 bands on all other sizes.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
with cutter in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.35     Chemical Rubber / Machined, Long Shank / Preformed

             I.D.                          Working Pressure                                   Test Pressure
 inch                     mm                           psi            (kPa)                             psi         (kPa)

 1/2”               (12.7 mm)      lesser of hose or 300            ( 2069 )      lesser of 2X hose or 600       ( 4137 )
 3/4”                 (19 mm)      lesser of hose or 300            ( 2069 )      lesser of 2X hose or 600       ( 4137 )
 1”                 (25.4 mm)      lesser of hose or 300            ( 2069 )      lesser of 2X hose or 600       ( 4137 )
 1 1/4"             (31.8 mm)      lesser of hose or 300            ( 2069 )      lesser of 2X hose or 600       ( 4137 )
 1 1/2"             (38.1 mm)       lesser of hose or 300           ( 2069 )       lesser of 2X hose or 600        ( 4137 )
 2”                 (50.8 mm)       lesser of hose or 250           ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 2 1/2"             (63.5 mm)       lesser of hose or 175           ( 1207 )       lesser of 2X hose or 350        ( 2413 )
 3”                 (76.2 mm)       lesser of hose or 150           ( 1034 )       lesser of 2X hose or 300        ( 2069 )
 4”                (101.6 mm)       lesser of hose or 125             ( 862 )      lesser of 2X hose or 250        ( 1724 )

Note:

Use 5 bands on 3” & 4”. Use 4 bands on 2” & 2 ½”. Use 3 bands ½” through 1 ½”.
        6.7.35.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
        small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every
        space between large bards. If all barbs or serrations are the same, place as many clamps over the
        serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4
        or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7
        mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19
        mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide
        clamps as fit on the shank, in the manner outlined above.

        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

        4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

        5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
        6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
        correct pressure settings that correspond to clamp width and material used.

        7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on
        hose.

        8. Activate tool to tighten clamp.
        9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        10. Roll hose up until shear hook engages buckle

        11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam
        to finish the clamp.

        12. Reset tool and remove scrap end of clamp.
        13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
        Special Considerations:

        Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
        seal.
        Testing:

        Hydrostatic testing as required.
        Conductivity test required.
        6.7.35.2     Preformed Clamps applied with Roll-Over Hand Tool and Adapter
        Special Tools Required:
Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and
small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space
between large barbs. If all bards or serrations are the same, place as many clamps over the serrations as
will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5
mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide
clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide
clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on
the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at
the same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round
seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.35.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine
until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot
in the machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches the
lock and cuts band off while maintaining correct tension. Due to many different types of hose and fitting
construction and styles, you may alter the manufacturer’s recommended setting after determining the
optimum for your application and making a note of this on the included chart for future uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.35.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly,
we suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside
diameter. This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter
while the fitting is inserted and select a clamp that is the closet to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves
between the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s)
are going to be located on the shank somewhere. It is recommended that you use as many clamps as
there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch hose and two or
three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is
applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.

6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool,
until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn
while tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the
clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock.
The amount of tension is directly related to the type and style of both the hose and fitting being used. After
proper ultimate tension has been attained, hold the ball handle in the down position with one hand.

8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a
hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than
once to obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the
center of the lock. This mark should be completely obscured by the punched lock. To free the tool, grasp
hose firmly to prevent turning, then lift both handles of tool together, in an up and down motion, which will
break band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool,
work it through the tool by operating ball handle. Next, press release lever and pull waste strip out toward
rear of tool.
9. For additional clamps repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.36     Chemical Rubber / Machined, Long Shank / Band & Buckle

              I.D.                          Working Pressure                                  Test Pressure
 inch                     mm                           psi           (kPa)                             psi         (kPa)

 1 1/4"              (31.8 mm)      lesser of hose or 375          ( 2586 )      lesser of 2X hose or 750       ( 5171 )
 1 1/2"              (38.1 mm)      lesser of hose or 375          ( 2586 )      lesser of 2X hose or 750       ( 5171 )
 2”                  (50.8 mm)      lesser of hose or 325          ( 2241 )      lesser of 2X hose or 650       ( 4482 )
 2 1/2"              (63.5 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500       ( 3448 )
 3”                  (76.2 mm)      lesser of hose or 200          ( 1379 )      lesser of 2X hose or 400       ( 2758 )
 4”              (101.6 mm)         lesser of hose or 150          ( 1034 )      lesser of 2X hose or 300       ( 2069 )

Note:

Use 5 bands on 3” & 4”. Use 4 bands on 2” & 2 ½”. Use 3 bands 1 ¼” & 1 ½”.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or
large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all
barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less
than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm)
wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For
diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the
manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band
with cutter in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose
and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.

7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:
Hydrostatic testing as required.
Conductivity test required.
6.7.37    Chemical Rubber / Internal Expanded Stem / Internal Expanded Ferrule

            I.D.                            Working Pressure                                  Test Pressure
 inch                   mm                            psi            (kPa)                                psi           (kPa)
 1”                (25.4 mm)         lesser of hose or 800        ( 5516 )      lesser of 2X hose or 1600            ( 11032 )
 1 1/4"            (31.8 mm)         lesser of hose or 800        ( 5516 )      lesser of 2X hose or 1600            ( 11032 )
 1 1/2"            (38.1 mm)         lesser of hose or 800        ( 5516 )      lesser of 2X hose or 1600            ( 11032 )
 2”                (50.8 mm)         lesser of hose or 800        ( 5516 )      lesser of 2X hose or 1600            ( 11032 )
 2 1/2"            (63.5 mm)         lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 3”                (76.2 mm)         lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 4”             (101.6 mm)           lesser of hose or 500        ( 3448 )      lesser of 2X hose or 1000             ( 6895 )
 6”             (152.4 mm)           lesser of hose or 400        ( 2758 )      lesser of 2X hose or 800              ( 5516 )

The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between the
fitting stem and the ferrule by expanding the I.D. of the fitting. The resulting assembly will have a fitting I.D. equal to the
size of the plug or mandrel allowing for full flow of material through the fitting.
Special Tools Required:

Internal expansion equipment
Fabrication Procedure:

Using a ball mandrel type expander -
1. Prepare the machine by:

a) Selecting and installing the proper accessories for the size hose you will be assembling following machine
manufacturer’s instructions.
b) Selecting the proper plug or determining the proper expansion of the mandrel by following manufacturer’s
recommendations.

2. Lubricate the stem I.D. with oil or grease.

3. Lubricate the smaller end of the plug .
4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.

5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by hand)
the plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.
7. Lubricate the rest of the plug.
8. Cut the end of the hose square and clean any debris from the hose tube

9. Pull the static wire our of hose approximately ½ inch and fold it inside the hose.

10. Measure hose O.D. approximately 3inches from end of hose using a diameter tape.
11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow the
coupling manufacturer’s recommendation.
12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into
depending on the size and style of coupling. Follow manufacturer’s recommendation.
13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to flow.
Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the shoulder of the
stem.
14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has
reached the point that the ferrule will no longer move.
15. The expansion process is complete when the stem comes free of the expansion plug.
16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug from
the rod.
17. Repeat steps above for other end.

Using a die segment internal expanding machine -
1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.
2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should be
within the manufacturer's specified expansion tolerances.
3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.

4. Mark the insertion depth of the coupling on the OD of the hose end.
5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the end
of the hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert bottoms out in
the ferrule.

6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.

7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or split,
stop immediately and check the expansion diameter of the machine and contact the manufacturer.

8. Remove excess lubrication from the inside of the coupling.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.38     Food Grade, Regulated / Sanitary / Internal Expanded

             I.D.                         Working Pressure                                  Test Pressure
 inch                    mm                          psi            (kPa)                               psi           (kPa)

 1”                 (25.4 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 1 1/2"             (38.1 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 2”                 (50.8 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 2 1/2"             (63.5 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 3”                 (76.2 mm)      lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 4”            (101.6 mm)          lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500            ( 3448 )

The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between the
fitting stem and the ferrule by expanding the I.D. of the fitting. The resulting assembly will have a fitting I.D. equal to the
size of the plug or mandrel allowing for full flow of material through the fitting.
Fabrication Procedure:

Using a ball mandrel type expander -
1. Prepare the machine by:
a) Selecting and installing the proper accessories for the size hose you will be assembling following machine
manufacturer’s instructions.
b) Selecting the proper plug or determining the proper expansion of the mandrel by following manufacturer’s
recommendations.
2. Lubricate the stem I.D. with oil or grease.
3. Lubricate the smaller end of the plug .
4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.

5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by hand)
the plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.
7. Lubricate the rest of the plug.

8. Cut the end of the hose square and clean any debris from the hose tube
9. Pull the static wire our of hose approximately ½ inch and fold it inside the hose.
10. Measure hose O.D. approximately 3inches from end of hose using a diameter tape.

11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow the
coupling manufacturer’s recommendation.
12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into
depending on the size and style of coupling. Follow manufacturer’s recommendation.
13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to flow.
Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the shoulder of the
stem.

14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has
reached the point that the ferrule will no longer move.

15. The expansion process is complete when the stem comes free of the expansion plug.

16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug from
the rod.

17. Repeat steps above for other end.

Using a die segment internal expanding machine -

1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.

2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should be
within the manufacturer's specified expansion tolerances.

3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.

4. Mark the insertion depth of the coupling on the OD of the hose end.

5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the end
of the hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert bottoms out in
the ferrule.

6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.
7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or split,
stop immediately and check the expansion diameter of the machine and contact the manufacturer.
8. Remove excess lubrication from the inside of the coupling.
Special Considerations:

If the products are certified to one of the governing agencies, documentation must be provided upon request. Contact
the hose manufacturer for requirements. On any high temperature application, a quality inspection program is an
absolute necessity.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.39     Food Grade, Unregulated / Cam & Groove / Crimp
                  I.D.                        Working Pressure                                 Test Pressure
       inch                   mm                          psi          (kPa)                               psi          (kPa)

       1/2”           (12.7 mm)       lesser of hose or 150         ( 1034 )       lesser of 2X hose or 300          ( 2069 )
       3/4”              (19 mm)      lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500          ( 3448 )
       1”             (25.4 mm)       lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500          ( 3448 )
       1 1/4"         (31.8 mm)       lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500          ( 3448 )
       1 1/2"         (38.1 mm)       lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500          ( 3448 )
       2”             (50.8 mm)       lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500          ( 3448 )
       2 1/2"         (63.5 mm)       lesser of hose or 150         ( 1034 )       lesser of 2X hose or 300          ( 2069 )
       3”             (76.2 mm)       lesser of hose or 125           ( 862 )      lesser of 2X hose or 250          ( 1724 )
       4”           (101.6 mm)        lesser of hose or 100           ( 690 )      lesser of 2X hose or 200          ( 1379 )
       6”           (152.4 mm)        lesser of hose or 75            ( 517 )      lesser of 2X hose or 150          ( 1034 )

      Fabrication Procedures:

      1. Cut hose end square and clean any debris from tube interior.

      2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

      3. Measure the outer diameter of the hose, preferably with a pi tape.
      4. Based on the hose outer diameter, select the proper ferrule. Mark a line on the hose covering at the distance from the
      end of the hose that equals the insertion depth. This becomes a visual check to determine if the hose was fully bottomed
      into the fitting.

      5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

      6. Lubrication should only be used if necessary.
      7. Insert the stem into the hose squarely without causing damage to the tube.

      8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
      9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.

      10. Place the hose assembly in the die opening.

      11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
      achieve the desired crimp length.
      12. Crimp the ferrule to the desired diameter.

      13. Retract the dies and remove the hose assembly.
      14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
      15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
      consult the coupling manufacturer.
      16. Repeat steps 1 through 15 for the other end.
      Testing:

      Hydrostatic testing as required.
      Conductivity test required.

>> continue to next section
Section 6 Industrial Hose - 6.7.40 to 6.7.63

6.7 Assembly Data Sheets

      6.7.40    Food Grade Unregulated / Cam & Groove / Swage
      6.7.41    Food Grade Unregulated / Cam & Groove / Preformed
      6.7.42    Food Grade Unregulated / Cam & Groove / Band & Buckle
      6.7.43    Food Grade Unregulated / Machined, Medium Shank / Preformed
      6.7.44    Food Grade Unregulated / Machined, Medium Shank / Band & Buckle
      6.7.45    Food Grade Unregulated / Interlocking Crimp-Swage / Crimp
      6.7.46    Food Grade Unregulated / Interlocking Crimp-Swage / Swage
      6.7.47    Food Unregulated / Internal Expansion Stem / Internal Expansion Ferrule
      6.7.48    Lay Flat / Cam & Groove / Crimp
      6.7.49    Lay Flat / Cam & Groove / Preformed
      6.7.50    Lay Flat or Mill / Machined, Medium Shank / Preformed
      6.7.51    Lay Flat / Machined. Long Shank / Preformed
      6.7.52    Lay Flat / Cast / Preformed
      6.7.53    Material Handling/Cam & Groove/Crimp
      6.7.54    Material Handling / Cam & Groove / Swaged
      6.7.55    Material Handling / Cam & Groove / Preformed
      6.7.56    Material Handling / Cam & Groove / Band & Buckle
      6.7.57    Material Handling (soft wall only) / Machined, Medium Shank / Bolt Clamp
      6.7.58    Material Handling / Machined, Medium Shank / Preformed
      6.7.59    Material Handling / Machined, Medium Shank / Band & Buckle
      6.7.60    Material Handling (soft wall only) / Machined, Long Shank / Bolt Clamp
      6.7.61    Material Handling / Machined, Long Shank / Preformed
      6.7.62    Material Handling / Machined, Long Shank / Band & Buckle
      6.7.63    Material Handling (soft wall only) / Cast / Bolt Clamp

>> continue to next section

6.7 Assembly Data Sheets

      6.7.40     Food Grade Unregulated / Cam & Groove / Swage

                       I.D.                            Working Pressure                                Test Pressure
       inch                         mm                             psi           (kPa)                             psi             (kPa)
       1/2"                    (12.7 mm)         lesser of hose or 150         (1034)        lesser of 2X hose or 300             (2069)
       3/4"                     (19 mm)          lesser of hose or 250         (1724)        lesser of 2X hose or 500             (3448)
       1"                      (25.4 mm)         lesser of hose or 250         (1724)        lesser of 2X hose or 500             (3448)
       1 1/4"                  (31.8 mm)         lesser of hose or 250         (1724)        lesser of 2X hose or 500             (3448)
       1 1/2"                  (38.1 mm)         lesser of hose or 250         (1724)        lesser of 2X hose or 500             (3448)
       2"                      (50.8 mm)         lesser of hose or 250         (1724)        lesser of 2X hose or 500             (3448)
       2 1/2"                  (63.5 mm)         lesser of hose or 150         (1034)        lesser of 2X hose or 300             (2069)
       3"                      (76.2 mm)         lesser of hose or 125           (862)       lesser of 2X hose or 250             (1724)
       4"                     (101.6 mm)         lesser of hose or 100           (690)       lesser of 2X hose or 200             (1379)
       6"                     (152.4 mm)         lesser of hose or 75            (517)       lesser of 2X hose or 150             (1034)


      Special Tools Required:

      Swaging equipment and appropriate dies
      Fabrication Procedures:

      1. Cut hose end square and clean any debris from tube interior.

      2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
      3. Use a diameter tape to measure hose O.D. and select proper Ferrule. Mark a line on the hose cover at the distance from
the end of the hose that equals the insertion depth. This will serve as a visual check to determine that the hose was fully
bottomed into the fitting.

4. Select proper die set and accessories using manufacturers recommendations.
5. Slide the ferrule over the stem collar . If the ferrule has flats, be sure they line up with the flats on the hose collar.

6. Lubrication should only be used if necessary.
7. Insert stem into hose squarely without causing damage to the tube.

8. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die and
the outside of the ferrule with oil or grease.

9. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start the
swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the ferrule
properly placed until the ferrule has been reduced to the point that it comes in contact with the hose cover. Continue the
swage until desired length has been achieved. Consult the coupling manufacturer for the swage length needed for proper
assembly.
10. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe off
lubricant from ferrule and hose.

11. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.41     Food Grade Unregulated / Cam & Groove / Preformed

                    I.D.                             Working Pressure                                       Test Pressure
 inch                            mm                               psi               (kPa)                                 psi      (kPa)

 1/2"                       (12.7 mm)         lesser of hose or 150                (1034)         lesser of 2X hose or 300      (2069)
 3/4"                        (19 mm)          lesser of hose or 250                (1724)         lesser of 2X hose or 500      (3448)
 1"                         (25.4 mm)         lesser of hose or 250                (1724)         lesser of 2X hose or 500      (3448)
 1 1/4"                     (31.8 mm)         lesser of hose or 250                (1724)         lesser of 2X hose or 500      (3448)
 1 1/2"                     (38.1 mm)         lesser of hose or 250                (1724)         lesser of 2X hose or 500      (3448)
 2"                         (50.8 mm)         lesser of hose or 250                (1724)         lesser of 2X hose or 500      (3448)
 2 1/2"                     (63.5 mm)         lesser of hose or 150              (1034 )          lesser of 2X hose or 300      (2069)
 3"                         (76.2 mm)         lesser of hose or 125                 (862)         lesser of 2X hose or 250      (1724)
 4"                        (101.6 mm)         lesser of hose or 100                (690 )         lesser of 2X hose or 200      (1379)
 6"                        (152.4 mm)         lesser of hose or 75                  (517)         lesser of 2X hose or 150      (1034)

         6.7.41.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
         fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
         diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
         inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
         inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
         above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

8. Activate tool to tighten clamp.
9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
10. Roll hose up until shear hook engages buckle

11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
finish the clamp.

12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.41.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:
Hydrostatic testing as required.
Conductivity test required.
6.7.41.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.

6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.

10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.41.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
         lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.42     Food Grade Unregulated / Cam & Groove / Band & Buckle

               I.D.                           Working Pressure                                Test Pressure
 inch                       mm                              psi            (kPa)                          psi          (kPa)

 1 1/4"                (31.8 mm)        lesser of hose or 250             (1724)   lesser of 2X hose or 500           (3448)
 1 1/2"                (38.1 mm)        lesser of hose or 250             (1724)   lesser of 2X hose or 500           (3448)
 2"                    (50.8 mm)        lesser of hose or 250             (1724)   lesser of 2X hose or 500          (3448 )
 2 1/2"                (63.5 mm)        lesser of hose or 150             (1034)   lesser of 2X hose or 300           (2069)
 3"                    (76.2 mm)        lesser of hose or 125              (862)   lesser of 2X hose or 250           (1724)
 4"                   (101.6 mm)        lesser of hose or 100              (690)   lesser of 2X hose or 200           (1379)
 6"                   (152.4 mm)        lesser of hose or 75               (517)   lesser of 2X hose or 150           (1034)


Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.

4. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.43     Food Grade Unregulated / Machined, Medium Shank / Preformed

               I.D.                           Working Pressure                                Test Pressure
 inch                       mm                             psi          (kPa)                             psi      (kPa)

 1/2"                  (12.7 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500    (3448)
 3/4"                   (19 mm)        lesser of hose or 250           (1724)        lesser of 2X hose or 500    (3448)
 1"                    (25.4 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500    (3448)
 1 1/4"                (31.8 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500    (3448)
 1 1/2"                (38.1 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500    (3448)
 2"                    (50.8 mm)       lesser of hose or 200           (1379)        lesser of 2X hose or 400    (2758)
 2 1/2"                (63.5 mm)       lesser of hose or 150           (1034)        lesser of 2X hose or 300    (2069)
 3"                    (76.2 mm)       lesser of hose or 125            (862)        lesser of 2X hose or 250    (1724)
 4"                   (101.6 mm)       lesser of hose or 100            (690)        lesser of 2X hose or 200    (1379)

Note:

Use 3 bands on 3" & 4". Use 2 bands on all other sizes.
         6.7.43.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
         fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
         diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
         inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
         inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
         above.
         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
         5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
         6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

8. Activate tool to tighten clamp.
9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

10. Roll hose up until shear hook engages buckle
11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
finish the clamp.
12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.43.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.43.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:
Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.

9. For additional clamps, repeat steps 6 and 7 above.

10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.43.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closet to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.
         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.
         8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.44     Food Grade Unregulated / Machined, Medium Shank / Band & Buckle

               I.D.                         Working Pressure                                  Test Pressure
 inch                       mm                           psi        (kPa)                                 psi      (kPa)
 1 1/4"                (31.8 mm)      lesser of hose or 300        (2069)           lesser of 2X hose or 600     (4137)
 1 1/2"                (38.1 mm)      lesser of hose or 300        (2069)           lesser of 2X hose or 600     (4137)
 2"                    (50.8 mm)      lesser of hose or 250        (1724)           lesser of 2X hose or 500     (3448)
 2 1/2"                (63.5 mm)      lesser of hose or 175        (1207)           lesser of 2X hose or 350     (2413)
 3"                    (76.2 mm)      lesser of hose or 150        (1034)           lesser of 2X hose or 300     (2069)
 4"                   (101.6 mm)      lesser of hose or 125         (862)           lesser of 2X hose or 250     (1724)


Note:

Use 3 bands on 3" & 4". Use 2 bands on all other sizes.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.45     Food Grade Unregulated / Interlocking Crimp-Swage / Crimp

              I.D.                        Working Pressure                                  Test Pressure
 inch                     mm                           psi         (kPa)                                  psi          (kPa)
 1/2"                (12.7 mm)      lesser of hose or 600         (4137)          lesser of 2X hose or 1200           (8274)
 3/4"                 (19 mm)       lesser of hose or 600         (4137)          lesser of 2X hose or 1200           (8274)
 1"                  (25.4 mm)      lesser of hose or 600         (4137)          lesser of 2X hose or 1200           (8274)
 1 1/4"              (31.8 mm)      lesser of hose or 600         (4137)          lesser of 2X hose or 1200           (8274)
 1 1/2"              (38.1 mm)      lesser of hose or 400         (2758)          lesser of 2X hose or 800            (5516)
 2"                  (50.8 mm)      lesser of hose or 350         (2413)          lesser of 2X hose or 700            (4827)
 2 1/2"              (63.5 mm)      lesser of hose or 600         (4137)          lesser of 2X hose or 1200           (8274)
 3"                  (76.2 mm)      lesser of hose or 300         (2069)          lesser of 2X hose or 600            (4137)
 4"              (101.6 mm)         lesser of hose or 500         (3448)          lesser of 2X hose or 1000           (6895)
 6"              (152.4 mm)         lesser of hose or 400         (2758)          lesser of 2X hose or 800            (5516)


For 1 1/2", 2" and 3" ferrules may be .065" wall.
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Measure the outer diameter of the hose, preferably with a pi tape.
5. Based on the hose outer diameter, select the proper ferrule.
6. Insert the stem into the hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.

8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.

11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.
12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.
14. Crimp the ferrule to the desired diameter.
15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.46     Food Grade Unregulated / Interlocking Crimp-Swage / Swage

              I.D.                         Working Pressure                                  Test Pressure
 inch                      mm                           psi          (kPa)                               psi          (kPa)
 1/2"                 (12.7 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 3/4"                  (19 mm)      lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 1"                   (25.4 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 1 1/4"               (31.8 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 1 1/2"               (38.1 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 2"                   (50.8 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 2 1/2"               (63.5 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 3"                   (76.2 mm)     lesser of hose or 600           (4137)        lesser of 2X hose or 1200          (8274)
 4"                  (101.6 mm)     lesser of hose or 500           (3448)        lesser of 2X hose or 1000          (6895)
 6"                  (152.4 mm)     lesser of hose or 400           (2758)        lesser of 2X hose or 800           (5516)


Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Use a diameter tape to measure hose O.D. and select proper ferrule.
5. Select proper die set and accessories using manufacturers recommendations.
6. Insert stem into hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.

8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.
9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes n contact with the stem
collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die and
the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start the
swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the ferrule
properly placed until the ferrule has been reduced to the point that it comes in contact with the hose cover. Continue the
swage until desired length has been achieved. Consult the coupling manufacturer for the swage length needed for proper
assembly.
12. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the machine. Wipe off
lubricant from ferrule and hose.
13. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.47     Food Unregulated / Internal Expansion Stem / Internal Expansion Ferrule

               I.D.                          Working Pressure                                Test Pressure
 inch                       mm                            psi         (kPa)                               psi       (kPa)

 1"                    (25.4 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 1 1/4"                (31.8 mm)      lesser of hose or 800         (5516)       lesser of 2X hose or 1600        (11032)
 1 1/2"                (38.1 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 2"                    (50.8 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 2 1/2"                (63.5 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 3"                    (76.2 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 4"                   (101.6 mm)      lesser of hose or 250         (1724)       lesser of 2X hose or 500          (3448)
 6"                   (152.4 mm)      lesser of hose or 400         (2758)       lesser of 2X hose or 800          (5516)


The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between the fitting
stem and the ferrule by expanding the I.D. of the fitting. The resulting assembly will have a fitting I.D. equal to the size of the
plug or mandrel allowing for full flow of material through the fitting.
Special Tools Required:

Internal expansion equipment
Fabrication Procedure:

Using a ball mandrel type expander -

1. Prepare the machine by:
         a) Selecting and installing the proper accessories for the size hose you will be assembling following machine
         manufacturer’s instructions.
         b) Selecting the proper plug or determining the proper expansion of the mandrel by following manufacturer’s
         recommendations.

2. Lubricate the stem I.D. with oil or grease.
3. Lubricate the smaller end of the plug .

4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.
5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by hand) the
plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.
7. Lubricate the rest of the plug.

8. Cut the end of the hose square and clean any debris from the hose tube

9. Pull the static wire our of hose approximately ½ inch and fold it inside the hose.
10. Measure hose O.D. approximately 3inches from end of hose using a diameter tape.
11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow the
coupling manufacturer’s recommendation.

12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into depending on
the size and style of coupling. Follow manufacturer’s recommendation.
13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to flow.
Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the shoulder of the stem.

14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has reached
the point that the ferrule will no longer move.

15. The expansion process is complete when the stem comes free of the expansion plug.
16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug from the
rod.

17. Repeat steps above for other end.
Using a die segment internal expanding machine -

1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.
2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should be within
the manufacturer's specified expansion tolerances.
3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.
4. Mark the insertion depth of the coupling on the OD of the hose end.

5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the end of the
hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert bottoms out in the ferrule.

6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.

7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or split, stop
immediately and check the expansion diameter of the machine and contact the manufacturer.

8. Remove excess lubrication from the inside of the coupling.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.48     Lay Flat / Cam & Groove / Crimp

              I.D.                           Working Pressure                                 Test Pressure
 inch                     mm                             psi           (kPa)                               psi         (kPa)
 1 1/2"              (38.1 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500           (3448)
 2"                  (50.8 mm)       lesser of hose or 250           (1724)        lesser of 2X hose or 500           (3448)
 2 1/2"              (63.5 mm)       lesser of hose or 150           (1034)        lesser of 2X hose or 300           (2069)
 3"                  (76.2 mm)       lesser of hose or 125             (862)       lesser of 2X hose or 250           (1724)
 4"               (101.6 mm)         lesser of hose or 100             (690)       lesser of 2X hose or 200           (1379)
 5"                  (127 mm)        lesser of hose or 75              (517)       lesser of 2X hose or 150           (1034)
 6"               (152.4 mm)         lesser of hose or 50              (345)       lesser of 2X hose or 100            (690)


Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm), in some material handling hoses.
3. Measure the outer diameter of the hose, preferably with a pi tape.

4. Based on the hose outer diameter, select the proper ferrule.
5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.

6. Lubrication should only be used if necessary.
7. Insert the stem into the hose squarely without causing damage to the tube.

8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.
10. Place the hose assembly in the die opening.

11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.

12. Crimp the ferrule to the desired diameter.
13. Retract the dies and remove the hose assembly.
14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

16. Repeat steps 1 through 15 for the other end.
Testing:

Hydrostatic testing as required.

6.7.49     Lay Flat / Cam & Groove / Preformed

              I.D.                            Working Pressure                               Test Pressure
 inch                     mm                             psi          (kPa)                            psi            (kPa)

 1 1/2"              (38.1 mm)       lesser of hose or 250           (1724)       lesser of 2X hose or 500           (3448)
 2"                  (50.8 mm)       lesser of hose or 250           (1724)       lesser of 2X hose or 500           (3448)
 2 1/2"              (63.5 mm)       lesser of hose or 150           (1034)       lesser of 2X hose or 300           (2069)
 3"                  (76.2 mm)       lesser of hose or 125            (862)       lesser of 2X hose or 250           (1724)
 4"              (101.6 mm)          lesser of hose or 100            (690)       lesser of 2X hose or 200           (1379)
 5"                  (127 mm)        lesser of hose or 75             (517)       lesser of 2X hose or 150           (1034)
 6"              (152.4 mm)          lesser of hose or 50             (345)       lesser of 2X hose or 100            (690)

         6.7.49.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
         smooth inside diameter to prevent leakage.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
         fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
         diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
         inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
         inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
         above.

         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
         4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

         5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
         pressure settings corresponding with clamp width and material used.
         6. Individually insert clamp tail into tool with buckle on top as far as it goes. Position clamp at mark on hose.

         7. Activate tool to tighten clamp.

         8. Upon completion of stroke, let the pressure drop down to the hold pressure setting.
9. Roll hose up until shear hook engages buckle
10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
finish the clamp.
11. Reset tool and remove scrap end of clamp.

12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.49.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
smooth inside diameter to prevent leakage.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4
to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over
1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner
outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.49.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.49.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.
6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
ultimate tension has been attained, hold the ball handle in the down position with one hand.

7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
         8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.50     Lay Flat or Mill / Machined, Medium Shank / Preformed

               I.D.                           Working Pressure                             Test Pressure
 inch                      mm                           psi         (kPa)                             psi            (kPa)
 1 1/2"               (38.1 mm)     lesser of hose or 250          (1724)       lesser of 2X hose or 500            (3448)
 2"                   (50.8 mm)     lesser of hose or 200          (1379)       lesser of 2X hose or 400            (2758)
 2 1/2"               (63.5 mm)     lesser of hose or 150          (1034)       lesser of 2X hose or 300            (2069)
 3"                   (76.2 mm)     lesser of hose or 125           (862)       lesser of 2X hose or 250            (1724)
 4"                 (101.6 mm)      lesser of hose or 100           (690)       lesser of 2X hose or 200            (1379)
 5"                   (127 mm)      lesser of hose or 75            (517)       lesser of 2X hose or 150            (1034)
 6"                 (152.4 mm)      lesser of hose or 50            (345)       lesser of 2X hose or 100              (690)

Note:

Use 3 bands on 3" through 6". Use 2 bands on all other sizes.
         6.7.50.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
         smooth inside diameter to prevent leakage.
         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
         fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
         diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
         inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
         inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
         above.
         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

         4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
         5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
         pressure settings corresponding with clamp width and material used.
         6. Individually insert clamp tail into tool with buckle on top as far as it goes. Position clamp at mark on hose.
         7. Activate tool to tighten clamp.

         8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
         9. Roll hose up until shear hook engages buckle
         10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
         finish the clamp.
         11. Reset tool and remove scrap end of clamp.
12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.50.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
smooth inside diameter to prevent leakage.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4
to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over
1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner
outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.50.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.50.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closet to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.
5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.
6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
ultimate tension has been attained, hold the ball handle in the down position with one hand.
7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

8. For additional clamps, repeat step 5-7, staggering the buckle positions.
9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:
Hydrostatic testing as required.
6.7.51     Lay Flat / Machined, Long Shank / Preformed

              I.D.                         Working Pressure                                 Test Pressure
 inch                     mm                           psi          (kPa)                             psi            (kPa)

 1 1/2"              (38.1 mm)       lesser of hose or 300         (2069)         lesser of 2X hose or 600          (4137)
 2"                  (50.8 mm)       lesser of hose or 250         (1724)         lesser of 2X hose or 500          (3448)
 2 1/2"              (63.5 mm)       lesser of hose or 175         (1027)         lesser of 2X hose or 350          (2413)
 3"                  (76.2 mm)       lesser of hose or 150         (1034)         lesser of 2X hose or 300          (2069)
 4"              (101.6 mm)          lesser of hose or 125          (862)         lesser of 2X hose or 250          (1724)
 5"                  (127 mm)        lesser of hose or 100          (690)         lesser of 2X hose or 200           1379
 6"              (152.4 mm)          lesser of hose or 75           (517)         lesser of 2X hose or 150          (1034)

Note:

Use 5 bands on 3" through 6". Use 4 bands on 2" & 2 ½". Use 3 bands on 1 ½".
6.7.51.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool
Special Tools Required:

Pneumatic Roll-over Tool
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
smooth inside diameter to prevent leakage.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
pressure settings corresponding with clamp width and material used.
6. Individually insert clamp tail into tool with buckle on top as far as it goes. Position clamp at mark on hose.
7. Activate tool to tighten clamp.

8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
9. Roll hose up until shear hook engages buckle
10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
finish the clamp.
11. Reset tool and remove scrap end of clamp.

12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.51.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
smooth inside diameter to prevent leakage.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4
to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over
1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner
outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.51.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.
         6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
         button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
         band off while maintaining correct tension. Due to many different types of hose and fitting construction and
         styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
         application and making a note of this on the included chart for future uniformity.
         7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
         8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         6.7.51.4     Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
         suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
         This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
         is inserted and select a clamp that is the closet to, but not less than that outside diameter.

         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
         be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
         the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
         be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
         the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
         and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

         4. Insert fitting into hose until the entire shank is covered.

         5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
         lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.
         6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.

         7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
         8. For additional clamps, repeat steps 5-7, staggering the buckle positions.
         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.52     Lay Flat / Cast / Preformed

               I.D.                           Working Pressure                                  Test Pressure
 inch                      mm                             psi             (kPa)                              psi         (kPa)
 1 1/2"             (38.1 mm)        lesser of hose or 75              (517)       lesser of 2X hose or 150        (1034)
 2"                 (50.8 mm)        lesser of hose or 75              (517)       lesser of 2X hose or 150        (1034)
 2 1/2"             (63.5 mm)        lesser of hose or 50              (345)       lesser of 2X hose or 100          (690)
 3"                 (76.2 mm)        lesser of hose or 50              (345)       lesser of 2X hose or 100          (690)
 4"                (101.6 mm)        lesser of hose or 50              (345)       lesser of 2X hose or 100          (690)
 5"                 (127 mm)         lesser of hose or 50              (345)       lesser of 2X hose or 100          (690)
 6"                (152.4 mm)        lesser of hose or 25              (172)       lesser of 2X hose or 50           (345)

Note:

Use 3 bands on 3” through 6”. Use 2 bands on all other sizes.
        6.7.52.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
        smooth inside diameter to prevent leakage.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
        barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
        large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
        fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
        diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
        inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
        inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
        above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.

        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
        pressure settings corresponding with clamp width and material used.

        6. Individually insert clamp tail into tool with buckle on top as far as it goes. Position clamp at mark on hose.
        7. Activate tool to tighten clamp.

        8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        9. Roll hose up until shear hook engages buckle

        10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
        finish the clamp.

        11. Reset tool and remove scrap end of clamp.
        12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
        Special Considerations:

        Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
        Testing:

        Hydrostatic testing as required.
        6.7.52.2    Preformed Clamps applied with Roll-Over Hand Tool and Adapter
        Special Tools Required:

        Spinner type Hand Tool and Adapter
        Fabrication Procedures:
1. Select smallest clamp, which slides over hose with fitting inserted. It is recommended to use a clamp with a
smooth inside diameter to prevent leakage.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4
to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over
1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner
outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Testing:

Hydrostatic testing as required.
6.7.52.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
         8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.
         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
         6.7.52.4     Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp which is larger than the hose outside diameter will function properly, we
         suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
         This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
         is inserted and select a clamp that is the closet to, but not less than that outside diameter.
         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
         be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
         the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
         be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
         the fitting is grooved and if not, you use at least one clamp up to two inch hose and two or three on two inch
         and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

         4. Insert fitting into hose until the entire shank is covered.

         5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
         lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.

         7. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
         8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.53     Material Handling/Cam & Groove/Crimp

               I.D.                           Working Pressure                                  Test Pressure
 inch                      mm                             psi              (kPa)                             psi         (kPa)

 1 1/2"               (38.1 mm)       lesser of hose or 250               (1724 )    lesser of 2X hose or 500           (3448)
 2"                   (50.8 mm)       lesser of hose or 250               (1724)     lesser of 2X hose or 500           (3448)
 2 1/2"               (63.5 mm)       lesser of hose or 150               (1034)     lesser of 2X hose or 300           (2069)
 3"                   (76.2 mm)       lesser of hose or 125                (862)     lesser of 2X hose or 250           (1724)
 4"                 (101.6 mm)        lesser of hose or 100                (690)     lesser of 2X hose or 200           (1379)
 5"                  (127 mm)        lesser of hose or 75              (517)        lesser of 2X hose or 150          (1034)
 6"              (152.4 mm)          lesser of hose or 75              (517)        lesser of 2X hose or 150          (1034)



Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
3. Measure the outer diameter of the hose, preferably with a pi tape.

4. Based on the hose outer diameter, select the proper ferrule. Mark a line on the hose covering at the distance from the end
of the hose that equals the insertion depth. This becomes a visual check to determine if the hose was fully bottomed into the
fitting.

5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.
7. Insert the stem into the hose squarely without causing damage to the tube.

8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.

9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.

10. Place the hose assembly in the die opening.
11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to achieve the
desired crimp length.
12. Crimp the ferrule to the desired diameter.

13. Retract the dies and remove the hose assembly.

14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too small,
consult the coupling manufacturer.

16. Repeat steps 1 through 15 for the other end.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.54     Material Handling / Cam & Groove / Swaged

              I.D.                          Working Pressure                                  Test Pressure
 inch                      mm                             psi          (kPa)                               psi         (kPa)
 1 1/2"               (38.1 mm)       lesser of hose or 250          (1724)        lesser of 2X hose or 500           (3448)
 2"                   (50.8 mm)       lesser of hose or 250          (1724)        lesser of 2X hose or 500           (3448)
 2 1/2"               (63.5 mm)       lesser of hose or 150          (1034)        lesser of 2X hose or 300           (2069)
 3"                   (76.2 mm)       lesser of hose or 125            (862)       lesser of 2X hose or 250           (1724)
 4"                  (101.6 mm)       lesser of hose or 100            (690)       lesser of 2X hose or 200           (1379)
 5"                   (127 mm)        lesser of hose or 75             (517)       lesser of 2X hose or 150           (1034)
 6"                  (152.4 mm)       lesser of hose or 75             (517)       lesser of 2X hose or 150           (1034)



Special Tools Required:
Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

3. Use a diameter tape to measure hose O.D. and select proper Ferrule. Mark a line on the hose cover at the distance from
the end of the hose that equals the insertion depth. This will serve as a visual check to determine that the hose was fully
bottomed into the fitting.

4. Select proper die set and accessories using manufacturers recommendations.
5. Slide the ferrule over the stem collar . If the ferrule has flats, be sure they line up with the flats on the hose collar.

6. Lubrication should only be used if necessary.
7. Insert stem into hose squarely without causing damage to the tube.

8. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between the
bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the swaging die and
the outside of the ferrule with oil or grease.

9. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled, start the
swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to keep the ferrule
properly placed until the ferrule has been reduced to the point that it comes in contact with the hose cover. Continue the
swage until desired length has been achieved. Consult the coupling manufacturer for the swage length needed for proper
assembly.

10. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine. Wipe off
lubricant from ferrule and hose.
11. Repeat above stems for other end of hose.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.55     Material Handling / Cam & Groove / Preformed

              I.D.                           Working Pressure                                  Test Pressure
 inch                     mm                               psi          (kPa)                               psi        (kPa)

 1 1/2"              (38.1 mm)         lesser of hose or 250          ( 1724 )      lesser of 2X hose or 500          (3448)
 2"                  (50.8 mm)         lesser of hose or 250           (1724)       lesser of 2X hose or 500          (3448)
 2 1/2"              (63.5 mm)         lesser of hose or 150           (1034)       lesser of 2X hose or 300          (2069)
 3"                  (76.2 mm)         lesser of hose or 125             (862)      lesser of 2X hose or 250          (1724)
 4"                 (101.6 mm)         lesser of hose or 100             (690)      lesser of 2X hose or 200          (1379)
 5"                  (127 mm)          lesser of hose or 75              (517)      lesser of 2X hose or 150          (1034)
 6"                 (152.4 mm)         lesser of hose or 75              (517)      lesser of 2X hose or 150          (1034)

         6.7.55.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.
         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
above.

3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
pressure settings that correspond to clamp width and material used.

7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.
8. Activate tool to tighten clamp.
9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

10. Roll hose up until shear hook engages buckle

11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
finish the clamp.

12. Reset tool and remove scrap end of clamp.

13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.55.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.55.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.

6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.

10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.55.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
         suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
         This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
         is inserted and select a clamp that is the closet to, but not less than that outside diameter.
         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
         be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
         the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
         be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
         the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
         lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

         9. For additional clamps, repeat step 6-8, staggering the buckle positions.

         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Special Considerations:

         Abrasive materials may cause erosion.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.56     Material Handling / Cam & Groove / Band & Buckle

               I.D.                           Working Pressure                                 Test Pressure
 inch                       mm                             psi            (kPa)                            psi           (kPa)
 1 1/2"                (38.1 mm)       lesser of hose or 250          (1724)       lesser of 2X hose or 500             (3448)
 2"                    (50.8 mm)       lesser of hose or 250          (1724)       lesser of 2X hose or 500             (3448)
 2 1/2"                (63.5 mm)       lesser of hose or 150          (1034)       lesser of 2X hose or 300             (2069)
 3"                    (76.2 mm)       lesser of hose or 125              (862)    lesser of 2X hose or 250             (1724)
 4"                   (101.6 mm)       lesser of hose or 100              (690)    lesser of 2X hose or 200             (1379)
 5"                    (127 mm)        lesser of hose or 75               (517)    lesser of 2X hose or 150             (1034)
 6"                   (152.4 mm)       lesser of hose or 75               (517)    lesser of 2X hose or 150             (1034)

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:
1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.

9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.57     Material Handling (soft wall only) / Machined, Medium Shank / Bolt Clamp

             I.D.                        Working Pressure                                 Test Pressure
 inch                   mm                           psi          (kPa)                            psi           (kPa)
 1 1/2"         (38.1 mm)          lesser of hose or 250         (1724)       lesser of 2X hose or 500         (3448)
 2"             (50.8 mm)          lesser of hose or 200         (1379)       lesser of 2X hose or 400         (2758)
 2 1/2"         (63.5 mm)          lesser of hose or 150         (1034)       lesser of 2X hose or 300         (2069)
 3"             (76.2 mm)          lesser of hose or 125           (862)      lesser of 2X hose or 250         (1724)
 4"            (101.6 mm)          lesser of hose or 100           (690)      lesser of 2X hose or 200         (1379)
 5"                 (127 mm)       lesser of hose or 75           (517 )      lesser of 2X hose or 150         (1034)
 6"            (152.4 mm)          lesser of hose or 75            (517)      lesser of 2X hose or 150         (1034)


Special Tools Required:

Appropriate size wrench or socket
Fabrication Procedures:

1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper clamp selection for
that end.
2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published minimum / maximum
range.
3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.

4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with the last serration
on the shank. The last serration is the one before the shank end.
5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger than the others, place
marks on the hose to correspond with all large nodes (or serrations) present on that stem.
6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail reads in the same
direction for all of the clamps.

                                 No. of
 I.D.
                                 Clamps
 Below 2" (50.8 mm)              1
 2" to 4" (50.8 mm to 101.6
                                 2
 mm)
 5" to 6" (127 mm to 152.4
                                 3
 mm)
 8" (203.2 mm) and above         4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.
8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as follows:

        a) Slide clamp towards the hose end past the mark placed on hose from Step 4.

        b) Position clamp so that there is ½" (12.7 mm) to 5/8" (15.9 mm) of rubber between clamp and hose end.
        Make sure that there is more rubber between clamp and mark on hose than there is between clamp and hose
        end. If this is not possible, center the clamp between the mark on the hose and the hose end.

        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of the saddle (the
        part that the bolt goes through) is midway between both clamp halves.
        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread showing past both
        nuts. Reposition the saddles as needed per Step 8c above. Saddle positioning is critical to proper sealing of the
        clamp.

        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that side.

        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.
        g) Tighten the opposite side nut one full turn.

        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch if necessary to
        reposition saddles.

        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.

9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:

        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.
        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.
        c) Repeat Steps 8c through 8i.
Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when recommended
torque is reached, the saddle loop is centered between the clamp halves.
10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble as follows:
        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        from Step 4.

        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure that the clamp
        saddles are at 90º angles to the saddles of the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.
11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as follows:
      a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.

      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
      furthest away from the hose end.

      c) Assemble clamp per Steps 8c through 8i.
      d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end making sure that
      the clamp saddles are at 90º angles to the saddles of the clamp just installed.

      e) Assemble clamp per Steps 8c through 8I.
12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS, assemble as follows:

      a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.
      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
      from Step 4.
      c) Assemble clamp per Steps 8c through 8i.

      d) Position the other clamps so that they are equally spaced between the clamp just installed and the hose end.
      Place marks on the hose to correspond with the location of these clamps.

      e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
      installed.

      f) Assemble clamp per Steps 8c through 8i.

      g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
      installed.

      h) Assemble clamp per Steps 8c through 8i.

13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble as follows:

      a) Slide all the clamps towards the hose end past the mark furthest from the hose end from Step 5.
      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
      furthest from the hose end from Step 5.

      c) Assemble clamp per Steps 8c through 8i.

      d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from Step 5 and position
      the saddles at 45º angles to the clamp just installed.

      e) Assemble clamp per Steps 8c through 8i.

      f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the hose end from Step 5
      and position the saddles at 45º angles to the clamp just installed.
      g) Assemble clamp per Steps 8c through 8I.

14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles of the clamp being
installed are to be positioned at 90º angles to the saddles of the clamp just installed.
Special Considerations:

1. Both bolts must be tightened evenly and equally to recommended torque.

2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than the other, the clamp
may walk at an angle to the hose body. This can result in sealing and retention problems.

3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they must bend for the
clamp to work properly.

4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any sharp edges. Do
not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in the metal of the bolt.
5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
Warnings:
Do not use Bolt Clamps on hoses that are constructed with helix wire.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.58     Material Handling / Machined, Medium Shank / Preformed

             I.D.                             Working Pressure                               Test Pressure
 inch                   mm                               psi           (kPa)                             psi         (kPa)

 1 1/2"         (38.1 mm)            lesser of hose or 250            (1724)        lesser of 2X hose or 500        (3448)
 2"             (50.8 mm)            lesser of hose or 200            (1379)        lesser of 2X hose or 400        (2758)
 2 1/2"         (63.5 mm)            lesser of hose or 150            (1034)        lesser of 2X hose or 300        (2069)
 3"             (76.2 mm)            lesser of hose or 125             (862)        lesser of 2X hose or 250        (1724)
 4"            (101.6 mm)            lesser of hose or 100             (690)        lesser of 2X hose or 200        (1379)
 5"                 (127 mm)         lesser of hose or 75              (517)        lesser of 2X hose or 150        (1034)
 6"            (152.4 mm)            lesser of hose or 75              (517)        lesser of 2X hose or 150        (1034)

Note:

Use 3 bands on 3" through 6". Use 2 bands 1 ½" through 2 ½".
         6.7.58.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.

         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
         barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
         large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
         fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
         diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
         inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
         inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
         above.

         3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
         5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

         6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
         pressure settings that correspond to clamp width and material used.

         7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

         8. Activate tool to tighten clamp.
         9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
         10. Roll hose up until shear hook engages buckle

         11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
         finish the clamp.

         12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.58.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.

9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.58.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.

10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.58.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

5. Insert fitting into hose until the entire shank is covered.
6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
ultimate tension has been attained, hold the ball handle in the down position with one hand.
         8.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.

         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Special Considerations:

         Abrasive materials may cause erosion.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.59     Material Handling / Machined, Medium Shank / Band & Buckle

               I.D.                         Working Pressure                                  Test Pressure
 inch                      mm                          psi         (kPa)                               psi         (kPa)
 1 1/2"               (38.1 mm)     lesser of hose or 300         (2069)        lesser of 2X hose or 600         (4137)
 2"                   (50.8 mm)     lesser of hose or 250         (1724)        lesser of 2X hose or 500         (3448)
 2 1/2"               (63.5 mm)     lesser of hose or 175         (1207)        lesser of 2X hose or 350         (2413)
 3"                   (76.2 mm)     lesser of hose or 150         (1034)        lesser of 2X hose or 300         (2069)
 4"                 (101.6 mm)      lesser of hose or 125           (862)       lesser of 2X hose or 250         (1724)
 5"                   (127 mm)      lesser of hose or 100           (690)       lesser of 2X hose or 200         (1379)
 6"                 (152.4 mm)      lesser of hose or 100           (690)       lesser of 2X hose or 200         (1379)

Note:

Use 3 bands on 3" through 6". Use 2 bands 1 ½" through 2 ½".
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.60     Material Handling (soft wall only) / Machined, Long Shank / Bolt Clamp

              I.D.                       Working Pressure                               Test Pressure
 inch                     mm                         psi          (kPa)                              psi        (kPa)
 1 1/2"              (38.1 mm)     lesser of hose or 300         (2069)      lesser of 2X hose or 600          (4137)
 2"                  (50.8 mm)     lesser of hose or 250         (1724)      lesser of 2X hose or 500          (3448)
 2 1/2"              (63.5 mm)     lesser of hose or 175         (1207)      lesser of 2X hose or 350          (2413)
 3"                  (76.2 mm)     lesser of hose or 150         (1034)      lesser of 2X hose or 300          (2069)
 4"              (101.6 mm)        lesser of hose or 125          (862)      lesser of 2X hose or 250          (1724)
 5"                  (127 mm)      lesser of hose or 100          (690)      lesser of 2X hose or 200          (1379)
 6"              (152.4 mm)        lesser of hose or 75           (517)      lesser of 2X hose or 150          (1034)


Special Tools Required:

Appropriate size wrench or socket
Fabrication Procedures:

1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper clamp selection for
that end.

2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published minimum / maximum
range.
3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.

4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with the last serration
on the shank. The last serration is the one before the shank end.

5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger than the others, place
marks on the hose to correspond with all large nodes (or serrations) present on that stem.

6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail reads in the same
direction for all of the clamps.

 I.D.                                        No. of Clamps
 Below 2" (50.8 mm)                          1
 2" to 4" (50.8 mm to 101.6 mm)              2
 5" to 6" (127 mm to 152.4 mm)               3
 8" (203.2 mm) and above                     4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.
8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as follows:

         a) Slide clamp towards the hose end past the mark placed on hose from Step 4.
         b) Position clamp so that there is ½" (12.7 mm) to 5/8" (15.9 mm) of rubber between clamp and hose end.
        Make sure that there is more rubber between clamp and mark on hose than there is between clamp and hose
        end. If this is not possible, center the clamp between the mark on the hose and the hose end.

        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of the saddle (the
        part that the bolt goes through) is midway between both clamp halves.

        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread showing past both
        nuts. Reposition the saddles as needed per Step 8c above. Saddle positioning is critical to proper sealing of the
        clamp.

        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that side.
        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.

        g) Tighten the opposite side nut one full turn.
        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch if necessary to
        reposition saddles.

        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.
9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:

        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.
        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.

        c) Repeat Steps 8c through 8i.
Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when recommended
torque is reached, the saddle loop is centered between the clamp halves.

10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble as follows:

        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure that the clamp
        saddles are at 90º angles to the saddles of the clamp just installed.

        e) Assemble clamp per Steps 8c through 8i.

11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as follows:

        a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        furthest away from the hose end.

        c) Assemble clamp per Steps 8c through 8i.
        d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end making sure that
        the clamp saddles are at 90º angles to the saddles of the clamp just installed.
        e) Assemble clamp per Steps 8c through 8I.

12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS, assemble as follows:
        a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position the other clamps so that they are equally spaced between the clamp just installed and the hose end.
        Place marks on the hose to correspond with the location of these clamps.
        e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
         installed.
         f) Assemble clamp per Steps 8c through 8i.

         g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
         installed.

         h) Assemble clamp per Steps 8c through 8i.
13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble as follows:

         a) Slide all the clamps towards the hose end past the mark furthest from the hose end from Step 5.
         b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
         furthest from the hose end from Step 5.

         c) Assemble clamp per Steps 8c through 8i.
         d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from Step 5 and position
         the saddles at 45º angles to the clamp just installed.
         e) Assemble clamp per Steps 8c through 8i.

         f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the hose end from Step 5
         and position the saddles at 45º angles to the clamp just installed.

         g) Assemble clamp per Steps 8c through 8I.

14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles of the clamp being
installed are to be positioned at 90º angles to the saddles of the clamp just installed.
Special Considerations:

1. Both bolts must be tightened evenly and equally to recommended torque.

2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than the other, the clamp
may walk at an angle to the hose body. This can result in sealing and retention problems.

3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they must bend for the
clamp to work properly.
4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any sharp edges. Do
not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in the metal of the bolt.

5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
Warnings:

Do not use Bolt Clamps on hoses that are constructed with helix wire.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.61     Material Handling / Machined, Long Shank / Preformed

              I.D.                        Working Pressure                               Test Pressure

 inch                      mm                      psi           (kPa)                              psi            (kPa)

 1 1/2"               (38.1 mm)   lesser of hose or 300         (2069)        lesser of 2X hose or 600            (4137)
 2"                   (50.8 mm)   lesser of hose or 250         (1724)        lesser of 2X hose or 500            (3448)
 2 1/2"               (63.5 mm)   lesser of hose or 175         (1207)        lesser of 2X hose or 350            (2413)
 3"                   (76.2 mm)   lesser of hose or 150         (1034)        lesser of 2X hose or 300            (2069)
 4"               (101.6 mm)      lesser of hose or 125           (862)       lesser of 2X hose or 250            (1724)
 5"                   (127 mm)    lesser of hose or 100           (690)       lesser of 2X hose or 200            (1379)
 6"             (152.4 mm)      lesser of hose or 100              (690)        lesser of 2X hose or 200           (1379)

Note:

Use 5 bands on 3" through 6". Use 4 bands 2" through 2 ½". Use 3 bands on 1 ½".
        6.7.61.1   Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
        barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for every space between
        large bards. If all barbs or serrations are the same, place as many clamps over the serration as will comfortable
        fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For
        diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
        inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2
        inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the manner outlined
        above.

        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
        4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

        5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

        6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for correct
        pressure settings that correspond to clamp width and material used.

        7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark on hose.

        8. Activate tool to tighten clamp.

        9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        10. Roll hose up until shear hook engages buckle

        11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off cam to
        finish the clamp.

        12. Reset tool and remove scrap end of clamp.

        13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
        Special Considerations:

        Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.
        Abrasive materials may cause erosion.
        Testing:

        Hydrostatic testing as required.
        Conductivity test required.
        6.7.61.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
        Special Tools Required:

        Spinner type Hand Tool and Adapter
        Fabrication Procedures:

        1. Select smallest clamps, which slides over hose with fitting inserted
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large and small
        barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for every space between
        large barbs. If all bards or serrations are the same, place as many clamps over the serrations as will
        comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide
        clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For
3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For hoses
over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit on the shank, in the
manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position clamp at
mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum tension has been
applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn at the
same time.

8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band thus
completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good round seal.

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.61.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
suggest that you use a clamp that is not more than approximately 1/4" larger than the hose outside diameter.
This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
is inserted and select a clamp that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the machine until
it can go no further. If no clamps are already on hose, insert tail piece of one clamp into the clamp slot in the
machine until it can go no further and then slip assembled hose and fitting through the clamp.

7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the tensioning
button with one finger until clamp has reached proper tension and automatically punches the lock and cuts
band off while maintaining correct tension. Due to many different types of hose and fitting construction and
styles, you may alter the manufacturer’s recommended setting after determining the optimum for your
application and making a note of this on the included chart for future uniformity.

8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Special Considerations:

         Abrasive materials may cause erosion.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
         6.7.61.4    Center Punch Clamp applied with Hand Tool
         Special Tools Required:

         Hand Tool & Mallet
         Fabrication Procedures:

         1. Although any diameter of clamp, which is larger than the hose outside diameter, will function properly, we
         suggest that you use a clamp that is no more than approximately 1/4" larger than the hose outside diameter.
         This will reduce clamp cost and installation time. Therefore, measure the hose outside diameter while the fitting
         is inserted and select a clamp that is the closet to, but not less than that outside diameter.
         2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s) should
         be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the grooves between
         the barbs. If there are many barbs (serrations or nodes) you need to make sure that the clamp(s) are going to
         be located on the shank somewhere. It is recommended that you use as many clamps as there are grooves if
         the fitting is grooved. If not, use at least one clamp up to two inch hose and two or three on two inch and above.
         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting. This
         enables you to use the smallest diameter of clamp possible. However, if, for whatever reason, you need or
         want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after the fitting is applied.

         4. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

         5. Insert fitting into hose until the entire shank is covered.

         6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into tool, until
         lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked lines.

         7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion, making
         smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the hose to turn while
         tightening the clamp. As a general rule of thumb, you will know the clamp is tight enough when the clamp
         surface is below the O.D. of the hose and/or the clamp’s band has stopped moving through the lock. The
         amount of tension is directly related to the type and style of both the hose and fitting being used. After proper
         ultimate tension has been attained, hold the ball handle in the down position with one hand.

         8.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch head a hard
         blow with a non-sparking mallet to lock the clamp. You may have to strike the punch head more than once to
         obtain the proper hold. As a general rule of thumb, the clamp will have an identifying mark in the center of the
         lock. This mark should be completely obscured by the punched lock. To free the tool, grasp hose firmly to
         prevent turning, then lift both handles of tool together, in an up and down motion, which will break band off at
         lock. You may smooth lock corners with mallet. To clear cut-off end of clamp from tool, work it through the tool
         by operating ball handle. Next, press release lever and pull waste strip out toward rear of tool.
         9. For additional clamps, repeat steps 6-8, staggering the buckle positions.

         10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Special Considerations:

         Abrasive materials may cause erosion.
         Testing:

         Hydrostatic testing as required.
         Conductivity test required.
6.7.62     Material Handling / Machined, Long Shank / Band & Buckle

              I.D.                          Working Pressure                                   Test Pressure
 inch                    mm                             psi           (kPa)                                psi           (kPa)
 1 1/2"          (38.1 mm)         lesser of hose or 375          (2586)         lesser of 2X hose or 750        (5171)
 2"              (50.8 mm)         lesser of hose or 325          (2241)         lesser of 2X hose or 650        (4482)
 2 1/2"          (63.5 mm)         lesser of hose or 250          (1724)         lesser of 2X hose or 500        (3448)
 3"              (76.2 mm)         lesser of hose or 200          (1379)         lesser of 2X hose or 400        (2758)
 4"            (101.6 mm)          lesser of hose or 150          (1034)         lesser of 2X hose or 300        (2069)
 5"              (127 mm)          lesser of hose or 125            (862)        lesser of 2X hose or 250        (1724)
 6"            (152.4 mm)          lesser of hose or 125            (862)        lesser of 2X hose or 250        (1724)

Note:

Use 5 bands on 3" through 6". Use 4 bands 2" through 2 ½". Use 3 bands on 1 ½".
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs, or large
barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs. If all barbs or
serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use for ID less than 1-¼
inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps.
For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger
than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2" (12.7 mm).

3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose twice
and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut band with cutter
in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches (38.1 to
50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time around hose and
through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by hand.

6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten clamp.
When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.

10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.63     Material Handling (soft wall only) / Cast / Bolt Clamp

                  I.D.                    Working Pressure                                Test Pressure
 inch                    mm                             psi        (kPa)                             psi      (kPa)

 1 1/2"           (38.1 mm)          lesser of hose or 75           (517)     lesser of 2X hose or           (1034)

 2"               (50.8 mm)          lesser of hose or 75           (517)     lesser of 2X hose or 150       (1034)
 2 1/2"           (63.5 mm)          lesser of hose or 50           (345)     lesser of 2X hose or 100         (690)
 3"               (76.2 mm)          lesser of hose or 50          (345)     lesser of 2X hose or 100         (690)
 4"              (101.6 mm)          lesser of hose or 50          (345)     lesser of 2X hose or 100         (690)
 5"                (127 mm)          lesser of hose or 50          (345)     lesser of 2X hose or 100         (690)
 6"              (152.4 mm)          lesser of hose or 25          (172)     lesser of 2X hose or 50          (345)

Special Tools Required:

Appropriate size wrench or socket
Fabrication Procedures:

1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper clamp selection for
that end.
2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published minimum / maximum
range.

3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.
4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with the last serration
on the shank. The last serration is the one before the shank end.

5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger than the others, place
marks on the hose to correspond with all large nodes (or serrations) present on that stem.

6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail reads in the same
direction for all of the clamps.

 I.D.                                         No. of Clamps
 Below 2" (50.8 mm)                           1
 2" to 4" (50.8 mm to 101.6 mm)               2
 5" to 6" (127 mm to 152.4 mm)                3
 8" (203.2 mm) and above                      4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.

8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as follows

        a) Slide clamp towards the hose end past the mark placed on hose from Step 4.

        b) Position clamp so that there is ½" (12.7 mm) to 5/8" (15.9 mm) of rubber between clamp and hose end.
        Make sure that there is more rubber between clamp and mark on hose than there is between clamp and hose
        end. If this is not possible, center the clamp between the mark on the hose and the hose end.
        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of the saddle (the
        part that the bolt goes through) is midway between both clamp halves.
        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread showing past both
        nuts. Reposition the saddles as needed per Step 8c above. Saddle positioning is critical to proper sealing of the
        clamp.
        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that side.

        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.
        g) Tighten the opposite side nut one full turn.

        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch if necessary to
        reposition saddles.
        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.

9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:

        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.
        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.
        c) Repeat Steps 8c through 8i.
Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when recommended
torque is reached, the saddle loop is centered between the clamp halves.

10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble as follows:
        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure that the clamp
        saddles are at 90º angles to the saddles of the clamp just installed.

        e) Assemble clamp per Steps 8c through 8i.
11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as follows:

        a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        furthest away from the hose end.

        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end making sure that
        the clamp saddles are at 90º angles to the saddles of the clamp just installed.
        e) Assemble clamp per Steps 8c through 8I.

12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS, assemble as follows:

        a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        from Step 4.

        c) Assemble clamp per Steps 8c through 8i.

        d) Position the other clamps so that they are equally spaced between the clamp just installed and the hose end.
        Place marks on the hose to correspond with the location of these clamps.

        e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
        installed.

        f) Assemble clamp per Steps 8c through 8i.
        g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to the clamp just
        installed.

        h) Assemble clamp per Steps 8c through 8i.
13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble as follows:

        a) Slide all the clamps towards the hose end past the mark furthest from the hose end from Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end side) of the mark
        furthest from the hose end from Step 5.
        c) Assemble clamp per Steps 8c through 8i.

        d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from Step 5 and position
        the saddles at 45º angles to the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.

        f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the hose end from Step 5
        and position the saddles at 45º angles to the clamp just installed.
        g) Assemble clamp per Steps 8c through 8I.
      14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles of the clamp being
      installed are to be positioned at 90º angles to the saddles of the clamp just installed.
      Special Considerations:

      1. Both bolts must be tightened evenly and equally to recommended torque.

      2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than the other, the clamp
      may walk at an angle to the hose body. This can result in sealing and retention problems.
      3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they must bend for the
      clamp to work properly.
      4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any sharp edges. Do
      not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in the metal of the bolt.
      5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
      Warnings:

      Do not use Bolt Clamps on hoses that are constructed with helix wire.
      Special Considerations:

      Abrasive materials may cause erosion.
      Testing:

      Hydrostatic testing as required.
      Conductivity test required.

>> continue to next section
Section 6 Industrial Hose - 6.7.64 to 6.7.93

6.7 Assembly Data Sheets

      6.7.64 Material Handling / Cast / Preformed
      6.7.65 Material Handling / Cast / Band & Buckle
      6.7.66 Material Handling / Interlocking Crimp-Swage / Crimp
      6.7.67 Material Handling / Interlocking Crimp-Swage / Swage
      6.7.68 Material Handling / Internal Expanded Stem / Internal Expanded Ferrule
      6.7.69 Material Handling Cement / Interlocking Crimp-Swage / Crimp
      6.7.70 Material Handling Cement / Interlocking Crimp-Swage / Swage
      6.7.71 Material Handling, Cement / Ground Joint or Interlocking Male Stem /Interlocking Clamp
      6.7.72 Material Handling, Cement / Internal Expanded Stem/ Internal Expanded Ferrule
      6.7.73 Petroleum Transfer /Cam & Groove / Crimp
      6.7.74 Petroleum Transfer / Cam & Groove / Swaged
      6.7.75 Petroleum Transfer / Cam & Groove / Preformed
      6.7.76 Petroleum Transfer / Cam & Groove / Band & Buckle
      6.7.77 Petroleum Transfer / Machined, Medium Shank / Preformed
      6.7.78 Petroleum Transfer / Machined, Medium Shank / Band & Buckle
      6.7.79 Petroleum Transfer / Machined, Long Shank / Preformed
      6.7.80 Petroleum Transfer / Machined, Long Shank / Band & Buckle
      6.7.81 Petroleum Transfer / Interlocking Crimp-Swage / Crimp
      6.7.82 Petroleum Transfer / Interlocking Crimp-Swage / Swaged
      6.7.83 Petroleum Transfer / Internal Expanded Stem/ Internal Expanded Ferrule
      6.7.84 Petroleum Transfer / Internal Expanded Short Brass / Internal Expansion Short Brass or Stainless Ferrule
      6.7.85 Push On / Push On
      6.7.86 Sand Blast / Sand Blast
      6.7.87 Steam Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp
      6.7.88 Water Hose / Cam & Groove / Crimp
      6.7.89 Water Hose / Cam & Groove / Swaged
      6.7.90 Water Hose / Cam & Groove / Preformed
      6.7.91 Water Hose / Cam & Groove / Band & Buckle
      6.7.92 Water Hose / Universals / Preformed
      6.7.93 Water Hose / Universals / Interlocking Clamp

>> continue to next section

6.7 Assembly Data Sheets
      6.7.64 Material Handling / Cast / Preformed

                   I.D.                        Working Pressure                            Test Pressure
       inch                    mm -                       psi         (kPa) -                          psi         (kPa)

       1 1/2"             (38.1 mm)      lesser of hose or 75        ( 517 )      lesser of 2X hose or 150      ( 1034 )
       2”                 (50.8 mm)      lesser of hose or 75        ( 517 )      lesser of 2X hose or 150      ( 1034 )
       2 1/2"             (63.5 mm)      lesser of hose or 50        ( 345 )      lesser of 2X hose or 100       ( 690 )
       3”                 (76.2 mm)      lesser of hose or 50        ( 345 )      lesser of 2X hose or 100       ( 690 )
       4”             (101.6 mm)         lesser of hose or 50        ( 345 )      lesser of 2X hose or 100       ( 690 )
       5”                 (127 mm)       lesser of hose or 50        ( 345 )      lesser of 2X hose or 100       ( 690 )
       6”             (152.4 mm)         lesser of hose or 25        ( 172 )      lesser of 2X hose or 50        ( 345 )

              6.7.64.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
              Special Tools Required:

              Pneumatic Roll-over Tool
Fabrication Procedures:

1. Select smallest clamp, which slides over hose with fitting inserted.
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
every space between large bards. If all barbs or serrations are the same, place as many clamps over
the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
(9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
(19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
on hose.
8. Activate tool to tighten clamp.

9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
10. Roll hose up until shear hook engages buckle
11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
cam to finish the clamp.

12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.64.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.64.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
9. For additional clamps, repeat steps 6 and 8 above, staggering the buckle positions.
10. Make sure the manufacturer’s markings are obliterated after punching on all clamps.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.64.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
lines.
7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
moving through the lock. The amount of tension is directly related to the type and style of both the
hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
the down position with one hand.
8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
identifying mark in the center of the lock. This mark should be completely obscured by the punched
lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
        release lever and pull waste strip out toward rear of tool.
        9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
        10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Special Considerations:

        Abrasive materials may cause erosion.
        Testing:

        Hydrostatic testing as required.
        Conductivity test required.
6.7.65 Material Handling / Cast / Band & Buckle

               I.D.                          Working Pressure                                 Test Pressure
 inch                       mm v                         psi           (kPa) .                          psi     (kPa)
 1 1/2"                (38.1 mm)      lesser of hose or 75            ( 517 )     lesser of 2X hose or 150    ( 1034 )
 2”                    (50.8 mm)      lesser of hose or 75            ( 517 )     lesser of 2X hose or 150    ( 1034 )
 2 1/2"                (63.5 mm)      lesser of hose or 50            ( 345 )     lesser of 2X hose or 100     ( 690 )
 3”                    (76.2 mm)      lesser of hose or 50            ( 345 )     lesser of 2X hose or 100     ( 690 )
 4”                   (101.6 mm)      lesser of hose or 50            ( 345 )     lesser of 2X hose or 100     ( 690 )
 5”                    (127 mm)       lesser of hose or 50            ( 345 )     lesser of 2X hose or 100     ( 690 )
 6”                   (152.4 mm)      lesser of hose or 25            ( 172 )     lesser of 2X hose or 50      ( 345 )

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs,
or large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs.
If all barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use
for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch
(12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1
mm) wide clamps. For diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as
will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.

4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut
band with cutter in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches
(38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time
around hose and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by
hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten
clamp. When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.66 Material Handling / Interlocking Crimp-Swage / Crimp

            I.D.                          Working Pressure                                   Test Pressure
 inch                   mm c                         psi            (kPa) .                             psi            (kPa)

 1 1/2"            (38.1 mm)     lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 2”                (50.8 mm)     lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 2 1/2"            (63.5 mm)     lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 3”                (76.2 mm)     lesser of hose or 600            ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 4”            (101.6 mm)        lesser of hose or 500            ( 3448 )      lesser of 2X hose or 1000           ( 6895 )
 5”                (127 mm)      lesser of hose or 450            ( 3103 )      lesser of 2X hose or 900            ( 6206 )
 6”            (152.4 mm)        lesser of hose or 400            ( 2758 )      lesser of 2X hose or 800            ( 5516 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle.
3. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
4. Measure the outer diameter of the hose, preferably with a pi tape.

5. Based on the hose outer diameter, select the proper ferrule.
6. Insert the stem into the hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.
8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
14. Crimp the ferrule to the desired diameter.
15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.

17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too
small, consult the coupling manufacturer.
18. Repeat steps 1 through 17 for the other end.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.67 Material Handling / Interlocking Crimp-Swage / Swage

            I.D.                         Working Pressure                               Test Pressure
 inch                   mm v                        psi           (kPa) .                         psi            (kPa)
 1 1/2"            (38.1 mm)       lesser of hose or 600       ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 2”                (50.8 mm)       lesser of hose or 600       ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 2 1/2"            (63.5 mm)       lesser of hose or 600       ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 3”                (76.2 mm)       lesser of hose or 600       ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 4”             (101.6 mm)         lesser of hose or 500       ( 3448 )     lesser of 2X hose or 1000          ( 6895 )
 5”                (127 mm)        lesser of hose or 450       ( 3103 )     lesser of 2X hose or 900           ( 6206 )
 6”             (152.4 mm)         lesser of hose or 400       ( 2758 )     lesser of 2X hose or 800           ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).

3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
4. Use a diameter tape to measure hose O.D. and select proper ferrule.

5. Select proper die set and accessories using manufacturers recommendations.
6. Insert stem into hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.
9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes n contact with
the stem collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance
between the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside
of the swaging die and the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled,
start the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to
keep the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose
cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the
swage length needed for proper assembly.

12. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the machine.
Wipe off lubricant from ferrule and hose.
13. Repeat above stems for other end of hose.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.68 Material Handling / Internal Expanded Stem / Internal Expanded Ferrule

             I.D.                          Working Pressure                                  Test Pressure
 inch                    mm v                        psi             (kPa) .                              psi       (kPa)

 1 1/2"             (38.1 mm)    lesser of hose or 600            ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 2”                 (50.8 mm)    lesser of hose or 600            ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 2 1/2"             (63.5 mm)    lesser of hose or 600            ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 3”                 (76.2 mm)    lesser of hose or 600            ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 4”             (101.6 mm)       lesser of hose or 500            ( 3448 )     lesser of 2X hose or 1000          ( 6895 )
 6”             (152.4 mm)       lesser of hose or 400            ( 3103 )     lesser of 2X hose or 900           ( 6206 )

The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between
the fitting stem and the ferrule by expanding the I.D. of the fitting. The resulting assembly will have a fitting I.D.
equal to the size of the plug or mandrel allowing for full flow of material through the fitting.
Special Tools Required:

Internally expansion equipment and the appropriate dies
Fabrication Procedure:

Using a ball mandrel type expander-
1. Prepare the machine by:
        a) Selecting and installing the proper accessories for the size hose you will be assembling following
        machine manufacturer instructions.
        b) Selecting the proper plug or determining the proper expansion of the mandrill by following
        manufacturer recommendations.
2. Lubricate the stem I.D. with oil or grease.

3. Lubricate the smaller end of the plug .
4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.
5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by
hand) the plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.
7. Lubricate the rest of the plug.
8. Cut the end of the hose square and clean any debris from the hose tube
9. Pull the static wire our of hose approximately ½ inch (12.7 mm) and fold it inside the hose.
10. Measure hose O.D. approximately 3 inches (76.2 mm) from end of hose using a diameter tape.
11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow
the coupling manufacturer’s recommendation.
12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into
depending on the size and style of coupling. Follow manufacturer’s recommendation.
13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to
flow. Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the
shoulder of the stem.
14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has
reached the point that the ferrule will no longer move.
15. The expansion process is complete when the stem comes free of the expansion plug.
16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug
from the rod
17. Repeat steps above for other end
Using a die segment internal expanding machine -
1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.
2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should
be within the manufacturer's specified expansion tolerances.
3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.
4. Mark the insertion depth of the coupling on the OD of the hose end.
5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the
end of the hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert
bottoms out in the ferrule.
6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.
7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or
split, stop immediately and check the expansion diameter of the machine and contact the manufacturer.
8. Remove excess lubrication from the inside of the coupling.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.69 Material Handling Cement / Interlocking Crimp-Swage / Crimp

            I.D.                        Working Pressure                                  Test Pressure
 inch                   mm .                          psi         (kPa) f                           psi              (kPa)
 1”                (25.4 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 1 1/4"            (31.8 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 1 1/2"            (38.1 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 2”                (50.8 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 2 1/2"            (63.5 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 3”                (76.2 mm)       lesser of hose or 600       ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 4”           (101.6 mm)           lesser of hose or 500       ( 3448 )      lesser of 2X hose or 1000            ( 6895 )
 5”                (127 mm)        lesser of hose or 450       ( 3103 )      lesser of 2X hose or 900             ( 6206 )
 6”           (152.4 mm)           lesser of hose or 400       ( 2758 )      lesser of 2X hose or 800             ( 5516 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle.
3. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
4. Measure the outer diameter of the hose, preferably with a pi tape.
5. Based on the hose outer diameter, select the proper ferrule.

6. Insert the stem into the hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.
12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
14. Crimp the ferrule to the desired diameter.

15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too
small, consult the coupling manufacturer.

18. Repeat steps 1 through 17 for the other end.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
6.7.70 Material Handling Cement / Interlocking Crimp-Swage / Swage

            I.D.                         Working Pressure                                   Test Pressure
 inch                  mm .                          psi           (kPa) .                             psi             (kPa)

 1”            (25.4 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 1 1/4"        (31.8 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 1 1/2"        (38.1 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 2”            (50.8 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 2 1/2"        (63.5 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 3”            (76.2 mm)         lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200            ( 8274 )
 4”           (101.6 mm)         lesser of hose or 500          ( 3448 )       lesser of 2X hose or 1000            ( 6895 )
 5”                (127 mm)      lesser of hose or 450          ( 3103 )       lesser of 2X hose or 900             ( 6206 )
 6”           (152.4 mm)         lesser of hose or 400          ( 2758 )       lesser of 2X hose or 800             ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
4. Use a diameter tape to measure hose O.D. and select proper ferrule.
5. Select proper die set and accessories using manufacturers recommendations.

6. Insert stem into hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the the hose
collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance
between the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside
of the swaging die and the outside of the ferule with oil or grease.

11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled,
start the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to
keep the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose
cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the
swage length needed for proper assembly.
12. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the machine.
Wipe off lubricant from ferrule and hose.
13. Repeat above stems for other end of hose.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
6.7.71 Material Handling, Cement / Ground Joint or Interlocking Male Stem /Interlocking Clamp

            I.D.                         Working Pressure                                  Test Pressure
 inch                   mm #                         psi          (kPa) .                             psi             (kPa)
 1”                (25.4 mm)       lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 1 1/4"            (31.8 mm)       lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 1 1/2"            (38.1 mm)       lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 2”                (50.8 mm)       lesser of hose or 600        ( 4137 )      lesser of 2X hose or 1200             ( 8274 )
 2 1/2"            (63.5 mm)       lesser of hose or 450        ( 3103 )      lesser of 2X hose or 900              ( 6206 )
 3”                (76.2 mm)       lesser of hose or 450        ( 3103 )      lesser of 2X hose or 900              ( 6206 )
 4”            (101.6 mm)          lesser of hose or 230        ( 1586 )      lesser of 2X hose or 460              ( 3172 )
 6”            (152.4 mm)          lesser of hose or 230        ( 1586 )      lesser of 2X hose or 460              ( 3172 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:
1. Determine the cut length of the hose per general fabrication methods.
2. Cut the hose square per general fabrication methods.
3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.
4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting
may help insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy
water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:

Assembly Procedure of Four Bolt Clamps:
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the
stem. Snug the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be
necessary to put the stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the
bolts equally (thread engagement between bolt and nut is equal on all 4 bolts).
7. Using a torque wrench, begin tightening the bolts as follows:

8. Back bolt (away from gripping finger) 1 full turn,
9. Front bolt (close to gripping finger) 1 full turn,
10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,
11. Opposite side back bolt 1 full turn,
12. Opposite side front bolt 1 full turn,

13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued.
14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published
torque.
Assembly Procedure of Six Bolt Clamps:

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar. Snug the bolts by hand equally
(thread engagement between bolt and nut is equal on all six bolts. Place a mark (X) on the clamp body of one of the
segments near the nut of the back bolt (away from gripping finger) with a magic marker or something similar.

7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) having “X” near it one full turn,
9. Front bolt (close to gripping finger) of same segment one full turn,
10. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),
11. Back bolt to one full turn,
12. Front bolt one full turn,

13. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),
14. Back bolt one full turn,
15. Front bolt one full turn.
16. Repeat above procedure “8” through “15” until all of the bolts have reached the recommended published torque.
Assembly procedure for U-bolt clamps:

6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.
7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.
8. Install U-bolts around steel liner and through clamp casting and apply nuts.
9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and interlocking
fingers engage collar of fitting.
10. Evenly tighten nuts to torque values shown on chart below.
                     Clamp Size                        Nut Torque
1” (25.4 mm) through 1¼” (31.75 mm)               25 ft.-lbs.
1½” (38.1 mm)                                     35 ft.-lbs.
2” (50.8 mm), 3” (76.2 mm)                        55 ft.-lbs.
4” (101.6 mm)                                     100 ft.-lbs.

Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
6.7.72 Material Handling, Cement / Internal Expanded Stem/ Internal Expanded Ferrule

              I.D.                           Working Pressure                             Test Pressure
 inch                      mm ..                      psi           (kPa) n                        psi              (kPa)
 1”                   (25.4 mm)    lesser of hose or 800         ( 5516 )     lesser of 2X hose or 1600         ( 11032 )
 1 1/4"               (31.8 mm)    lesser of hose or 800         ( 5516 )     lesser of 2X hose or 1600         ( 11032 )
 1 1/2"               (38.1 mm)    lesser of hose or 800         ( 5516 )     lesser of 2X hose or 1600         ( 11032 )
 2”                   (50.8 mm)    lesser of hose or 800         ( 5516 )     lesser of 2X hose or 1600         ( 11032 )
 2 1/2"               (63.5 mm)    lesser of hose or 600         ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 3”                   (76.2 mm)    lesser of hose or 600         ( 4137 )     lesser of 2X hose or 1200          ( 8274 )
 4”                  (101.6 mm)    lesser of hose or 500         ( 3448 )     lesser of 2X hose or 1000          ( 6895 )
 6”                  (152.4 mm)    lesser of hose or 400         ( 2758 )     lesser of 2X hose or 800           ( 5516 )

The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between
the fitting stem and the ferrule by expanding the I.D. of the fitting. The resulting assembly will have a fitting I.D.
equal to the size of the plug or mandrel allowing for full flow of material through the fitting.
SPECIAL NOTE:

This does not include brass short shank (Scovill-type) internal expansion fittings.
Special Tools Required:

Internally expansion equipment and the appropriate dies
Fabrication Procedure:

Using a ball mandrel type expander -

1. Prepare the machine by:
        a) Selecting and installing the proper accessories for the size hose you will be assembling following
        machine manufacturer instructions.
        b) Selecting the proper plug or determining the proper expansion of the mandrill by following
        manufacturer recommendations.
2. Lubricate the stem I.D. with oil or grease.
3. Lubricate the smaller end of the plug .
4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.
5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by
hand) the plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.
7. Lubricate the rest of the plug.
8. Cut the end of the hose square and clean any debris from the hose tube
9. Pull the static wire our of hose approximately ½ inch (12.7 mm) and fold it inside the hose.
10. Measure hose O.D. approximately 3 inches (76.2 mm) from end of hose using a diameter tape.

11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow
the coupling manufacturer’s recommendation.
12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into
depending on the size and style of coupling. Follow manufacturer’s recommendation.
13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to
flow. Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the
shoulder of the stem.
14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has
reached the point that the ferrule will no longer move.
15. The expansion process is complete when the stem comes free of the expansion plug.
16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug
from the rod
17. Repeat steps above for other end.
Using a die segment internal expanding machine -

1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.
2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should
be within the manufacturer's specified expansion tolerances.

3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.
4. Mark the insertion depth of the coupling on the OD of the hose end.
5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the
end of the hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert
bottoms out in the ferrule.
6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.

7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or
split, stop immediately and check the expansion diameter of the machine and contact the manufacturer.
8. Remove excess lubrication from the inside of the coupling.
Special Considerations:

Abrasive materials may cause erosion.
Testing:

Hydrostatic testing as required.
6.7.73 Petroleum Transfer /Cam & Groove / Crimp

            I.D.                           Working Pressure                                  Test Pressure
 inch                   mm .                             psi          (kPa) .                            psi           (kPa)
 1/2”             (12.7 mm)        lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300           ( 2069 )
 3/4”              (19 mm)         lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500           ( 3448 )
 1”               (25.4 mm)        lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500           ( 3448 )
 1 1/4"           (31.8 mm)        lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500           ( 3448 )
 1 1/2"           (38.1 mm)        lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500           ( 3448 )
 2”               (50.8 mm)        lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500           ( 3448 )
 2 1/2"           (63.5 mm)        lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300           ( 2069 )
 3”               (76.2 mm)        lesser of hose or 125             ( 862 )     lesser of 2X hose or 250           ( 1724 )
 4”            (101.6 mm)          lesser of hose or 100             ( 690 )     lesser of 2X hose or 200           ( 1379 )
 5”               (127 mm)         lesser of hose or 75              ( 517 )     lesser of 2X hose or 150           ( 1034 )
 6”            (152.4 mm)          lesser of hose or 75              ( 517 )     lesser of 2X hose or 150           ( 1034 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
3. Measure the outer diameter of the hose, preferably with a pi tape.
4. Based on the hose outer diameter, select the proper ferrule.

5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.

7. Insert the stem into the hose squarely without causing damage to the tube.
8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.
10. Place the hose assembly in the die opening.
11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
12. Crimp the ferrule to the desired diameter.
13. Retract the dies and remove the hose assembly.
14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too
small, consult the coupling manufacturer.

16. Repeat steps 1 through 16 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.74 Petroleum Transfer / Cam & Groove / Swaged

           I.D.                         Working Pressure                                    Test Pressure
 inch                 mm .                         psi            (kPa) .                              psi             (kPa)
 1/2”          (12.7 mm)        lesser of hose or 150           ( 1034 )        lesser of 2X hose or 300       ( 2069 )
 3/4”               (19 mm)     lesser of hose or 250           ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1”            (25.4 mm)        lesser of hose or 250           ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1 1/4"        (31.8 mm)        lesser of hose or 250           ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1 1/2"        (38.1 mm)        lesser of hose or 250           ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 2”            (50.8 mm)        lesser of hose or 250           ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 2 1/2"        (63.5 mm)        lesser of hose or 150           ( 1034 )        lesser of 2X hose or 300       ( 2069 )
 3”            (76.2 mm)        lesser of hose or 125            ( 862 )        lesser of 2X hose or 250       ( 1724 )
 4”           (101.6 mm)        lesser of hose or 100            ( 690 )        lesser of 2X hose or 200       ( 1379 )
 5”             (127 mm)        lesser of hose or 75             ( 517 )        lesser of 2X hose or 150       ( 1034 )
 6”           (152.4 mm)        lesser of hose or 75             ( 517 )        lesser of 2X hose or 150       ( 1034 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).

3. Use a diameter tape to measure hose O.D. and select proper ferrule
4. Select proper die set and accessories using manufacturers recommendations.

5. Slide ferrule over the stem collar. If ferrule has flats, be sure they line up with flats on hose collar.
6. Lubrication should only be used if necessary.
7. Insert stem into hose squarely without causing damage to the tube
8. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between
the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the
swaging die and the outside of the ferule with oil or grease.

9. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled,
start the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to
keep the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose
cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the
swage length needed for proper assembly.
10. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the machine.
Wipe off lubricant from ferrule and hose.
11. Repeat above steps for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.75 Petroleum Transfer / Cam & Groove / Preformed

             I.D.                         Working Pressure                                   Test Pressure
 inch                    mm v                         psi          (kPa) v                              psi      (kPa)

 1/2”               (12.7 mm)      lesser of hose or 150        ( 1034 )        lesser of 2X hose or 300       ( 2069 )
 3/4”                 (19 mm)      lesser of hose or 250        ( 1724 )        lesser of 2X hose or 500       ( 3448 )
1”              (25.4 mm)      lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500              ( 3448 )
1 1/4"          (31.8 mm)      lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500              ( 3448 )
1 1/2"          (38.1 mm)      lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500              ( 3448 )
2”              (50.8 mm)      lesser of hose or 250         ( 1724 )       lesser of 2X hose or 500              ( 3448 )
2 1/2"          (63.5 mm)      lesser of hose or 150         ( 1034 )       lesser of 2X hose or 300              ( 2069 )
3”              (76.2 mm)      lesser of hose or 125          ( 862 )       lesser of 2X hose or 250              ( 1724 )
4”            (101.6 mm)       lesser of hose or 100          ( 690 )       lesser of 2X hose or 200              ( 1379 )
5”              (127 mm)       lesser of hose or 75           ( 517 )       lesser of 2X hose or 150              ( 1034 )
6”            (152.4 mm)       lesser of hose or 75           ( 517 )       lesser of 2X hose or 150              ( 1034 )

     6.7.75.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
     Special Tools Required:

     Pneumatic Roll-over Tool
     Fabrication Procedures:

     1. Select smallest clamp, which slides over hose with fitting inserted.
     2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
     and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
     every space between large bards. If all barbs or serrations are the same, place as many clamps over
     the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
     inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
     (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
     inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
     (19 mm) wide clamps as fit on the shank, in the manner outlined above.
     3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
     4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
     5. Insert fitting into hose as far as it will go. Hose must cover entire shank.

     6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
     correct pressure settings that correspond to clamp width and material used.
     7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
     on hose.
     8. Activate tool to tighten clamp.
     9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
     10. Roll hose up until shear hook engages buckle
     11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
     cam to finish the clamp.
     12. Reset tool and remove scrap end of clamp.

     13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
     Special Considerations:

     Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
     round seal.
     Testing:

     Hydrostatic testing as required.
Conductivity test required.
6.7.75.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.
7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.

9. Repeat steps 6 to 8 with each clamp.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.75.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
9. For additional clamps, repeat steps 6 and 8 above, staggering the buckle positions.

10. Make sure manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.75.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
lines.
7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
        making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
        hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
        enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
        moving through the lock. The amount of tension is directly related to the type and style of both the
        hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
        the down position with one hand.
        8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
        head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
        head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
        identifying mark in the center of the lock. This mark should be completely obscured by the punched
        lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
        up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
        clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
        release lever and pull waste strip out toward rear of tool.
        9. For additional clamps, repeat step 6-8, staggering buckle positions.

        10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
        Conductivity test required.
6.7.76 Petroleum Transfer / Cam & Groove / Band & Buckle

             I.D.                          Working Pressure                                   Test Pressure
 inch                    mm .                           psi        (kPa) .                             psi             (kPa)
 1 1/4"             (31.8 mm)       lesser of hose or 250       ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 1 1/2"             (38.1 mm)       lesser of hose or 250       ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 2”                 (50.8 mm)       lesser of hose or 250       ( 1724 )       lesser of 2X hose or 500            ( 3448 )
 2 1/2"             (63.5 mm)       lesser of hose or 150       ( 1034 )       lesser of 2X hose or 300            ( 2069 )
 3”                 (76.2 mm)       lesser of hose or 125         ( 862 )      lesser of 2X hose or 250            ( 1724 )
 4”              (101.6 mm)         lesser of hose or 100         ( 690 )      lesser of 2X hose or 200            ( 1379 )
 5”                 (127 mm)        lesser of hose or 75          ( 517 )      lesser of 2X hose or 150            ( 1034 )
 6”              (152.4 mm)         lesser of hose or 75          ( 517 )      lesser of 2X hose or 150            ( 1034 )

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs,
or large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs.
If all barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use
for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch
(12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1
mm) wide clamps. For diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as
will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut
band with cutter in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches
(38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time
around hose and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by
hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten
clamp. When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.77 Petroleum Transfer / Machined, Medium Shank / Preformed

             I.D.                         Working Pressure                                 Test Pressure
 inch                    mm ,                         psi           (kPa) ,                             psi          (kPa)

 1/2”               (12.7 mm)      lesser of hose or 125           ( 862 )        lesser of 2X hose or 250       ( 1724 )
 3/4”                (19 mm)       lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1”                 (25.4 mm)      lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1 1/4"             (31.8 mm)      lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 1 1/2"             (38.1 mm)      lesser of hose or 250          ( 1724 )        lesser of 2X hose or 500       ( 3448 )
 2”                 (50.8 mm)      lesser of hose or 200          ( 1379 )        lesser of 2X hose or 400       ( 2758 )
 2 1/2"             (63.5 mm)      lesser of hose or 150          ( 1034 )        lesser of 2X hose or 300       ( 2069 )
 3”                 (76.2 mm)      lesser of hose or 125           ( 862 )        lesser of 2X hose or 250       ( 1724 )
 4”             (101.6 mm)         lesser of hose or 100           ( 690 )        lesser of 2X hose or 200       ( 1379 )
 5”                 (127 mm)       lesser of hose or 75            ( 517 )        lesser of 2X hose or 150       ( 1034 )
 6”             (152.4 mm)         lesser of hose or 75            ( 517 )        lesser of 2X hose or 150       ( 1034 )

Note:

Use 3 bands on 3” through 6”. Use 2 bands 1” through 2 ½”. Use 1 band on 1/2” and 3/4”.
        6.7.77.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
        and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
        every space between large bards. If all barbs or serrations are the same, place as many clamps over
        the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
        inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
(9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
(19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
correct pressure settings that correspond to clamp width and material used.
7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
on hose.
8. Activate tool to tighten clamp.
9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
10. Roll hose up until shear hook engages buckle
11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
cam to finish the clamp.
12. Reset tool and remove scrap end of clamp.
13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.77.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.77.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
       Conductivity test required.
       6.7.77.4 Center Punch Clamp applied with Hand Tool
       Special Tools Required:

       Hand Tool & Mallet
       Fabrication Procedures:

       1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
       properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
       hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
       outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
       that outside diameter.
       2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
       should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
       grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
       the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
       many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
       hose and two or three on two inch and above.
       3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
       This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
       you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
       the fitting is applied.

       4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
       5. Insert fitting into hose until the entire shank is covered.
       6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
       tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
       lines.
       7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
       making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
       hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
       enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
       moving through the lock. The amount of tension is directly related to the type and style of both the
       hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
       the down position with one hand.
       8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
       head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
       head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
       identifying mark in the center of the lock. This mark should be completely obscured by the punched
       lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
       up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
       clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
       release lever and pull waste strip out toward rear of tool.
       9. For additional clamps, repeat step 6-8, staggering the buckle positions.
       10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
       Testing:

       Hydrostatic testing as required.
       Conductivity test required.
6.7.78 Petroleum Transfer / Machined, Medium Shank / Band & Buckle

              I.D.                           Working Pressure                               Test Pressure
inch                        mm -                        psi             (kPa) -                        psi             (kPa)
1 1/4"               (31.8 mm)       lesser of hose or 300        ( 2069 )        lesser of 2X hose or 600           ( 4137 )
 1 1/2"              (38.1 mm)      lesser of hose or 300         ( 2069 )      lesser of 2X hose or 600      ( 4137 )
 2”                  (50.8 mm)      lesser of hose or 250         ( 1724 )      lesser of 2X hose or 500      ( 3448 )
 2 1/2"              (63.5 mm)      lesser of hose or 175         ( 1207 )      lesser of 2X hose or 350      ( 2413 )
 3”                  (76.2 mm)      lesser of hose or 150         ( 1034 )      lesser of 2X hose or 300      ( 2069 )
 4”                (101.6 mm)       lesser of hose or 125          ( 862 )      lesser of 2X hose or 250      ( 1724 )
 5”                  (127 mm)       lesser of hose or 100          ( 690 )      lesser of 2X hose or 200      ( 1379 )
 6”                (152.4 mm)       lesser of hose or 100          ( 690 )      lesser of 2X hose or 200      ( 1379 )

Note:

Use 3 bands on 3” through 6”. Use 2 bands 1 1/4” through 2 ½”.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs,
or large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs.
If all barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use
for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch
(12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1
mm) wide clamps. For diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as
will fit on the shank, in the manner outlined above.

2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut
band with cutter in tool.
5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches
(38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time
around hose and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by
hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten
clamp. When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.
10. Repeat steps 4 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.79 Petroleum Transfer / Machined, Long Shank / Preformed

            I.D.                        Working Pressure                                 Test Pressure
 inch                   mm vv                       psi          (kPa) v                           psi        (kPa)
 1/2”             (12.7 mm)      lesser of hose or 300         ( 2069 )        lesser of 2X hose or 600         ( 4137 )
 3/4”               (19 mm)      lesser of hose or 300         ( 2069 )        lesser of 2X hose or 600         ( 4137 )
 1”               (25.4 mm)      lesser of hose or 300         ( 2069 )        lesser of 2X hose or 600         ( 4137 )
 1 1/4"           (31.8 mm)      lesser of hose or 300         ( 2069 )        lesser of 2X hose or 600         ( 4137 )
 1 1/2"           (38.1 mm)      lesser of hose or 300         ( 2069 )        lesser of 2X hose or 600         ( 4137 )
 2”               (50.8 mm)      lesser of hose or 250         ( 1724 )        lesser of 2X hose or 500         ( 3448 )
 2 1/2"           (63.5 mm)      lesser of hose or 175         ( 1207 )        lesser of 2X hose or 350         ( 2413 )
 3”               (76.2 mm)      lesser of hose or 150         ( 1034 )        lesser of 2X hose or 300         ( 2069 )
 4”             (101.6 mm)       lesser of hose or 125          ( 862 )        lesser of 2X hose or 250         ( 1724 )
 5”               (127 mm)       lesser of hose or 100          ( 690 )        lesser of 2X hose or 200         ( 1379 )
 6”             (152.4 mm)       lesser of hose or 100          ( 690 )        lesser of 2X hose or 200         ( 1379 )

Note:

Use 3 bands on 1/2” through 1 1/2”. Use 4 bands on 2” and 2 1/2”. Use 5 bands on 3” through 6”.
        6.7.79.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.

        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
        and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
        every space between large bards. If all barbs or serrations are the same, place as many clamps over
        the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
        inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
        (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
        inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
        (19 mm) wide clamps as fit on the shank, in the manner outlined above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
        4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
        5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
        6. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
        correct pressure settings that correspond to clamp width and material used.
        7. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
        on hose.
        8. Activate tool to tighten clamp.
        9. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        10. Roll hose up until shear hook engages buckle
        11. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
        cam to finish the clamp.
        12. Reset tool and remove scrap end of clamp.
        13. Repeat steps 6 to 12 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.79.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose as far as it will go. Hose must cover entire shank.
6. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.

7. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.
8. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.
9. Repeat steps 6 to 8 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.79.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
5. Insert fitting into hose until the entire shank is covered.
6. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.
7. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
8. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
9. For additional clamps, repeat steps 6 and 7 above, staggering the buckle positions.
10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.79.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
        4. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
        5. Insert fitting into hose until the entire shank is covered.
        6. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
        tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
        lines.
        7. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
        making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
        hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
        enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
        moving through the lock. The amount of tension is directly related to the type and style of both the
        hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
        the down position with one hand.
        8. With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
        head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
        head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
        identifying mark in the center of the lock. This mark should be completely obscured by the punched
        lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
        up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
        clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
        release lever and pull waste strip out toward rear of tool.

        9. For additional clamps, repeat steps 6-8, staggering the buckle positions.
        10. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
        Conductivity test required.
6.7.80 Petroleum Transfer / Machined, Long Shank / Band & Buckle

             I.D.                          Working Pressure                                 Test Pressure
 inch                    mm v                            psi        (kPa) v                            psi             (kPa)

 1 1/4"             (31.8 mm)        lesser of hose or 375       ( 2586 )       lesser of 2X hose or 750           ( 5171 )
 1 1/2"             (38.1 mm)        lesser of hose or 375       ( 2586 )       lesser of 2X hose or 750           ( 5171 )
 2”                 (50.8 mm)        lesser of hose or 325       ( 2241 )       lesser of 2X hose or 650           ( 4482 )
 2 1/2"             (63.5 mm)        lesser of hose or 250       ( 1724 )       lesser of 2X hose or 500           ( 3448 )
 3”                 (76.2 mm)        lesser of hose or 200       ( 1379 )       lesser of 2X hose or 400           ( 2758 )
 4”             (101.6 mm)           lesser of hose or 150       ( 1034 )       lesser of 2X hose or 300           ( 2069 )
 5”                 (127 mm)         lesser of hose or 125         ( 862 )      lesser of 2X hose or 250           ( 1724 )
 6”             (152.4 mm)           lesser of hose or 125         ( 862 )      lesser of 2X hose or 250           ( 1724 )

Note:

Use 5 bands on 3” through 6”. Use 4 bands 2” through 2 ½”. Use 3 bands on ½” through 1 ½”.
Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs,
or large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs.
If all barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use
for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch
(12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1
mm) wide clamps. For diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as
will fit on the shank, in the manner outlined above.
2. Bend grounding wire inside of the hose with wire extended approximately 1/2” (12.7 mm).
3. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
4. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut
band with cutter in tool.

5. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches
(38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time
around hose and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by
hand.
6. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten
clamp. When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
7. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
8. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
9. Clinch stub by hammering down buckle ears.
10. Repeat steps 5 through 9 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.81 Petroleum Transfer / Interlocking Crimp-Swage / Crimp

           I.D.                        Working Pressure                                   Test Pressure
 inch                 mm v                         psi          (kPa) v                           psi           (kPa)
 1/4”             (6.4 mm)     lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 3/8”             (9.5 mm)     lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1/2”          (12.7 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 5/8”          (15.9 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 3/4”              (19 mm)     lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1”            (25.4 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1 1/4"        (31.8 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 1 1/2"        (38.1 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 2”            (50.8 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 2 1/2"        (63.5 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 3”            (76.2 mm)       lesser of hose or 600          ( 4137 )       lesser of 2X hose or 1200        ( 8274 )
 4”          (101.6 mm)        lesser of hose or 500          ( 3448 )       lesser of 2X hose or 1000        ( 6895 )
 5”               (127 mm)     lesser of hose or 450          ( 3103 )       lesser of 2X hose or 900         ( 6206 )
 6”          (152.4 mm)        lesser of hose or 400          ( 2758 )       lesser of 2X hose or 800         ( 5516 )

Fabrication Procedures:
1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
4. Measure the outer diameter of the hose, preferably with a pi tape.
5. Based on the hose outer diameter, select the proper ferrule.

6. Insert the stem into the hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
10. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.

14. Crimp the ferrule to the desired diameter.
15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too
small, consult the coupling manufacturer.
18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.82 Petroleum Transfer / Interlocking Crimp-Swage / Swaged

            I.D.                          Working Pressure                                   Test Pressure
 inch                   mm .                         psi             (kPa) .                             psi           (kPa)

 1/4”               (6.4 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 3/8”               (9.5 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 1/2”              (12.7 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 5/8”              (15.9 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 3/4”               (19 mm)      lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 1”                (25.4 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 1 1/4"            (31.8 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 1 1/2"            (38.1 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 2”                (50.8 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 2 1/2"            (63.5 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 3”                (76.2 mm)     lesser of hose or 600            ( 4137 )       lesser of 2X hose or 1200          ( 8274 )
 4”            (101.6 mm)        lesser of hose or 500            ( 3448 )       lesser of 2X hose or 1000          ( 6895 )
 5”             (127 mm)         lesser of hose or 450         ( 3103 )       lesser of 2X hose or 900         ( 6206 )
 6”           (152.4 mm)         lesser of hose or 400         ( 2758 )       lesser of 2X hose or 800         ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. For stems having a welded collar, chamfer hose tube 1/8 inch (3.175 mm) wide by 45° angle.
3. Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).
4. Use a diameter tape to measure hose O.D. and select proper ferrule.

5. Select proper die set and accessories using manufacturer’s recommendations.
6. Insert stem into hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling manufacturer.
9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes in contact with
the stem collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance
between the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside
of the swaging die and the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled,
start the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to
keep the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose
cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the
swage length needed for proper assembly.

12. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine.
Wipe off lubricant from ferrule and hose.
13. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.83 Petroleum Transfer / Internal Expanded Stem/ Internal Expanded Ferrule

             I.D.                          Working Pressure                                  Test Pressure
 inch                     mm .                           psi        (kPa) .                            psi                (kPa)
 1 1/4"              (31.8 mm)      lesser of hose or 800         ( 5516 )      lesser of 2X hose or 1600           ( 11032 )
 1 1/2"              (38.1 mm)      lesser of hose or 800         ( 5516 )      lesser of 2X hose or 1600           ( 11032 )
 2”                  (50.8 mm)      lesser of hose or 800         ( 5516 )      lesser of 2X hose or 1600           ( 11032 )
 2 1/2"              (63.5 mm)      lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 3”                  (76.2 mm)      lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200            ( 8274 )
 4”                 (101.6 mm)      lesser of hose or 500         ( 3448 )      lesser of 2X hose or 1000            ( 6895 )
 6”                 (152.4 mm)      lesser of hose or 400         ( 2758 )      lesser of 2X hose or 800             ( 5516 )
The Internal Expanded process achieves compression of the tube, reinforcement and cover of the hose between
the fitting stem and the ferrule by expanding the I.D. of the fitting.. The resulting assembly will have a fitting I.D.
equal to the size of the plug or mandrel allowing for full flow of material through the fitting.
SPECIAL NOTE:

This does not include brass short shank (Scovill-type) internal expansion fittings.
Fabrication Procedure:

Using a ball mandrel type expander -

1. Prepare the machine by:
a) Selecting and installing the proper accessories for the size hose you will be assembling following machine
manufacturer’s instructions.
b) Selecting the proper plug or determining the proper expansion of the mandrel by following manufacturer’s
recommendations.
2. Lubricate the stem I.D. with oil or grease.
3. Lubricate the smaller end of the plug .
4. Slide the stem over the pull rod (connection end first) until it is properly seated in the plate or adapter.

5. Put the expansion plug on the pull rod (small end first) by either threading it on or sliding it on.
6. Insert the small end of the expansion plug into the end of the stem and secure the stem by either tightening (by
hand) the plug on the pull rod or tightening (by hand) the lock nut until the plug does not move.

7. Lubricate the rest of the plug.
8. Cut the end of the hose square and clean any debris from the hose tube
9. Pull the static wire our of hose approximately ½ inch and fold it inside the hose.
10. Measure hose O.D. approximately 3inches from end of hose using a diameter tape.

11. Select the correct internal expansion ferrule based on the hose O.D. and the style of stem being used. Follow
the coupling manufacturer’s recommendation.
12. Put the ferrule over the end of the hose. Leave the correct amount of space (pocket) for rubber to flow into
depending on the size and style of coupling. Follow manufacturer’s recommendation.

13. Slide the hose and ferrule over the stem while maintaining correct amount of space (step 12) for the rubber to
flow. Continue to slide the hose and ferrule up the shank until the turned-over part of the ferrule contacts the
shoulder of the stem.

14. Begin the expansion process. It may be necessary to hold the ferrule in place until the expansion process has
reached the point that the ferrule will no longer move.

15. The expansion process is complete when the stem comes free of the expansion plug.
16. Remove excess lubrication form inside the coupling. Wipe lubricant from expansion plug and remove the plug
from the rod.

17. Repeat steps above for other end.
Using a die segment internal expanding machine -
1. Prepare the machine by selecting and installing the proper mandrel following the manufacturer's instructions.
2. Without a coupling, expand the dies and measure the expansion diameter using calipers. The diameter should
be within the manufacturer's specified expansion tolerances.
3. Lubricate the mandrel and dies', using the manufacturer's specified lubrication.
4. Mark the insertion depth of the coupling on the OD of the hose end.
5. Push the coupling on the hose to the insertion depth mark. If using a two piece coupling, push the ferrule on the
end of the hose until the hose bottoms out in the ferrule, and then push the insert into the hose until the insert
bottoms out in the ferrule.
6. Slide the coupling and hose over the dies to the specified insertion depth. Expand the coupling.
7. Visually inspect the ID of the coupling to insure the coupling has not cracked or split. If the insert is cracked or
split, stop immediately and check the expansion diameter of the machine and contact the manufacturer.
8. Remove excess lubrication from the inside of the coupling.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.84 Petroleum Transfer / Internal Expanded Short Brass / Internal Expansion Short Brass or Stainless
Ferrule

            I.D.                         Working Pressure                                   Test Pressure
 inch                   mm .                         psi           (kPa) .                           psi               (kPa)

 1 1/4"            (31.8 mm)       lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )
 1 1/2"            (38.1 mm)       lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )
 2”                (50.8 mm)       lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )
 2 1/2"            (63.5 mm)       lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )
 3”                (76.2 mm)       lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )
 4”            (101.6 mm)          lesser of hose or 300        ( 2069 )         lesser of 2X hose or 600            ( 4137 )

Special Tools Required:

Internal expansion equipment and appropriate dies/plugs
Fabrication Procedures:

1. Care must be used when installing stem into hose as not to cause damage to the hose tube.

2. Always push stems into hose end square to the end of the hose and never allow coupling to become “cocked” in
hose.

3. Care must be used to protect brass fittings and hose from damage during coupling installation.
4. The inside diameter of the stem should be waxed to facilitate the expansion die/ plug being pulled through the
fitting.
5. Cut hose end square and clean any debris from tube interior.
6. Bend grounding wire inside of hose with wire extended approximately ½”
7. Use a diameter tape to measure hose O.D. and select proper Ferrule in accordance to manufactures
recommendation.
8. Mark the fitting length on the hose to assure proper coupling insertion depth.
9. Install the fitting into the properly selected thrust plate of the expander
10. Nest the properly selected die/plug onto the fitting.
11. Begin to advance the die/plug until it makes contact with the nested fitting into the thrust plate with slight
pressure.
12. Install the properly selected ferrule on the hose.

13. Install the hose with the attached ferrule over the installed fitting up to the mark made previously.
14. Actuate the machine to pull the die/ plug completely through the fitting.
15. Prepare the machine for the next coupling assembly.
Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.85 Push On / Push On

           I.D.                      Working Pressure                                  Test Pressure
 inch                mm .                        psi        (kPa)                                psi          (kPa)

 1/2"         (12.7 mm)       lesser of hose or 175       ( 1207 )        lesser of 2X hose or 350           (2414)
 3/4"             (19 mm)     lesser of hose or 175       ( 1207 )        lesser of 2X hose or 350           (2414)
 1"           (25.4 mm)       lesser of hose or 175       ( 1207 )        lesser of 2X hose or 350           (2414)
 1 1/4""      (31.8 mm)       lesser of hose or 150       ( 1034 )        lesser of 2X hose or 300           (2068)
 1 1/2"       (38.1 mm)       lesser of hose or 150       ( 1034 )        lesser of 2X hose or 300           (2068)
 2”           (50.8 mm)       lesser of hose or 100        ( 690 )        lesser of 2X hose or 200           (1379)
 2 1/2"       (63.5 mm)       lesser of hose or 100        ( 690 )        lesser of 2X hose or 200           (1379)
 3”           (76.2 mm)       lesser of hose or 100        ( 690 )        lesser of 2X hose or 200           (1379)

Fabrication Procedures:

1. Cut hose end square and clean of any debris from the tube interior of the hose.
2. Place insert into a vice and lubricate stem and inside of hose with a manufacturer’s recommend lubricant.
3. Grip the hose from the end a distance equal to the length of the insert stem.
4. Push the hose on the stem until fully seated under the plastic cap of the insert.
Testing:

Hydrostatic testing as required.
6.7.86 Sand Blast / Sand Blast

           I.D.                         Working Pressure                                    Test Pressure
 inch                 mm .                        psi             (kPa)                                psi            (kPa)
 1/2"         (12.7 mm)        lesser of hose or 175             (1207)         lesser of 2X hose or 350          (2414)
 3/4"             (19 mm)      lesser of hose or 175             (1207)         lesser of 2X hose or 350          (2414)
 1"           (25.4 mm)        lesser of hose or 175             (1207)         lesser of 2X hose or 350          (2414)
 1 1/4""      (31.8 mm)        lesser of hose or 150             (1034)         lesser of 2X hose or 300          (2068)
 1 1/2"       (38.1 mm)        lesser of hose or 150             (1034)         lesser of 2X hose or 300          (2068)
 2”           (50.8 mm)        lesser of hose or 100              (690)         lesser of 2X hose or 200          (1379)
 2 1/2"       (63.5 mm)        lesser of hose or 100              (690)         lesser of 2X hose or 200          (1379)
 3”           (76.2 mm)        lesser of hose or 100              (690)         lesser of 2X hose or 200          (1379)

Special Tools Required:

Screwdriver
Fabrication Procedures:
1. Cut hose end square and clean of any debris from the tube interior of the hose.
2. Insert hose into fitting, making sure hose is fully seated into the fitting.
3. Insert screws into designated areas of the fitting.
4. Using a screwdriver, insert the screws into the hose until they bottom out into the fitting. Make sure that the
screws do not penetrate through the hose into the ID of the hose.
Testing:

Hydrostatic testing as required.
6.7.87 Steam Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

            I.D.                          Working Pressure                                   Test Pressure
 inch                   mm .                          psi           (kPa) .                            psi             (kPa)

 1/2”              (12.7 mm)      lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 3/4”               (19 mm)       lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 1”                (25.4 mm)      lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 1 1/4"            (31.8 mm)      lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 1 1/2"            (38.1 mm)      lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 2”                (50.8 mm)      lesser of hose or 600          ( 4137 )         lesser of 2X hose or 1200          ( 8274 )
 2 1/2"            (63.5 mm)      lesser of hose or 450          ( 3103 )         lesser of 2X hose or 900            (6206)
 3”                (76.2 mm)      lesser of hose or 450          ( 3103 )         lesser of 2X hose or 900           ( 6206 )
 4”            (101.6 mm)         lesser of hose or 230          ( 1586 )         lesser of 2X hose or 460            (3172)
 6”            (152.4 mm)         lesser of hose or 230          ( 1586 )         lesser of 2X hose or 460           ( 3172 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.

2. Cut the hose square per general fabrication methods.
3. Make static conductive per the General Fabrication Methods and ensure hose is clean of any residue, oil, dirt,
etc. from cutting or storage.
4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting
may help insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy
water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:
Assembly Procedure for 2 Bolt Clamps:
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the
stem or the wing nut on the stem. Snug the bolts equally by hand.

7. Snug the bolts equally by hand again.
8. Using a torque wrench, begin tightening the bolts as follows:
9. First bolt (nut facing assembler) 1 full turn,
10. Second bolt (opposite first bolt) 1 full turn.
11. Repeat procedure “9” and “10” until both bolts have reached recommended published torque.
Assembly Procedure of 4 Bolt Clamps:
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the
stem. Snug the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be
necessary to put the stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the
bolts equally (thread engagement between bolt and nut is equal on all 4 bolts).
7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) 1 full turn,
9. Front bolt (close to gripping finger) 1 full turn,
10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,
11. Opposite side back bolt 1 full turn,
12. Opposite side front bolt 1 full turn,

13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued.
14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published
torque.

Assembly Procedure of 6 Bolt Clamps:
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar. Snug the bolts by hand equally
(thread engagement between bolt and nut is equal on all six bolts. Place a mark (X) on the clamp body of one of the
segments near the nut of the back bolt (away from gripping finger) with a magic marker or something similar.
7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) having “X” near it one full turn,
9. Front bolt (close to gripping finger) of same segment one full turn,

10. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),
11. Back bolt to one full turn,
12. Front bolt one full turn,
13. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),

14. Back bolt one full turn,
15. Front bolt one full turn.
16. Repeat above procedure “8” through “15” until all of the bolts have reached the recommended published torque.
Assembly procedure for U-bolt clamps:
6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.
7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.

8. Install U-bolts around steel liner and through clamp casting and apply nuts.
9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and interlocking
fingers engage collar of fitting.
10. Evenly tighten nuts to torque values shown on chart below.

 Clamp Size                                             Nut Torque
 ½” (12.7 mm)                                           15 ft.-lbs.
 ¾” (19.05 mm) through 1¼” (31.75 mm)                   25 ft.-lbs.
 1½” (38.1 mm)                                             35 ft.-lbs.
 2” (50.8 mm), 3” (76.2 mm)                                55 ft.-lbs.
 4” (101.6 mm)                                             100 ft.-lbs.

Testing:

Hydrostatic testing as required.
Conductivity test required.
6.7.88 Water Hose / Cam & Groove / Crimp

             I.D.                          Working Pressure                                   Test Pressure
 inch                    mm -                        psi                  (kPa) -                        psi           (kPa)
 1/2”               (12.7 mm)    lesser of hose or 150               ( 1034 )       lesser of 2X hose or 300        ( 2069 )
 3/4”                (19 mm)     lesser of hose or 250               ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 1”                 (25.4 mm)    lesser of hose or 250               ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 1 1/4"             (31.8 mm)    lesser of hose or 250               ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 1 1/2"             (38.1 mm)    lesser of hose or 250               ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 2”                 (50.8 mm)    lesser of hose or 250               ( 1724 )       lesser of 2X hose or 500        ( 3448 )
 2 1/2"             (63.5 mm)    lesser of hose or 150               ( 1034 )       lesser of 2X hose or 300        ( 2069 )
 3”                 (76.2 mm)    lesser of hose or 125                   ( 862 )    lesser of 2X hose or 250        ( 1724 )
 4”             (101.6 mm)       lesser of hose or 100                   ( 690 )    lesser of 2X hose or 200        ( 1379 )
 5”                 (127 mm)     lesser of hose or 75                    ( 517 )    lesser of 2X hose or 150        ( 1034 )
 6”             (152.4 mm)       lesser of hose or 75                    ( 517 )    lesser of 2X hose or 150        ( 1034 )

Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).
3. Measure the outer diameter of the hose, preferably with a pi tape.
4. Based on the hose outer diameter, select the proper ferrule.
5. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.

7. Insert the stem into the hose squarely without causing damage to the tube.
8. Select the desired crimp length and crimp OD using manufacturer’s recommendations.
9. Based on #8, select the proper die set using the crimp machine manufacturer’s recommendations.
10. Place the hose assembly in the die opening.
11. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up properly to
achieve the desired crimp length.
12. Crimp the ferrule to the desired diameter.
13. Retract the dies and remove the hose assembly.
14. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
15. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter is too
small, consult the coupling manufacturer.
16. Repeat steps 1 through 15 for the other end.
Testing:

Hydrostatic testing as required.
6.7.89 Water Hose / Cam & Groove / Swaged

           I.D.                        Working Pressure                                    Test Pressure
 inch                mm                           psi            (kPa)                            psi                  (kPa)

 1/2”         (12.7 mm)       lesser of hose or 150            ( 1034 )    lesser of 2X hose or 300                 ( 2069 )
 3/4”             (19 mm)     lesser of hose or 250            ( 1724 )    lesser of 2X hose or 500                 ( 3448 )
 1”           (25.4 mm)       lesser of hose or 250            ( 1724 )    lesser of 2X hose or 500                 ( 3448 )
 1 1/4"       (31.8 mm)       lesser of hose or 250            ( 1724 )    lesser of 2X hose or 500                 ( 3448 )
 1 1/2"       (38.1 mm)       lesser of hose or 250            ( 1724 )    lesser of 2X hose or 500                 ( 3448 )
 2”           (50.8 mm)       lesser of hose or 250            ( 1724 )    lesser of 2X hose or 500                 ( 3448 )
 2 1/2"       (63.5 mm)       lesser of hose or 150            ( 1034 )    lesser of 2X hose or 300                 ( 2069 )
 3”           (76.2 mm)       lesser of hose or 125             ( 862 )    lesser of 2X hose or 250                 ( 1724 )
 4”          (101.6 mm)       lesser of hose or 100             ( 690 )    lesser of 2X hose or 200                 ( 1379 )
 5”            (127 mm)       lesser of hose or 75              ( 517 )    lesser of 2X hose or 150                 ( 1034 )
 6”          (152.4 mm)       lesser of hose or 75              ( 517 )    lesser of 2X hose or 150                 ( 1034 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.
2. Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).

3. Use a diameter tape to measure hose O.D. and select proper ferrule.
4. Select proper die set and accessories using manufacturer’s recommendations.

5.Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the hose collar.
6. Lubrication should only be used if necessary.
7. Insert stem into hose squarely without causing damage to the tube.
8. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough clearance between
the bottom of the ferrule and the die holders for the swaging dies to be put into place. Lubricate the inside of the
swaging die and the outside of the ferule with oil or grease.

9. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being assembled,
start the swaging process. Depending on coupling style, it may be necessary to put pressure against the pusher to
keep the ferrule properly placed until the ferrule has been reduced to the point that it comes in contact with the hose
cover. Continue the swage until desired length has been achieved. Consult the coupling manufacturer for the
swage length needed for proper assembly.
10. After the ram cylinder has retracted, lift the dies out of the die bed and remove the assembly from the machine.
Wipe off lubricant from ferrule and hose.
11. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
6.7.90 Water Hose / Cam & Groove / Preformed

            I.D.                         Working Pressure                                  Test Pressure
 inch                  mm .                         psi           (kPa) .                            psi               (kPa)

 1/2”           (12.7 mm)       lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300               ( 2069 )
 3/4”               (19 mm)     lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500               ( 3448 )
 1”             (25.4 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500               ( 3448 )
 1 1/4"         (31.8 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500               ( 3448 )
 1 1/2"         (38.1 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500               ( 3448 )
 2”             (50.8 mm)       lesser of hose or 250           ( 1724 )      lesser of 2X hose or 500               ( 3448 )
 2 1/2"         (63.5 mm)       lesser of hose or 150           ( 1034 )      lesser of 2X hose or 300               ( 2069 )
 3”             (76.2 mm)       lesser of hose or 125            ( 862 )      lesser of 2X hose or 250               ( 1724 )
 4”            (101.6 mm)       lesser of hose or 100            ( 690 )      lesser of 2X hose or 200               ( 1379 )
 5”                (127 mm)     lesser of hose or 75             ( 517 )      lesser of 2X hose or 150               ( 1034 )
 6”            (152.4 mm)       lesser of hose or 75             ( 517 )      lesser of 2X hose or 150               ( 1034 )

        6.7.90.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
        and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
        every space between large bards. If all barbs or serrations are the same, place as many clamps over
        the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
        inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
        (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
        inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
        (19 mm) wide clamps as fit on the shank, in the manner outlined above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
        correct pressure settings that correspond to clamp width and material used.
        6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
        on hose.
        7. Activate tool to tighten clamp.
        8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
        9. Roll hose up until shear hook engages buckle
        10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
        cam to finish the clamp.
        11. Reset tool and remove scrap end of clamp.
12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
6.7.90.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
6.7.90.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.

6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
8. For additional clamps, repeat steps 5-7 above, staggering the buckle positions.

9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.90.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
lines.
        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
        making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
        hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
        enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
        moving through the lock. The amount of tension is directly related to the type and style of both the
        hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
        the down position with one hand.
        7.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
        head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
        head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
        identifying mark in the center of the lock. This mark should be completely obscured by the punched
        lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
        up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
        clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
        release lever and pull waste strip out toward rear of tool.
        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.
        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
6.7.91 Water Hose / Cam & Groove / Band & Buckle

              I.D.                           Working Pressure                                 Test Pressure
 inch                      mm .                       psi              (kPa) .                           psi           (kPa)

 1 1/4"               (31.8 mm)    lesser of hose or 250             ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 1 1/2"               (38.1 mm)    lesser of hose or 250             ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 2”                   (50.8 mm)    lesser of hose or 250             ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 2 1/2"               (63.5 mm)    lesser of hose or 150             ( 1034 )     lesser of 2X hose or 300         ( 2069 )
 3”                   (76.2 mm)    lesser of hose or 125              ( 862 )     lesser of 2X hose or 250         ( 1724 )
 4”                  (101.6 mm)    lesser of hose or 100              ( 690 )     lesser of 2X hose or 200         ( 1379 )
 5”                   (127 mm)     lesser of hose or 75               ( 517 )     lesser of 2X hose or 150         ( 1034 )
 6”                  (152.4 mm)    lesser of hose or 75               ( 517 )     lesser of 2X hose or 150         ( 1034 )

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and small barbs,
or large barbs only, locate each clamp between two large barbs. Use a clamp for every space between large barbs.
If all barbs or serrations are the same, place as many clamps over the serrations as will comfortably fit. Do not use
for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to 38.1 mm) diameter, use ½ or 5/8 inch
(12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch (38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1
mm) wide clamps. For diameters larger than 2-½ inch (63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as
will fit on the shank, in the manner outlined above.
2. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
3. Pull band from container as needed. To determine length of band required, either form band roughly around hose
twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter in inches plus 2. Cut
band with cutter in tool.

4. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2 inches
(38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a second time
around hose and through buckle. Double wrapped banding must be used for hose clamping. Snug clamp up by
hand.
5. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose. Tighten
clamp. When band appears to stop moving through buckle, optimum tension has been applied. Stop turning handle.
6. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.
7. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
8. Clinch stub by hammering down buckle ears.

9. Repeat steps 3 through 8 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
6.7.92 Water Hose / Universals / Preformed

            I.D.                        Working Pressure                                  Test Pressure
 inch                  mm .                        psi          (kPa) .                            psi               (kPa)

 3/8”              (9.5 mm)    lesser of hose or 110           ( 758 )      lesser of 2X hose or 220            ( 1517 )
 1/2”          (12.7 mm)       lesser of hose or 110           ( 758 )      lesser of 2X hose or 220            ( 1517 )
 5/8”          (15.9 mm)       lesser of hose or 110           ( 758 )      lesser of 2X hose or 220            ( 1517 )
 3/4”              (19 mm)     lesser of hose or 110           ( 758 )      lesser of 2X hose or 220            ( 1517 )
 1”            (25.4 mm)       lesser of hose or 110           ( 758 )      lesser of 2X hose or 220            ( 1517 )

        6.7.92.1 Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted. Clamp diameter should be within
        1/2 inch (12.7 mm) of hose outside diameter.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
        and small barbs or only large barbs, locate each clamp in-between the large barbs. Use a clamp for
        every space between large bards. If all barbs or serrations are the same, place as many clamps over
        the serration as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or 3/8
        inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch
        (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4
        inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch
        (19 mm) wide clamps as fit on the shank, in the manner outlined above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into hose.
        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s manual for
        correct pressure settings that correspond to clamp width and material used.
        6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp at mark
        on hose.
        7. Activate tool to tighten clamp.
8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
9. Roll hose up until shear hook engages buckle
10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait for cut-off
cam to finish the clamp.
11. Reset tool and remove scrap end of clamp.
12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
6.7.92.2 Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has large
and small barbs or only large barbs, locate the clamps in between the large barbs. Use a clamp for
every space between large barbs. If all bards or serrations are the same, place as many clamps over
the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm) or less, use at least one 1/4 or
3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½
inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or
3/4 inch (15.9 or 19 mm) wide clamps. For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾
inch (19 mm) wide clamps as fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever. Position
clamp at mark on hose. Tighten clamp. When band appears to stop moving through buckle, optimum
tension has been applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to 1/2 turn
at the same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut the band
thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a good
round seal.
Testing:

Hydrostatic testing as required.
6.7.92.3 Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is not more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closest to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in the
machine until it can go no further. If no clamps are already on hose, insert tail piece of one clamp into
the clamp slot in the machine until it can go no further and then slip assembled hose and fitting
through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and hold the
tensioning button with one finger until clamp has reached proper tension and automatically punches
the lock and cuts band off while maintaining correct tension. Due to many different types of hose and
fitting construction and styles, you may alter the manufacturer’s recommended setting after
determining the optimum for your application and making a note of this on the included chart for future
uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into the scrap
bucket.
8. For additional clamps, repeat steps 5-7 above, staggering the buckle positions.
9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.92.4 Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will function
properly, we suggest that you use a clamp that is no more than approximately 1/4" larger than the
hose outside diameter. This will reduce clamp cost and installation time. Therefore, measure the hose
outside diameter while the fitting is inserted and select a clamp that is the closet to, but not less than
that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the clamp(s)
should be applied. If there are one or two barbs on the fitting, the clamp(s) should be placed in the
grooves between the barbs. If there are many barbs (serrations or nodes) you need to make sure that
the clamp(s) are going to be located on the shank somewhere. It is recommended that you use as
many clamps as there are grooves if the fitting is grooved. If not, use at least one clamp up to two inch
hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing the fitting.
This enables you to use the smallest diameter of clamp possible. However, if, for whatever reason,
        you need or want to use a larger clamp, and it will fit over the fitting, you may slide the clamp on after
        the fitting is applied.
        4. Insert fitting into hose until the entire shank is covered.
        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the way into
        tool, until lock is held in pusher housing jaws. Position clamp(s) around hose according to pre marked
        lines.
        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting motion,
        making smaller strokes when clamp begins to get tighter. You must resist the natural tendency of the
        hose to turn while tightening the clamp. As a general rule of thumb, you will know the clamp is tight
        enough when the clamp surface is below the O.D. of the hose and/or the clamp’s band has stopped
        moving through the lock. The amount of tension is directly related to the type and style of both the
        hose and fitting being used. After proper ultimate tension has been attained, hold the ball handle in
        the down position with one hand.
        7.With clamp resting on a solid surface, and ball handle held in the down position, strike the punch
        head a hard blow with a non-sparking mallet to lock the clamp. You may have to strike the punch
        head more than once to obtain the proper hold. As a general rule of thumb, the clamp will have an
        identifying mark in the center of the lock. This mark should be completely obscured by the punched
        lock. To free the tool, grasp hose firmly to prevent turning, then lift both handles of tool together, in an
        up and down motion, which will break band off at lock. You may smooth lock corners with mallet. To
        clear cut-off end of clamp from tool, work it through the tool by operating ball handle. Next, press
        release lever and pull waste strip out toward rear of tool.
        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.
        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
6.7.93 Water Hose / Universals / Interlocking Clamp

            I.D.                           Working Pressure                                  Test Pressure
 inch                  mm v                            psi           (kPa) .                             psi           (kPa)

 3/8”              (9.5 mm)        lesser of hose or 110            ( 758 )        lesser of 2X hose or 220          ( 1517 )
 1/2”           (12.7 mm)          lesser of hose or 110            ( 758 )        lesser of 2X hose or 220          ( 1517 )
 5/8”           (15.9 mm)          lesser of hose or 110            ( 758 )        lesser of 2X hose or 220          ( 1517 )
 3/4”              (19 mm)         lesser of hose or 110            ( 758 )        lesser of 2X hose or 220          ( 1517 )
 1”             (25.4 mm)          lesser of hose or 110            ( 758 )        lesser of 2X hose or 220          ( 1517 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.
2. Cut the hose square per general fabrication methods.
3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.
4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight twisting
may help insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or a slightly soapy
water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:
Assembly Procedure for 2 Bolt Clamps:
      6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the
      stem or the wing nut on the stem. Snug the bolts equally by hand.
      7. Snug the bolts equally by hand again.
      8. Using a torque wrench, begin tightening the bolts as follows:
      9. First bolt (nut facing assembler) 1 full turn,
      10. Second bolt (opposite first bolt) 1 full turn.
      11. Repeat procedure “9” and “10” until both bolts have reached recommended published torque.
      Assembly Procedure of 4 Bolt Clamps:
      6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex on the
      stem. Snug the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the clamp, it may be
      necessary to put the stem, hose and clamp halves in a vise to close the clamp enough to start the bolts. Snug the
      bolts equally (thread engagement between bolt and nut is equal on all 4 bolts).
      7. Using a torque wrench, begin tightening the bolts as follows:
      8. Back bolt (away from gripping finger) 1 full turn,

      9. Front bolt (close to gripping finger) 1 full turn,
      10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,

      11. Opposite side back bolt 1 full turn,
      12. Opposite side front bolt 1 full turn,

      13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued.
      14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended published
      torque.

      Assembly procedure for U-bolt clamps:
      6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.
      7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.
      8. Install U-bolts around steel liner and through clamp casting and apply nuts.

      9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and interlocking
      fingers engage collar of fitting.

      10. Evenly tighten nuts to torque values shown on chart below.

       Clamp Size                                             Nut Torque
       ½” (12.7 mm)                                           15 ft.-lbs.
       ¾” (19.05 mm) through 1” (31.75 mm)                    25 ft.-lbs.

      Special Considerations:

      Do not use Bolt Clamps on hoses that are constructed with a helix wire.
      Testing:

      Hydrostatic testing as required.

>> continue to next section
Section 6 Industrial Hose - 6.7.94 to 6.7.107

6.7 Assembly Data Sheets

      6.7.94 Water Hose / Machined, Short Shank / Crimp
      6.7.95 Water Hose / Machined, Short Shank / Preformed
      6.7.96 Water Hose / Machined, Short Shank / Clamp, Pinch
      6.7.97 Water Hose (soft wall only) / Machined, Medium Shank / Bolt Clamp
      6.7.98 Water Hose / Machined, Medium Shank / Preformed
      6.7.99 Water Hose / Machined, Medium Shank / Pinch Clamp
      6.7.100 Water Hose (soft wall only) / Machined, Long Shank / Bolt Clamp
      6.7.101 Water Hose / Machined, Long Shank / Preformed
      6.7.102 Water Hose (soft wall only) / Cast / Bolt Clamp
      6.7.103 Water Hose / Cast / Preformed
      6.7.104 Water Hose / Cast / Band & Buckle
      6.7.105 Water Hose / Interlocking Crimp-Swage / Crimp
      6.7.106 Water Hose / Interlocking Crimp-Swage / Swaged
      6.7.107 Water Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

>> continue to next section

6.7 Assembly Data Sheets
      6.7.94   Water Hose / Machined, Short Shank / Crimp

                I.D.                       Working Pressure                                   Test Pressure
       inch             mm -                           psi           (kPa) -                              psi             (kPa)
       1/4”       (6.4 mm)         lesser of hose or 200          ( 1379 )         lesser of 2X hose or 400             ( 2758 )
       3/8”       (9.5 mm)         lesser of hose or 150          ( 1034 )         lesser of 2X hose or 300             ( 2069 )
       1/2”      (12.7 mm)         lesser of hose or 150          ( 1034 )         lesser of 2X hose or 300             ( 2069 )
       5/8”      (15.9 mm)         lesser of hose or 100            ( 690 )        lesser of 2X hose or 200             ( 1379 )
       3/4”        (19 mm)         lesser of hose or 100            ( 690 )        lesser of 2X hose or 200             ( 1379 )
       1”        (25.4 mm)         lesser of hose or 100            ( 690 )        lesser of 2X hose or 200             ( 1379 )

      Fabrication Procedures:

      1. Cut hose end square and clean any debris from tube interior.

      2. Measure the outer diameter of the hose, preferably with a pi tape.

      3. Based on the hose outer diameter, select the proper ferrule.
      4. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the
      hose collar.

      5. Insert the stem into the hose squarely without causing damage to the tube.
      6. Lubrication should only be used if necessary.
      7. Select the desired crimp length and crimp O.D. using manufacturer’s recommendations.

      8. Based on #7, select the proper die set using the crimp machine manufacturer’s recommendations.

      9. Place the hose assembly in the die opening.
10. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up
properly to achieve the desired crimp length.

11. Crimp the ferrule to the desired diameter.
12. Retract the dies and remove the hose assembly.

13. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
14. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter
is too small, consult the coupling manufacturer.

15. Repeat steps 1 through 14 for the other end.
Testing:

Hydrostatic testing as required.
6.7.95     Water Hose / Machined, Short Shank / Preformed

            I.D.                        Working Pressure                                   Test Pressure
 inch                  mm -                         psi          (kPa) -                             psi            (kPa)
 1/4”              (6.4 mm)      lesser of hose or 200         ( 1379 )       lesser of 2X hose or 400         ( 2758 )
 3/8”              (9.5 mm)      lesser of hose or 150         ( 1034 )       lesser of 2X hose or 300         ( 2069 )
 1/2”          (12.7 mm)         lesser of hose or 150         ( 1034 )       lesser of 2X hose or 300         ( 2069 )
 5/8”          (15.9 mm)         lesser of hose or 100          ( 690 )       lesser of 2X hose or 200         ( 1379 )
 3/4”              (19 mm)       lesser of hose or 100          ( 690 )       lesser of 2X hose or 200         ( 1379 )
 1”            (25.4 mm)         lesser of hose or 100          ( 690 )       lesser of 2X hose or 200         ( 1379 )

         6.7.95.1     Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:

         1. Select smallest clamp, which slides over hose with fitting inserted.
         2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
         large and small barbs or only large barbs, locate each clamp in-between the large barbs.
         Use a clamp for every space between large bards. If all barbs or serrations are the same,
         place as many clamps over the serration as will comfortable fit. For hoses ID 3/8 inch (9.5
         mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2
         to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to
         1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
         For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as
         fit on the shank, in the manner outlined above.
         3. Slide clamps over hose with tails facing away from installer before inserting fitting into
         hose.

         4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

         5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s
         manual for correct pressure settings that correspond to clamp width and material used.
         6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp
at mark on hose.

7. Activate tool to tighten clamp.
8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

9. Roll hose up until shear hook engages buckle
10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait
for cut-off cam to finish the clamp.

11. Reset tool and remove scrap end of clamp.

12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.95.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted
2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
large and small barbs or only large barbs, locate the clamps in between the large barbs. Use
a clamp for every space between large barbs. If all bards or serrations are the same, place
as many clamps over the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm)
or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8
inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For
hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit
on the shank, in the manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever.
Position clamp at mark on hose. Tighten clamp. When band appears to stop moving through
buckle, optimum tension has been applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to
1/2 turn at the same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut
the band thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.95.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is not more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in
the machine until it can go no further. If no clamps are already on hose, insert tail piece of
one clamp into the clamp slot in the machine until it can go no further and then slip
assembled hose and fitting through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and
hold the tensioning button with one finger until clamp has reached proper tension and
automatically punches the lock and cuts band off while maintaining correct tension. Due to
many different types of hose and fitting construction and styles, you may alter the
manufacturer’s recommended setting after determining the optimum for your application and
making a note of this on the included chart for future uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into
the scrap bucket.

8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.
9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.95.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:
         1. Although any diameter of clamp, which is larger than the hose outside diameter, will
         function properly, we suggest that you use a clamp that is no more than approximately 1/4"
         larger than the hose outside diameter. This will reduce clamp cost and installation time.
         Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
         that is the closet to, but not less than that outside diameter.

         2. Place fitting along side the hose and make mark with a pen or marker to denote where the
         clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
         be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
         you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
         is recommended that you use as many clamps as there are grooves if the fitting is grooved.
         If not, use at least one clamp up to two inch hose and two or three on two inch and above.

         3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
         the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
         whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
         may slide the clamp on after the fitting is applied.
         4. Insert fitting into hose until the entire shank is covered.

         5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the
         way into tool, until lock is held in pusher housing jaws. Position clamp(s) around hose
         according to pre marked lines.
         6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting
         motion, making smaller strokes when clamp begins to get tighter. You must resist the natural
         tendency of the hose to turn while tightening the clamp. As a general rule of thumb, you will
         know the clamp is tight enough when the clamp surface is below the O.D. of the hose and/or
         the clamp’s band has stopped moving through the lock. The amount of tension is directly
         related to the type and style of both the hose and fitting being used. After proper ultimate
         tension has been attained, hold the ball handle in the down position with one hand.

         7.With clamp resting on a solid surface, and ball handle held in the down position, strike the
         punch head a hard blow with a non-sparking mallet to lock the clamp. You may have to
         strike the punch head more than once to obtain the proper hold. As a general rule of thumb,
         the clamp will have an identifying mark in the center of the lock. This mark should be
         completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
         turning, then lift both handles of tool together, in an up and down motion, which will break
         band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp
         from tool, work it through the tool by operating ball handle. Next, press release lever and pull
         waste strip out toward rear of tool.
         8. For additional clamps, repeat step 5-7, staggering the buckle positions.

         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.96     Water Hose / Machined, Short Shank / Clamp, Pinch

            I.D.                        Working Pressure                                Test Pressure
 inch                mm -                            psi          (kPa) -                           psi        (kPa)
 1/4”           (6.4 mm)         lesser of hose or 200         ( 1379 )      lesser of 2X hose or 400        ( 2758 )
 3/8”           (9.5 mm)         lesser of hose or 150         ( 1034 )      lesser of 2X hose or 300        ( 2069 )
 1/2”         (12.7 mm)          lesser of hose or 150         ( 1034 )      lesser of 2X hose or 300        ( 2069 )
 5/8”         (15.9 mm)          lesser of hose or 100          ( 690 )      lesser of 2X hose or 200        ( 1379 )
 3/4”           (19 mm)          lesser of hose or 100           ( 690 )     lesser of 2X hose or 200   ( 1379 )
 1”           (25.4 mm)          lesser of hose or 100           ( 690 )     lesser of 2X hose or 200   ( 1379 )

Special Tools Required:

Pincer




Fabrication Procedures:

         1. Place fitting along side of hose end and mark the hose for location of clamp or clamps.

         2. On short shank fittings locate clamp directly over the machined barbs.
         3. Insert fitting into hose until hose meets shoulder of fitting.
         4. Place clamp over assembly. Holding clamp directly over barbed area of fitting, pinch one
         ear of the clamp down completely, then go to the second ear and pinch it down completely.
         5. Do not be concerned if the ear which was pinched first seems to open slightly.
Testing:

Hydrostatic testing as required.




Illustration 1. When installing Ear Type Clamps, please note that each ear must be crimped as
recommended to obtain a proper seal. An installation made incorrectly may impair the best connection. If
a clamp ear can be closed all the way, the clamp size selected is probably too big and the next smaller
clamp size should be used.
How to Apply

Illustration 2. Position Clamp as illustrated.
Illustration 3. Give each ear a firm squeeze with pincers.

6.7.97    Water Hose (soft wall only) / Machined, Medium Shank / Bolt Clamp

            I.D.                       Working Pressure                              Test Pressure
 inch                   mm -                      psi          (kPa) -                        psi             (kPa)

 1/4”               (6.4 mm)   lesser of hose or 300         ( 2069 )    lesser of 2X hose or 600          ( 4137 )
 3/8”               (9.5 mm)   lesser of hose or 300         ( 2069 )    lesser of 2X hose or 600          ( 4137 )
 1/2”              (12.7 mm)   lesser of hose or 300         ( 2069 )    lesser of 2X hose or 600          ( 4137 )
 5/8”              (15.9 mm)   lesser of hose or 300         ( 2069 )    lesser of 2X hose or 600          ( 4137 )
 3/4”               (19 mm)    lesser of hose or 300         ( 2069 )    lesser of 2X hose or 600          ( 4137 )
 1”                (25.4 mm)   lesser of hose or 250         ( 1724 )    lesser of 2X hose or 500          ( 3448 )
 1 1/4"            (31.8 mm)   lesser of hose or 250         ( 1724 )    lesser of 2X hose or 500          ( 3448 )
 1 1/2"            (38.1 mm)   lesser of hose or 250         ( 1724 )    lesser of 2X hose or 500          ( 3448 )
 2”                (50.8 mm)   lesser of hose or 200         ( 1379 )    lesser of 2X hose or 400          ( 2758 )
 2 1/2"            (63.5 mm)   lesser of hose or 150         ( 1034 )    lesser of 2X hose or 300          ( 2069 )
 3”                (76.2 mm)   lesser of hose or 125          ( 862 )    lesser of 2X hose or 250          ( 1724 )
 4”           (101.6 mm)       lesser of hose or 100          ( 690 )    lesser of 2X hose or 200          ( 1379 )
 5”                (127 mm)    lesser of hose or 75           ( 517 )    lesser of 2X hose or 150          ( 1034 )
 6”           (152.4 mm)       lesser of hose or 75           ( 345 )    lesser of 2X hose or 100           ( 690 )

Special Tools Required:

Appropriate size wrench or socket
Fabrication Procedures:

1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper
clamp selection for that end.
2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published
minimum / maximum range.
3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.
4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with
the last serration on the shank. The last serration is the one before the shank end.
5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger
than the others, place marks on the hose to correspond with all large nodes (or serrations) present on that
stem.
6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail
reads in the same direction for all of the clamps.

 I.D.                                         No. of Clamps
 Below 2” (50.8 mm)                           1
 2” to 4” (50.8 mm to 101.6 mm)               2
 5” to 6” (127 mm to 152.4 mm)                3
 8” (203.2 mm) and above                        4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.

8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as
follows:
        a) Slide clamp towards the hose end past the mark placed on hose from Step 4.

        b) Position clamp so that there is ½” (12.7 mm) to 5/8” (15.9 mm) of rubber between clamp
        and hose end. Make sure that there is more rubber between clamp and mark on hose than
        there is between clamp and hose end. If this is not possible, center the clamp between the
        mark on the hose and the hose end.
        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of
        the saddle (the part that the bolt goes through) is midway between both clamp halves.
        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread
        showing past both nuts. Reposition the saddles as needed per Step 8c above. Saddle
        positioning is critical to proper sealing of the clamp.

        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that
        side.
        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.
        g) Tighten the opposite side nut one full turn.
        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch
        if necessary to reposition saddles.
        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.
9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:

        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.
        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.
        c) Repeat Steps 8c through 8i.
Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when
recommended torque is reached, the saddle loop is centered between the clamp halves.

10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble
as follows:

        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark from Step 4.

        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure
        that the clamp saddles are at 90º angles to the saddles of the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.

11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as
follows:
      a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.

      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
      side) of the mark furthest away from the hose end.
      c) Assemble clamp per Steps 8c through 8i.

      d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end
      making sure that the clamp saddles are at 90º angles to the saddles of the clamp just
      installed.
      e) Assemble clamp per Steps 8c through 8I.

12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS,
assemble as follows:
      a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.

      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
      side) of the mark from Step 4.

      c) Assemble clamp per Steps 8c through 8i.
      d) Position the other clamps so that they are equally spaced between the clamp just installed
      and the hose end. Place marks on the hose to correspond with the location of these clamps.
      e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles
      to the clamp just installed.
      f) Assemble clamp per Steps 8c through 8i.
      g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to
      the clamp just installed.

      h) Assemble clamp per Steps 8c through 8i.
13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble
as follows:
      a) Slide all the clamps towards the hose end past the mark furthest from the hose end from
      Step 5.
      b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
      side) of the mark furthest from the hose end from Step 5.

      c) Assemble clamp per Steps 8c through 8i.

      d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from
      Step 5 and position the saddles at 45º angles to the clamp just installed.
      e) Assemble clamp per Steps 8c through 8i.

      f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the
      hose end from Step 5 and position the saddles at 45º angles to the clamp just installed.

      g) Assemble clamp per Steps 8c through 8I.
14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles
of the clamp being installed are to be positioned at 90º angles to the saddles of the clamp just installed.
Special Considerations:

1. Both bolts must be tightened evenly and equally to recommended torque.
2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than
the other, the clamp may walk at an angle to the hose body. This can result in sealing and retention
problems.

3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they
must bend for the clamp to work properly.
4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any
sharp edges. Do not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in
the metal of the bolt.
5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
Warnings:

Do not use Bolt Clamps on hoses that are constructed with helix wire.
Testing:

Hydrostatic testing as required.
6.7.98     Water Hose / Machined, Medium Shank / Preformed

             I.D.                         Working Pressure                            Test Pressure
 inch                    mm -                        psi        (kPa) -                        psi              (kPa)
 1/4”                (6.4 mm)       lesser of hose or 300    ( 2069 )     lesser of 2X hose or 600         ( 4137 )
 3/8”                (9.5 mm)       lesser of hose or 300    ( 2069 )     lesser of 2X hose or 600         ( 4137 )
 1/2”               (12.7 mm)       lesser of hose or 300    ( 2069 )     lesser of 2X hose or 600         ( 4137 )
 5/8”               (15.9 mm)       lesser of hose or 300    ( 2069 )     lesser of 2X hose or 600         ( 4137 )
 3/4”                (19 mm)        lesser of hose or 300    ( 2069 )     lesser of 2X hose or 600         ( 4137 )
 1”                 (25.4 mm)       lesser of hose or 250    ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 1 1/4"             (31.8 mm)       lesser of hose or 250    ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 1 1/2"             (38.1 mm)       lesser of hose or 250    ( 1724 )     lesser of 2X hose or 500         ( 3448 )
 2”                 (50.8 mm)       lesser of hose or 200    ( 1379 )     lesser of 2X hose or 400         ( 2758 )
 2 1/2"             (63.5 mm)       lesser of hose or 150    ( 1034 )     lesser of 2X hose or 300         ( 2069 )
 3”                 (76.2 mm)       lesser of hose or 125      ( 862 )    lesser of 2X hose or 250         ( 1724 )
 4”             (101.6 mm)          lesser of hose or 125      ( 862 )    lesser of 2X hose or 250         ( 1724 )
 5”                 (127 mm)        lesser of hose or 75       ( 517 )    lesser of 2X hose or 150         ( 1034 )
 6”             (152.4 mm)          lesser of hose or 50       ( 345 )    lesser of 2X hose or 100          ( 690 )

Note:

Use 3 bands on 3” through 6”. Use 2 bands on ¾” through 2”. Use 1 band on ¼” through 5/8”.
         6.7.98.1    Preformed Clamps, applied with Roll-Over Pneumatic Tool
         Special Tools Required:

         Pneumatic Roll-over Tool
         Fabrication Procedures:
1. Select smallest clamp, which slides over hose with fitting inserted.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
large and small barbs or only large barbs, locate each clamp in-between the large barbs.
Use a clamp for every space between large bards. If all barbs or serrations are the same,
place as many clamps over the serration as will comfortable fit. For hoses ID 3/8 inch (9.5
mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2
to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to
1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as
fit on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing away from installer before inserting fitting into
hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s
manual for correct pressure settings that correspond to clamp width and material used.

6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp
at mark on hose.
7. Activate tool to tighten clamp.

8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.
9. Roll hose up until shear hook engages buckle
10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait
for cut-off cam to finish the clamp.
11. Reset tool and remove scrap end of clamp.

12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.98.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
large and small barbs or only large barbs, locate the clamps in between the large barbs. Use
a clamp for every space between large barbs. If all bards or serrations are the same, place
as many clamps over the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm)
or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8
inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For
hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit
on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever.
Position clamp at mark on hose. Tighten clamp. When band appears to stop moving through
buckle, optimum tension has been applied. Stop turning handle.

6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to
1/2 turn at the same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut
the band thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.98.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is not more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in
the machine until it can go no further. If no clamps are already on hose, insert tail piece of
one clamp into the clamp slot in the machine until it can go no further and then slip
assembled hose and fitting through the clamp.
6. Set air tension regulator to the correct tension recommended by the manufacturer and
hold the tensioning button with one finger until clamp has reached proper tension and
automatically punches the lock and cuts band off while maintaining correct tension. Due to
many different types of hose and fitting construction and styles, you may alter the
manufacturer’s recommended setting after determining the optimum for your application and
making a note of this on the included chart for future uniformity.

7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into
the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.

9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.98.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is no more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the
way into tool, until lock is held in pusher housing jaws. Position clamp(s) around hose
according to pre marked lines.

6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting
motion, making smaller strokes when clamp begins to get tighter. You must resist the natural
tendency of the hose to turn while tightening the clamp. As a general rule of thumb, you will
know the clamp is tight enough when the clamp surface is below the O.D. of the hose and/or
the clamp’s band has stopped moving through the lock. The amount of tension is directly
related to the type and style of both the hose and fitting being used. After proper ultimate
tension has been attained, hold the ball handle in the down position with one hand.
7.With clamp resting on a solid surface, and ball handle held in the down position, strike the
punch head a hard blow with a non-sparking mallet to lock the clamp. You may have to
strike the punch head more than once to obtain the proper hold. As a general rule of thumb,
the clamp will have an identifying mark in the center of the lock. This mark should be
completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
turning, then lift both handles of tool together, in an up and down motion, which will break
band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp
from tool, work it through the tool by operating ball handle. Next, press release lever and pull
waste strip out toward rear of tool.
         8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

         9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
         Testing:

         Hydrostatic testing as required.
6.7.99 Water Hose / Machined, Medium Shank / Pinch Clamp

            I.D.                     Working Pressure                         Test Pressure
 inch                  mm -                       psi       (kPa) -                       psi     (kPa)
 1/4”              (6.4 mm)    lesser of hose or 300       (2069)     lesser of 2X hose or 600   (4137)
 3/8”              (9.5 mm)    lesser of hose or 300       (2069)     lesser of 2X hose or 600   (4137)
 1/2”          (12.7 mm)       lesser of hose or 250       (1724)     lesser of 2X hose or 500   (3448)
 5/8”          (15.9 mm)       lesser of hose or 200       (1379)     lesser of 2X hose or 400   (2758)
 3/4”              (19 mm)     lesser of hose or 200       (1379)     lesser of 2X hose or 400   (2758)
 1”            (25.4 mm)       lesser of hose or 150       (1034)     lesser of 2X hose or 300   (2069)

Special Tools Required:

Pincer




Fabrication Procedures:

1. Place fitting along side of hose end and mark the hose for location of clamp or clamps.
2. On short shank fittings locate clamp directly over the machined barbs.

3. Insert fitting into hose until hose meets shoulder of fitting.
4. Place clamp over assembly. Holding clamp directly over barbed area of fitting, pinch one ear of the
clamp down completely, then go to the second ear and pinch it down completely.
5. Do not be concerned if the ear which was pinched first seems to open slightly.
Testing:

Hydrostatic testing as required.
Illustration 1. When installing Ear Type Clamps, please note that each ear must be crimped as
recommended to obtain a proper seal. An installation made incorrectly may impair the best connection. If
a clamp ear can be closed all the way, the clamp size selected is probably too big and the next smaller
clamp size should be used.
How to Apply
Illustration 2. Position Clamp as illustrated.

Illustration 3. Give each ear a firm squeeze with pincers.
6.7.100   Water Hose (soft wall only) / Machined, Long Shank / Bolt Clamp

             I.D.                         Working Pressure                          Test Pressure
 inch                    mm -                     psi           (kPa) -                        psi         (kPa)

 1/2”               (12.7 mm)    lesser of hose or 400       ( 2758 )     lesser of 2X hose or 800     ( 5516 )
 5/8”               (15.9 mm)    lesser of hose or 400       ( 2758 )     lesser of 2X hose or 800     ( 5516 )
 3/4”                (19 mm)     lesser of hose or 400       ( 2758 )     lesser of 2X hose or 800     ( 5516 )
 1”                 (25.4 mm)    lesser of hose or 300       ( 2069 )     lesser of 2X hose or 600     ( 4137 )
 1 1/4"             (31.8 mm)    lesser of hose or 300       ( 2069 )     lesser of 2X hose or 600     ( 4137 )
 1 1/2"             (38.1 mm)    lesser of hose or 300       ( 2069 )     lesser of 2X hose or 600     ( 4137 )
 2”                 (50.8 mm)    lesser of hose or 250       ( 1724 )     lesser of 2X hose or 500     ( 3448 )
 2 1/2"             (63.5 mm)    lesser of hose or 175       ( 1207 )     lesser of 2X hose or 350     ( 2413 )
 3”                 (76.2 mm)    lesser of hose or 150       ( 1034 )     lesser of 2X hose or 300     ( 2069 )
 4”             (101.6 mm)       lesser of hose or 125         ( 862 )    lesser of 2X hose or 250     ( 1724 )
 5”                 (127 mm)     lesser of hose or 100         ( 690 )    lesser of 2X hose or 200     ( 1379 )
 6”             (152.4 mm)       lesser of hose or 75          ( 517 )    lesser of 2X hose or 150     ( 1034 )

Special Tools Required:

Appropriate size wrench or socket
Fabrication Procedures:
1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper
clamp selection for that end.

2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published
minimum / maximum range.
3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.

4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with
the last serration on the shank. The last serration is the one before the shank end.
5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger
than the others, place marks on the hose to correspond with all large nodes (or serrations) present on that
stem.
6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail
reads in the same direction for all of the clamps.

 I.D.                                           No. of Clamps
 Below 2” (50.8 mm)                             1
 2” to 4” (50.8 mm to 101.6 mm)                 2
 5” to 6” (127 mm to 152.4 mm)                  3
 8” (203.2 mm) and above                        4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.
8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as
follows:
        a) Slide clamp towards the hose end past the mark placed on hose from Step 4.
        b) Position clamp so that there is ½” (12.7 mm) to 5/8” (15.9 mm) of rubber between clamp
        and hose end. Make sure that there is more rubber between clamp and mark on hose than
        there is between clamp and hose end. If this is not possible, center the clamp between the
        mark on the hose and the hose end.
        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of
        the saddle (the part that the bolt goes through) is midway between both clamp halves.

        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread
        showing past both nuts. Reposition the saddles as needed per Step 8c above. Saddle
        positioning is critical to proper sealing of the clamp.
        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that
        side.

        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.

        g) Tighten the opposite side nut one full turn.
        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch
        if necessary to reposition saddles.

        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.

9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:

        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.
        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.
        c) Repeat Steps 8c through 8i.
Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when
recommended torque is reached, the saddle loop is centered between the clamp halves.

10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble
as follows:
        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure
        that the clamp saddles are at 90º angles to the saddles of the clamp just installed.

        e) Assemble clamp per Steps 8c through 8i.
11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as
follows:
        a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark furthest away from the hose end.

        c) Assemble clamp per Steps 8c through 8i.
        d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end
        making sure that the clamp saddles are at 90º angles to the saddles of the clamp just
        installed.
        e) Assemble clamp per Steps 8c through 8I.
12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS,
assemble as follows:
        a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position the other clamps so that they are equally spaced between the clamp just installed
        and the hose end. Place marks on the hose to correspond with the location of these clamps.

        e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles
        to the clamp just installed.

        f) Assemble clamp per Steps 8c through 8i.
        g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to
        the clamp just installed.

        h) Assemble clamp per Steps 8c through 8i.
13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble
as follows:
        a) Slide all the clamps towards the hose end past the mark furthest from the hose end from
        Step 5.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark furthest from the hose end from Step 5.
        c) Assemble clamp per Steps 8c through 8i.

        d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from
        Step 5 and position the saddles at 45º angles to the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.

        f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the
        hose end from Step 5 and position the saddles at 45º angles to the clamp just installed.
        g) Assemble clamp per Steps 8c through 8I.

14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles
of the clamp being installed are to be positioned at 90º angles to the saddles of the clamp just installed.
Special Considerations:

1. Both bolts must be tightened evenly and equally to recommended torque.
2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than
the other, the clamp may walk at an angle to the hose body. This can result in sealing and retention
problems.
3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they
must bend for the clamp to work properly.
4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any
sharp edges. Do not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in
the metal of the bolt.
5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
Warnings:

Do not use Bolt Clamps on hoses that are constructed with helix wire.
Testing:

Hydrostatic testing as required.
6.7.101    Water Hose / Machined, Long Shank / Preformed

            I.D.                       Working Pressure                              Test Pressure
 inch                 mm -                        psi          (kPa) -                           psi            (kPa)
 1/2”          (12.7 mm)       lesser of hose or 400        ( 2758 )      lesser of 2X hose or 800            ( 5516 )
 5/8”          (15.9 mm)       lesser of hose or 400        ( 2758 )      lesser of 2X hose or 800            ( 5516 )
 3/4”              (19 mm)     lesser of hose or 400        ( 2758 )      lesser of 2X hose or 800            ( 5516 )
 1”            (25.4 mm)       lesser of hose or 300        ( 2069 )      lesser of 2X hose or 600            ( 4137 )
 1 1/4"        (31.8 mm)       lesser of hose or 300        ( 2069 )      lesser of 2X hose or 600            ( 4137 )
 1 1/2"        (38.1 mm)       lesser of hose or 300        ( 2069 )      lesser of 2X hose or 600            ( 4137 )
 2”            (50.8 mm)       lesser of hose or 250        ( 1724 )      lesser of 2X hose or 500            ( 3448 )
 2 1/2"        (63.5 mm)        lesser of hose or 200          ( 1379 )      lesser of 2X hose or 400        ( 2758 )
 3”            (76.2 mm)        lesser of hose or 175          ( 1207 )      lesser of 2X hose or 350        ( 2413 )
 4”           (101.6 mm)        lesser of hose or 175          ( 1207 )      lesser of 2X hose or 350        ( 2413 )
 5”             (127 mm)        lesser of hose or 125           ( 862 )      lesser of 2X hose or 250        ( 1724 )
 6”           (152.4 mm)        lesser of hose or 75            ( 517 )      lesser of 2X hose or 150        ( 1034 )

Note:

Use 5 bands on 3” through 6”. Use 4 bands on 2” through 2 ½”. Use 3 bands on ½” through 1 ½”.
        6.7.101.1   Preformed Clamps, applied with Roll-Over Pneumatic Tool
        Special Tools Required:

        Pneumatic Roll-over Tool
        Fabrication Procedures:

        1. Select smallest clamp, which slides over hose with fitting inserted.
        2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
        large and small barbs or only large barbs, locate each clamp in-between the large barbs.
        Use a clamp for every space between large bards. If all barbs or serrations are the same,
        place as many clamps over the serration as will comfortable fit. For hoses ID 3/8 inch (9.5
        mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2
        to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to
        1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
        For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as
        fit on the shank, in the manner outlined above.
        3. Slide clamps over hose with tails facing away from installer before inserting fitting into
        hose.
        4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
        5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s
        manual for correct pressure settings that correspond to clamp width and material used.

        6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp
        at mark on hose.
        7. Activate tool to tighten clamp.
        8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

        9. Roll hose up until shear hook engages buckle.

        10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait
        for cut-off cam to finish the clamp.

        11. Reset tool and remove scrap end of clamp.

        12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
        Special Considerations:

        Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
        good round seal.
        Testing:
Hydrostatic testing as required.
6.7.101.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
large and small barbs or only large barbs, locate the clamps in between the large barbs. Use
a clamp for every space between large barbs. If all bards or serrations are the same, place
as many clamps over the serrations as will comfortable fit. . For hoses ID 3/8 inch (9.5 mm)
or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8
inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For
hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit
on the shank, in the manner outlined above.

3. Slide clamps over hose with tails facing installer before inserting fitting into hose.
4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever.
Position clamp at mark on hose. Tighten clamp. When band appears to stop moving through
buckle, optimum tension has been applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to
1/2 turn at the same time.

7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut
the band thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.101.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool

Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is not more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closest to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.

5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in
the machine until it can go no further. If no clamps are already on hose, insert tail piece of
one clamp into the clamp slot in the machine until it can go no further and then slip
assembled hose and fitting through the clamp.

6. Set air tension regulator to the correct tension recommended by the manufacturer and
hold the tensioning button with one finger until clamp has reached proper tension and
automatically punches the lock and cuts band off while maintaining correct tension. Due to
many different types of hose and fitting construction and styles, you may alter the
manufacturer’s recommended setting after determining the optimum for your application and
making a note of this on the included chart for future uniformity.

7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into
the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.
9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.101.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is no more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closet to, but not less than that outside diameter.

2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.
3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
4. Insert fitting into hose until the entire shank is covered.
        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the
        way into tool, until lock is held in pusher housing jaws. Position clamp(s) around hose
        according to pre marked lines.

        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting
        motion, making smaller strokes when clamp begins to get tighter. You must resist the natural
        tendency of the hose to turn while tightening the clamp. As a general rule of thumb, you will
        know the clamp is tight enough when the clamp surface is below the O.D. of the hose and/or
        the clamp’s band has stopped moving through the lock. The amount of tension is directly
        related to the type and style of both the hose and fitting being used. After proper ultimate
        tension has been attained, hold the ball handle in the down position with one hand.
        7.With clamp resting on a solid surface, and ball handle held in the down position, strike the
        punch head a hard blow with a non-sparking mallet to lock the clamp. You may have to
        strike the punch head more than once to obtain the proper hold. As a general rule of thumb,
        the clamp will have an identifying mark in the center of the lock. This mark should be
        completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
        turning, then lift both handles of tool together, in an up and down motion, which will break
        band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp
        from tool, work it through the tool by operating ball handle. Next, press release lever and pull
        waste strip out toward rear of tool.
        8. For additional clamps, repeat steps 5-7, staggering the buckle positions.

        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required
6.7.102    Water Hose (soft wall only) / Cast / Bolt Clamp

            I.D.                          Working Pressure                               Test Pressure
 inch                  mm -                         psi           (kPa) -                             psi     (kPa)
 1/4”              (6.4 mm)      lesser of hose or 200          ( 1379 )       lesser of 2X hose or 400     ( 2758 )
 3/8”              (9.5 mm)      lesser of hose or 200          ( 1379 )       lesser of 2X hose or 400     ( 2758 )
 1/2”          (12.7 mm)         lesser of hose or 150          ( 1034 )       lesser of 2X hose or 300     ( 2069 )
 5/8”          (15.9 mm)         lesser of hose or 100           ( 690 )       lesser of 2X hose or 200     ( 1379 )
 3/4”              (19 mm)       lesser of hose or 100           ( 690 )       lesser of 2X hose or 200     ( 1379 )
 1”            (25.4 mm)         lesser of hose or 100           ( 690 )       lesser of 2X hose or 200     ( 1379 )
 1 1/4"        (31.8 mm)         lesser of hose or 75            ( 517 )       lesser of 2X hose or 150     ( 1034 )
 1 1/2"        (38.1 mm)         lesser of hose or 75            ( 517 )       lesser of 2X hose or 150     ( 1034 )
 2”            (50.8 mm)         lesser of hose or 75            ( 517 )       lesser of 2X hose or 150     ( 1034 )
 2 1/2"        (63.5 mm)         lesser of hose or 50            ( 345 )       lesser of 2X hose or 100      ( 690 )
 3”            (76.2 mm)         lesser of hose or 50            ( 345 )       lesser of 2X hose or 100      ( 690 )
 4”          (101.6 mm)          lesser of hose or 50            ( 345 )       lesser of 2X hose or 100      ( 690 )
 5”            (127 mm)          lesser of hose or 50            ( 345 )       lesser of 2X hose or 100      ( 690 )
 6”          (152.4 mm)          lesser of hose or 25            ( 172 )       lesser of 2X hose or 50       ( 345 )

Special Tools Required:
Appropriate size wrench or socket
Fabrication Procedures:

1. Measure hose O.D. with a diameter tape. Each end of the hose should be measured to ensure proper
clamp selection for that end.

2. Select correct Double Bolt clamp. Hose O.D. just measured must be within the clamps published
minimum / maximum range.
3. Place stem or nipple next to hose end to simulate the shank being fully inserted into the hose.

4. If the stem or nipple has many serrations the same diameter, put a mark on the hose to correspond with
the last serration on the shank. The last serration is the one before the shank end.

5. If the stem or nipple has large nodes (or serrations) or nodes (or serrations) that are obviously larger
than the others, place marks on the hose to correspond with all large nodes (or serrations) present on that
stem.
6. Slide the clamp(s) over the hose. If more than one clamp is used make sure the clamp lettering detail
reads in the same direction for all of the clamps.

 I.D.                                           No. of Clamps
 Below 2” (50.8 mm)                             1
 2” to 4” (50.8 mm to 101.6 mm)                 2
 5” to 6” (127 mm to 152.4 mm)                  3
 8” (203.2 mm) and above                        4

7. Using lubricant on the stem shank and the hose I.D., insert the stem or nipple into the hose.
8. For stems or nipples having many serrations the same diameter and using ONE CLAMP, assemble as
follows:
        a) Slide clamp towards the hose end past the mark placed on hose from Step 4.
        b) Position clamp so that there is ½” (12.7 mm) to 5/8” (15.9 mm) of rubber between clamp
        and hose end. Make sure that there is more rubber between clamp and mark on hose than
        there is between clamp and hose end. If this is not possible, center the clamp between the
        mark on the hose and the hose end.
        c) Position both clamp saddles so that they are fully under both clamp halves and the loop of
        the saddle (the part that the bolt goes through) is midway between both clamp halves.

        d) Hand tighten the nuts equally on both bolts so that there is the same amount of thread
        showing past both nuts. Reposition the saddles as needed per Step 8c above. Saddle
        positioning is critical to proper sealing of the clamp.
        e) Using a permanent marker, place a mark on one of the clamp halves near the nut on that
        side.

        f) Using a torque wrench, tighten the nut close to the mark from Step 8e above one full turn.

        g) Tighten the opposite side nut one full turn.
        h) Reposition the saddles as needed per Step 8c above. Use a hammer or mallet and punch
        if necessary to reposition saddles.

        i) Repeat Steps 8f through 8h until both bolts are at recommended torque.

9. For stems having one large node (or serration) and using ONE CLAMP, assemble as follows:
        a) Slide the clamp towards the hose end past the mark on the hose from Step 5.

        b) Position the clamp so that it is just inside (the hose end side) of the mark from Step 5.
        c) Repeat Steps 8c through 8i.

Note:

It may be necessary to slightly off-set the saddle loop (ref. Step 8c). towards the bolt head so that when
recommended torque is reached, the saddle loop is centered between the clamp halves.

10. For stems or nipples having many serrations the same diameter and using TWO CLAMPS, assemble
as follows:

        a) Slide both clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position remaining clamp midway between clamp just installed and hose end making sure
        that the clamp saddles are at 90º angles to the saddles of the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.
11. For stems or nipples having two large nodes (or serrations) and using TWO CLAMPS, assemble as
follows:
        a) Slide both clamps towards the hose end past the first mark on the hose from Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark furthest away from the hose end.
        c) Assemble clamp per Steps 8c through 8i.
        d) Position remaining clamp just inside (the hose end side) of mark closest to the hose end
        making sure that the clamp saddles are at 90º angles to the saddles of the clamp just
        installed.
        e) Assemble clamp per Steps 8c through 8I.
12. For stems or nipples having many serrations the same diameter and using THREE CLAMPS,
assemble as follows:
        a) Slide all the clamps towards the hose end past the mark on the hose from Step 4.

        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark from Step 4.
        c) Assemble clamp per Steps 8c through 8i.

        d) Position the other clamps so that they are equally spaced between the clamp just installed
        and the hose end. Place marks on the hose to correspond with the location of these clamps.
        e) Place the middle clamp on its marks from Step 12d and position the saddles at 45º angles
        to the clamp just installed.
        f) Assemble clamp per Steps 8c through 8i.

        g) Place the end clamp on its marks from Step 12d and position the saddles at 45º angles to
        the clamp just installed.

        h) Assemble clamp per Steps 8c through 8i.
13. For stems or nipples having three large nodes (or serrations) and using THREE CLAMPS, assemble
as follows:

        a) Slide all the clamps towards the hose end past the mark furthest from the hose end from
        Step 5.
        b) Position the clamp furthest away from the hose end so that it is just inside (the hose end
        side) of the mark furthest from the hose end from Step 5.

        c) Assemble clamp per Steps 8c through 8i.
        d) Place the middle clamp just inside (the hose end side) the middle mark on the hose from
        Step 5 and position the saddles at 45º angles to the clamp just installed.
        e) Assemble clamp per Steps 8c through 8i.
        f) Place the end clamp just inside (the hose end side) the mark on the hose closest to the
        hose end from Step 5 and position the saddles at 45º angles to the clamp just installed.
        g) Assemble clamp per Steps 8c through 8I.

14. When installing FOUR CLAMPS, follow instructions from Step 12 with the exception that the saddles
of the clamp being installed are to be positioned at 90º angles to the saddles of the clamp just installed.
Special Considerations:

1. Both bolts must be tightened evenly and equally to recommended torque.
2. The clamp must be perpendicular (straight across) to the hose body. If one bolt is tightened more than
the other, the clamp may walk at an angle to the hose body. This can result in sealing and retention
problems.
3. The bolts will bend when tightened to recommended torque. The bolts are designed to bend and they
must bend for the clamp to work properly.
4. If the excess bolt past the nut is to be removed, remove it with bolt cutters or a hack saw. File down any
sharp edges. Do not remove the bolt with an abrasive wheel or blowtorch as these can alter the temper in
the metal of the bolt.
5. If the clamp is removed from the hose, discard it. Do not reuse any portion of the clamp.
Warnings:

Do not use Bolt Clamps on hoses that are constructed with helix wire.
Testing:

Hydrostatic testing as required.
6.7.103    Water Hose / Cast / Preformed

            I.D.                         Working Pressure                              Test Pressure
 inch                  mm -                         psi           (kPa) -                        psi            (kPa)
 1/4”              (6.4 mm)        lesser of hose or 200       ( 1379 )     lesser of 2X hose or 400          ( 2758 )
 3/8”              (9.5 mm)        lesser of hose or 200       ( 1379 )     lesser of 2X hose or 400          ( 2758 )
 1/2”          (12.7 mm)           lesser of hose or 150       ( 1034 )     lesser of 2X hose or 300          ( 2069 )
 5/8”          (15.9 mm)           lesser of hose or 100        ( 690 )     lesser of 2X hose or 200          ( 1379 )
 3/4”              (19 mm)         lesser of hose or 100        ( 690 )     lesser of 2X hose or 200          ( 1379 )
1”           (25.4 mm)         lesser of hose or 100            ( 690 )   lesser of 2X hose or 200        ( 1379 )
1 1/4"       (31.8 mm)         lesser of hose or 75             ( 517 )   lesser of 2X hose or 150        ( 1034 )
1 1/2"       (38.1 mm)         lesser of hose or 75             ( 517 )   lesser of 2X hose or 150        ( 1034 )
2”           (50.8 mm)         lesser of hose or 75             ( 517 )   lesser of 2X hose or 150        ( 1034 )
2 1/2"       (63.5 mm)         lesser of hose or 50             ( 345 )   lesser of 2X hose or 100         ( 690 )
3”           (76.2 mm)         lesser of hose or 50             ( 345 )   lesser of 2X hose or 100         ( 690 )
4”         (101.6 mm)          lesser of hose or 50             ( 345 )   lesser of 2X hose or 100         ( 690 )
5”           (127 mm)          lesser of hose or 50             ( 345 )   lesser of 2X hose or 100         ( 690 )
6”         (152.4 mm)          lesser of hose or 25             ( 172 )   lesser of 2X hose or 50          ( 345 )

     6.7.103.1   Preformed Clamps, applied with Roll-Over Pneumatic Tool
     Special Tools Required:

     Pneumatic Roll-over Tool
     Fabrication Procedures:

     1. Select smallest clamp, which slides over hose with fitting inserted.
     2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
     large and small barbs or only large barbs, locate each clamp in-between the large barbs.
     Use a clamp for every space between large bards. If all barbs or serrations are the same,
     place as many clamps over the serration as will comfortable fit. For hoses ID 3/8 inch (9.5
     mm) or less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2
     to 5/8 inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to
     1-1/2 inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps.
     For hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as
     fit on the shank, in the manner outlined above.
     3. Slide clamps over hose with tails facing away from installer before inserting fitting into
     hose.
     4. Insert fitting into hose as far as it will go. Hose must cover entire shank.

     5. Set pull-up and hold pressure to proper settings. Reference decal on tool or operator’s
     manual for correct pressure settings that correspond to clamp width and material used.
     6. Individually insert clamp tail into tool with buckle on top as far as it can go. Position clamp
     at mark on hose.
     7. Activate tool to tighten clamp.
     8. Upon completion of stroke , let the pressure drop down to the hold pressure setting.

     9. Roll hose up until shear hook engages buckle.

     10. Pull cut-off lever quickly to lock and complete clamp. For automatic air tool, simply wait
     for cut-off cam to finish the clamp.
     11. Reset tool and remove scrap end of clamp.

     12. Repeat steps 5 to 11 with each clamp, staggering the buckle positions.
     Special Considerations:

     Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.103.2   Preformed Clamps applied with Roll-Over Hand Tool and Adapter
Special Tools Required:

Spinner type Hand Tool and Adapter
Fabrication Procedures:

1. Select smallest clamps, which slides over hose with fitting inserted.

2. Place fitting along side hose and mark positions of clamps on hose cover. If the shank has
large and small barbs or only large barbs, locate the clamps in between the large barbs. Use
a clamp for every space between large barbs. If all bards or serrations are the same, place
as many clamps over the serrations as will comfortable fit. For hoses ID 3/8 inch (9.5 mm) or
less, use at least one 1/4 or 3/8 inch (6.4 or 9.5 mm) wide clamp. For diameters 1/2 to 5/8
inch (12.7 to 15.9 mm), use 3/8 or ½ inch (9.5 or 12.7 mm) wide clamps. For 3/4 to 1-1/2
inch (19 to 38.1 mm) diameter hose, use 5/8 or 3/4 inch (15.9 or 19 mm) wide clamps. For
hoses over 1-1/2 inch (38.1 mm) diameter use as many ¾ inch (19 mm) wide clamps as fit
on the shank, in the manner outlined above.
3. Slide clamps over hose with tails facing installer before inserting fitting into hose.

4. Insert fitting into hose as far as it will go. Hose must cover entire shank.
5. Individually insert clamp tail through adapter and tool nose, and grip tail with gripper lever.
Position clamp at mark on hose. Tighten clamp. When band appears to stop moving through
buckle, optimum tension has been applied. Stop turning handle.
6. Roll hose over until buckle is positioned under shear hook, reversing tension handle 1/4 to
1/2 turn at the same time.
7. Engage buckle with shear hook, and with a firm quick movement of the cutter handle cut
the band thus completing the clamp.
8. Repeat steps 5 to 7 with each clamp, staggering the buckle positions.
Special Considerations:

Apply number of clamps specified. Make sure clamps selected are narrow enough to make a
good round seal.
Testing:

Hydrostatic testing as required.
6.7.103.3   Center Punch Clamp applied with Pneumatic Tool
Special Tools Required:

Pneumatic Center Punch Tool
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is not more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closest to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.

4. Insert fitting into hose until the entire shank is covered.
5. If the clamp(s) are already on the hose, place tail piece of one clamp into the clamp slot in
the machine until it can go no further. If no clamps are already on hose, insert tail piece of
one clamp into the clamp slot in the machine until it can go no further and then slip
assembled hose and fitting through the clamp.

6. Set air tension regulator to the correct tension recommended by the manufacturer and
hold the tensioning button with one finger until clamp has reached proper tension and
automatically punches the lock and cuts band off while maintaining correct tension. Due to
many different types of hose and fitting construction and styles, you may alter the
manufacturer’s recommended setting after determining the optimum for your application and
making a note of this on the included chart for future uniformity.
7. After the assembly is complete, the waste tail piece of the clamp will automatically fall into
the scrap bucket.
8. For additional clamps, repeat steps 5 and 6 above, staggering the buckle positions.
9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
Testing:

Hydrostatic testing as required.
6.7.103.4   Center Punch Clamp applied with Hand Tool
Special Tools Required:

Hand Tool & Mallet
Fabrication Procedures:

1. Although any diameter of clamp, which is larger than the hose outside diameter, will
function properly, we suggest that you use a clamp that is no more than approximately 1/4"
larger than the hose outside diameter. This will reduce clamp cost and installation time.
Therefore, measure the hose outside diameter while the fitting is inserted and select a clamp
that is the closet to, but not less than that outside diameter.
2. Place fitting along side the hose and make mark with a pen or marker to denote where the
clamp(s) should be applied. If there are one or two barbs on the fitting, the clamp(s) should
be placed in the grooves between the barbs. If there are many barbs (serrations or nodes)
you need to make sure that the clamp(s) are going to be located on the shank somewhere. It
is recommended that you use as many clamps as there are grooves if the fitting is grooved.
If not, use at least one clamp up to two inch hose and two or three on two inch and above.

3. Slide clamp(s) over the end of hose with clamp tails facing the installer before installing
the fitting. This enables you to use the smallest diameter of clamp possible. However, if, for
whatever reason, you need or want to use a larger clamp, and it will fit over the fitting, you
may slide the clamp on after the fitting is applied.
        4. Insert fitting into hose until the entire shank is covered.

        5. Place ball handle fully forward. Holding the mouth of the tool open, insert clamp tail all the
        way into tool, until lock is held in pusher housing jaws. Position clamp(s) around hose
        according to pre marked lines.
        6. Tighten clamp by ratcheting down and up with the ball handle. Continue this ratcheting
        motion, making smaller strokes when clamp begins to get tighter. You must resist the natural
        tendency of the hose to turn while tightening the clamp. As a general rule of thumb, you will
        know the clamp is tight enough when the clamp surface is below the O.D. of the hose and/or
        the clamp’s band has stopped moving through the lock. The amount of tension is directly
        related to the type and style of both the hose and fitting being used. After proper ultimate
        tension has been attained, hold the ball handle in the down position with one hand.

        7.With clamp resting on a solid surface, and ball handle held in the down position, strike the
        punch head a hard blow with a non-sparking mallet to lock the clamp. You may have to
        strike the punch head more than once to obtain the proper hold. As a general rule of thumb,
        the clamp will have an identifying mark in the center of the lock. This mark should be
        completely obscured by the punched lock. To free the tool, grasp hose firmly to prevent
        turning, then lift both handles of tool together, in an up and down motion, which will break
        band off at lock. You may smooth lock corners with mallet. To clear cut-off end of clamp
        from tool, work it through the tool by operating ball handle. Next, press release lever and pull
        waste strip out toward rear of tool.
        8. For additional clamps, repeat step 5-7, staggering the buckle positions.
        9. Make sure that the manufacturer’s markings are obliterated after punching on all clamps.
        Testing:

        Hydrostatic testing as required.
6.7.104    Water Hose / Cast / Band & Buckle

             I.D.                          Working Pressure                             Test Pressure
 inch                   mm -                           psi         (kPa) -                         psi        (kPa)
 1 1/4"         (31.8 mm)          lesser of hose or 75           ( 517 )    lesser of 2X hose or 150       ( 1034 )
 1 1/2"         (38.1 mm)          lesser of hose or 75           ( 517 )    lesser of 2X hose or 150       ( 1034 )
 2”             (50.8 mm)          lesser of hose or 75           ( 517 )    lesser of 2X hose or 150       ( 1034 )
 2 1/2"         (63.5 mm)          lesser of hose or 50           ( 345 )    lesser of 2X hose or 100        ( 690 )
 3”             (76.2 mm)          lesser of hose or 50           ( 345 )    lesser of 2X hose or 100        ( 690 )
 4”            (101.6 mm)          lesser of hose or 50           ( 345 )    lesser of 2X hose or 100        ( 690 )
 5”                 (127 mm)       lesser of hose or 50           ( 345 )    lesser of 2X hose or 100        ( 690 )
 6”            (152.4 mm)          lesser of hose or 25           ( 172 )    lesser of 2X hose or 50         ( 345 )

Special Tools Required:

Spinner type Hand Tool
Fabrication Procedures:

1. Place fitting along side hose and mark position of clamps on hose cover. If the shank has large and
small barbs, or large barbs only, locate each clamp between two large barbs. Use a clamp for every space
between large barbs. If all barbs or serrations are the same, place as many clamps over the serrations as
will comfortably fit. Do not use for ID less than 1-¼ inch (31.75 mm). For hoses 1-¼ to 1-½ inch (31.75 to
38.1 mm) diameter, use ½ or 5/8 inch (12.7 or 15.9 mm) wide clamps. For diameters of 1-½ to 2-½ inch
(38.1 to 63.5 mm), use 5/8 or ¾ inch (15.9 or 19.1 mm) wide clamps. For diameters larger than 2-½ inch
(63.5 mm), use as many ¾ inch (19.1 mm) wide clamps as will fit on the shank, in the manner outlined
above.

2. Insert the fitting into the hose as far as it will go. Hose must cover the entire shank.
3. Pull band from container as needed. To determine length of band required, either form band roughly
around hose twice and add four inches: or, if band is imprinted, count spaces equal to twice the diameter
in inches plus 2. Cut band with cutter in tool.

4. Slide buckle on band, ears of buckle away from the operator. Bend end of band under buckle, 1-½ to 2
inches (38.1 to 50.8 mm) long. Bring end of band around hose and again through buckle. Continue band a
second time around hose and through buckle. Double wrapped banding must be used for hose clamping.
Snug clamp up by hand.

5. Insert first clamp tail through tool nose and grip tail with gripper lever. Position clamp at mark on hose.
Tighten clamp. When band appears to stop moving through buckle, optimum tension has been applied.
Stop turning handle.
6. Roll tool over buckle, reversing tension handle ¾ to one full turn at the same time.

7. Pull cutting handle to cut band. Remove tool, while holding band stub down with thumb.
8. Clinch stub by hammering down buckle ears.

9. Repeat steps 3 through 8 for each clamp, staggering the buckle positions.
Special Considerations:

Make sure clamp is narrow enough to give a good round seal.
Testing:

Hydrostatic testing as required.
6.7.105    Water Hose / Interlocking Crimp-Swage / Crimp

            I.D.                         Working Pressure                                Test Pressure
 inch                   mm -                        psi          (kPa) -                          psi            (kPa)

 1/4”               (6.4 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 3/8”               (9.5 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 1/2”              (12.7 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 5/8”              (15.9 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 3/4”               (19 mm)     lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 1”                (25.4 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 1 1/4"            (31.8 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 1 1/2"            (38.1 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 2”                (50.8 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 2 1/2"            (63.5 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 3”                (76.2 mm)    lesser of hose or 600          ( 4137 )     lesser of 2X hose or 1200        ( 8274 )
 4”            (101.6 mm)       lesser of hose or 500          ( 3448 )     lesser of 2X hose or 1000        ( 6895 )
 6”            (152.4 mm)       lesser of hose or 400          ( 2758 )     lesser of 2X hose or 800         ( 5516 )
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. For stems having a welded collar, chamfer the hose tube 1/8" (3.175 mm) wide by 45º angle (if
applicable).
3. Bend grounding wire inside of hose, extending wire approximately 1/2" (12.7 mm).

4. Measure the outer diameter of the hose, preferably with a pi tape.

5. Based on the hose outer diameter, select the proper ferrule.
6. Insert the stem into the hose squarely without causing damage to the tube.
7. Lubrication should only be used if necessary.
8. Note: On some stems, the ferrule is assembled on the stem prior to insertion.
9. Slide the ferrule over the stem collar. If the ferrule has flats, be sure they line up with the flats on the
hose collar.

10.Select the desired crimp length and crimp OD using manufacturer’s recommendations.
11. Based on #10, select the proper die set using the crimp machine manufacturer’s recommendations.

12. Place the hose assembly in the die opening.
13. Jog the crimp dies until they just contact the ferrule. Be sure the ferrule and crimp dies are line up
properly to achieve the desired crimp length.
14. Crimp the ferrule to the desired diameter.

15. Retract the dies and remove the hose assembly.
16. Measure the crimp diameter to ensure it meets manufacturer’s specifications.
17. If the OD is too large, re-crimp the ferrule until it meets the required specification. If the crimp diameter
is too small, consult the coupling manufacturer.
18. Repeat steps 1 through 17 for the other end.
Testing:

Hydrostatic testing as required.
6.7.106    Water Hose / Interlocking Crimp-Swage / Swaged

           I.D.                         Working Pressure                                  Test Pressure
 inch                 mm -                          psi            (kPa) -                          psi             (kPa)
 1/4”             (6.4 mm)      lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 3/8”             (9.5 mm)      lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1/2”         (12.7 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 5/8”         (15.9 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 3/4”             (19 mm)       lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1”           (25.4 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1 1/4"       (31.8 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 1 1/2"       (38.1 mm)         lesser of hose or 600           ( 4137 )     lesser of 2X hose or 1200            ( 8274 )
 2”           (50.8 mm)        lesser of hose or 600         ( 4137 )    lesser of 2X hose or 1200           ( 8274 )
 2 1/2"       (63.5 mm)        lesser of hose or 600         ( 4137 )    lesser of 2X hose or 1200           ( 8274 )
 3”           (76.2 mm)        lesser of hose or 600         ( 4137 )    lesser of 2X hose or 1200           ( 8274 )
 4”          (101.6 mm)        lesser of hose or 500         ( 3448 )    lesser of 2X hose or 1000           ( 6895 )
 6”          (152.4 mm)        lesser of hose or 400         ( 2758 )    lesser of 2X hose or 800            ( 5516 )

Special Tools Required:

Swaging equipment and appropriate dies
Fabrication Procedures:

1. Cut hose end square and clean any debris from tube interior.

2. For stems having a welded collar, chamfer the hose tube 1/8 inch (3.175 mm) wide by 45° angle.

3. Bend grounding wire inside of hose with wire extended approximately ½ inch (12.7 mm).
4. Use a diameter tape to measure hose O.D. and select proper ferrule.
5. Select proper die set and accessories using manufacturers recommendations.
6. Insert stem into hose squarely without causing damage to the tube.

7. Lubrication should only be used if necessary.
8. Note: On some stems the ferrule is assembled on the stem prior to insertion consult coupling
manufacturer.
9. Slide the ferrule over the end of the stem and hose until the turned-over part of the ferrule comes in
contact with the stem collar.
10. Bring the hose stem and ferrule through the bottom of the die bed. Make sure there is enough
clearance between the bottom of the ferrule and the die holders for the swaging dies to be put into place.
Lubricate the inside of the swaging die and the outside of the ferule with oil or grease.
11. Lower the swaging dies into the die holders. Using the required pusher for the style coupling being
assembled, start the swaging process. Depending on coupling style, it may be necessary to put pressure
against the pusher to keep the ferrule properly placed until the ferrule has been reduced to the point that it
comes in contact with the hose cover. Continue the swage until desired length has been achieved.
Consult the coupling manufacturer for the swage length needed for proper assembly.

12. After the ram cylinder has retracted lift the dies out of the die bed and remove the assembly from the
machine. Wipe off lubricant from ferrule and hose.

13. Repeat above stems for other end of hose.
Testing:

Hydrostatic testing as required.
6.7.107    Water Hose / Ground Joint or Interlocking Male Stem / Interlocking Clamp

           I.D.                      Working Pressure                                Test Pressure
 inch                 mm -                         psi        (kPa) -                           psi              (kPa)

 1/4”             (6.4 mm)    lesser of hose or 600         ( 4137 )     lesser of 2X hose or 1200           ( 8274 )
 3/8”             (9.5 mm)    lesser of hose or 600         ( 4137 )     lesser of 2X hose or 1200           ( 8274 )
 1/2”         (12.7 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 3/4”           (19 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 1”           (25.4 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 1 1/4"       (31.8 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 1 1/2"       (38.1 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 2”           (50.8 mm)         lesser of hose or 600         ( 4137 )      lesser of 2X hose or 1200           ( 8274 )
 2 1/2"       (63.5 mm)         lesser of hose or 450         ( 3103 )      lesser of 2X hose or 900            ( 6206 )
 3”           (76.2 mm)         lesser of hose or 450         ( 3103 )      lesser of 2X hose or 900            ( 6206 )
 4”          (101.6 mm)         lesser of hose or 230         ( 1586 )      lesser of 2X hose or 460            ( 3172 )
 6”          (152.4 mm)         lesser of hose or 230         ( 1586 )      lesser of 2X hose or 460            ( 3172 )

Special Tools Required:

Torque wrench.
Fabrication Procedures:

1. Determine the cut length of the hose per general fabrication methods.
2. Cut the hose square per general fabrication methods.
3. Ensure hose is clean of any residue, oil, dirt, etc. from cutting or storage.
4. Insert the fitting fully into the hose until the end of the hose is up against the interlocking collar. Slight
twisting may help insertion. If a lubricant must be used to aid full insertion, it is suggested to use water or
a slightly soapy water solution.
5. Attach clamp per manufacturer’s recommendation or the following procedures:
Assembly Procedure for 2 Bolt Clamps:

Perform steps 1-5 above.
6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex
on the stem or the wing nut on the stem. Snug the bolts equally by hand.
7. Snug the bolts equally by hand again.
8. Using a torque wrench, begin tightening the bolts as follows:

9. First bolt (nut facing assembler) 1 full turn,

10. Second bolt (opposite first bolt) 1 full turn.
11. Repeat procedure “9” and “10” until both bolts have reached recommended published torque.
Assembly Procedure of 4 Bolt Clamps:

Perform steps 1-5 above.

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar, but in front of the hex
on the stem. Snug the bolts equally by hand. If the hose free O.D. is at or near the maximum range of the
clamp, it may be necessary to put the stem, hose and clamp halves in a vise to close the clamp enough to
start the bolts. Snug the bolts equally (thread engagement between bolt and nut is equal on all 4 bolts).
7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) 1 full turn,

9. Front bolt (close to gripping finger) 1 full turn,
10. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued,

11. Opposite side back bolt 1 full turn,
12. Opposite side front bolt 1 full turn,

13. Snug by hand (if bolts are loose) nuts on opposite side of bolts just torqued.

14. Repeat above procedures “8” through “13” until all of the bolts have reached the recommended
published torque.
Assembly Procedure of 6 Bolt Clamps:

Perform steps 1-5 above.

6. Hand assemble the clamp so that the gripping fingers are behind the stem collar. Snug the bolts by
hand equally (thread engagement between bolt and nut is equal on all six bolts. Place a mark (X) on the
clamp body of one of the segments near the nut of the back bolt (away from gripping finger) with a magic
marker or something similar.
7. Using a torque wrench, begin tightening the bolts as follows:
8. Back bolt (away from gripping finger) having “X” near it one full turn,
9. Front bolt (close to gripping finger) of same segment one full turn,

10. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),
11. Back bolt to one full turn,

12. Front bolt one full turn,
13. Moving to clamp segment to the left of the one just torqued, snug bolts by hand (if bolts are loose),
14. Back bolt one full turn,
15. Front bolt one full turn.
16. Repeat above procedure “8” through “15” until all of the bolts have reached the recommended
published torque.
Assembly procedure for U-bolt clamps:

Perform steps 1-5 above.
6. Place cast part of clamp on top of hose so interlocking fingers fit onto collar of fitting.

7. Place ribbed steel liner under hose so it aligns with ribs in clamp casting.

8. Install U-bolts around steel liner and through clamp casting and apply nuts.
9. Tighten nuts on U-bolts evenly until steel liner is drawn up into clamp casting on both sides and
interlocking fingers engage collar of fitting.

10. Evenly tighten nuts to torque values shown on chart below.

 Clamp Size                                             Nut Torque
 ½” (12.7 mm)                                           15 ft.-lbs.
 ¾” (19.05 mm) through 1¼” (31.75 mm)                   25 ft.-lbs.
       1½” (38.1 mm)                     35 ft.-lbs.
       2” (50.8 mm), 3” (76.2 mm)        55 ft.-lbs.
       4” (101.6 mm)                     100 ft.-lbs.


      Testing:

      Hydrostatic testing as required.

>> continue to next section
Section 6.2 - Selection Chart - Chart I (click to Chart II if you coudn't your Fitting Type in this chart)
                                                           Fitting Type
                           Cam and     Universal-         Machined-       Machined-         Machined- Long    Cast Shank-Pin Lug
                           Grove       Chicago,           Short Shank     Medium Shank      Shank             Water Hose Cplg,
-      -                               Crowsfoot, Claw                                                        Suction Cplg, Shank
                                                                                                              Cplg




Hose                                                      Crimp           Crimp Ferrule/
Type                                   Crimped Ferrule/                   Sleeve
                                                          Ferrule/
                                       Sleeve
                                                          Sleeve                            Pinch Clamp
                                                                          Pinch Clamp
                           NOT TO      Inter-
       Air Hose                                           Pinch                             Preformed Clamp Not Recommended
                           BE USED     locking
                                                          Clamp           Preformed
                                       Clamp
                                                                          Clamp             Band & Byckle
                                                          Preformed
                                       Preformed Clamp
                                                          Clamp           Band & Buckle

       Asphalt

                           Crimped
                           Ferrule/
                           Sleeve

                           Preformed                                      Preformed
                                                                                            Preformed Clamp
       Chemical- Plastic   Clamp                          NOT TO          Clamp
       Lined                                              BE USED
                                                                                            Band and Buckle
                           Band &                                         Band and Buckle
                           Buckle

                           Swaged
                           Ferrule

                           Crimped
                           Ferrule/
                           Sleeve

                           Preformed                                      Preformed
                                                                                            Preformed Clamp
       Chemical- Rubber    Clamp                                          Clamp
       Lined
                                                                                            Band and Buckle
                           Band &                                         Band and Buckle
                           Buckle

                           Swaged
                           Ferrule
       Food Handling-
       Regulated

                           Crimped
                           Ferrule/
                           Sleeve
                                                                          Bolt Clamp
                                                                                            Bolt Clamp        Bolt Clamp
                           Preformed
                           Clamp                                          Preformed
       Food Handling-
                                                                          Clamp             Preformed Clamp Preformed Clamp
       Non-Regulated
                           Band &
                           Buckle                                         Band &            Band & Buckle     Band & Buckle
                                                                          Buckle
                           Swaged
                           Ferrule

                           Crimped
                           Ferrule/
                           Sleeve
                                                                          Preformed
                                                                                            Preformed Clamp Preformed Clamp
                                                                          Clamp
       Lay Flat            Preformed
                           Clamp                                                            Band and Buckle   Band and Buckle
                                                                          Band & Buckle
                           Band &
                           Buckle
                     Crimped
                     Ferrule/
                     Sleeve
                                                                 Bolt Clamp
                                                                                   Bolt Clamp        Bolt Clamp
                     Preformed
                     Clamp                                       Preformed
Material Handling-
                                                                 Clamp             Preformed Clamp Preformed Clamp
Bulk Transfer
                     Band &
                     Buckle                                      Band &            Band & Buckle     Band & Buckle
                                                                 Buckle
                     Swaged
                     Ferrule
Material Handling-
Cement

Petroleum -

Fuel Oil             Crimped
                     Ferrule/
Petroleum            Sleeve
Drop
                     Preformed                                   Preformed
Petroleum                                                                          Preformed Clamp
                     Clamp                                       Clamp
Vapor
Recovery                                                                           Band and Buckle
                     Band &                                      Band and Buckle
                     Buckle
Petroleum
Discharge            Swaged
                     Ferrule
Petroleum
Suction &
Discharge

Push On

Sandblast

                     NOT TO      NOT TO
Steam
                     BE USED     BE USED

                     Crimped
                     Ferrule/
                     Sleeve                        Crimp
                                                   Ferrule/      Bolt Clamp
                                                                                   Bolt Clamp        Bolt Clamp
                     Preformed   Inter-            Sleeve
Water/Multi          Clamp       locking Clamp                   Pinch Clamp
                                                                                   Pinch Clamp       Pinch Clamp
Purpose                                            Pinch Clamp
                     Band &      Preformed Clamp                 Preformed
                     Buckle                                                        Preformed Clamp Preformed Clamp
                                                   Preformed     Clamp
                                                   Clamp
                     Swaged
                     Ferrule
Section 6.2 - Selection Chart - Chart II (click to Chart I if you coudn't your Fitting Type in this chart)
                                                           Fitting Type
                         Interlocking      Ground Joint Sanitary          Sandblast   Push On    Internal    Internal
-      -                 Swage/                                                                  Expansion   Expansion Short
                         Crimp                                                                               Brass Cplg




Hose                     Crimp
Type                     Ferrule/
                         Sleeve            Inter-
       Air Hose
                                           locking Clamp
                         Swaged Ferrule

                         Inter-
       Asphalt
                         locking Clamp

                         Crimp
       Chemical-
                         Ferrule/
       Plastic Lined
                         Sleeve

                         Crimp
       Chemical-         Ferrule/ Sleeve                                                         Internal
       Rubber Lined                                                                              Expansion
                         Swaged Ferrule
       Food Handling-                                      Internal                              Internal
       Regulated                                           Expansion                             Expansion

                         Crimp
       Food Handling-    Ferrule/ Sleeve                                                         Internal
       Non-Regulated                                                                             Expansion
                         Swaged Ferrule

       Lay Flat

                         Crimp
       Material
                         Ferrule/ Sleeve
       Handling- Bulk
       Transfer
                         Swaged Ferrule

                         Crimp
       Material
                         Ferrule/ Sleeve   Inter-                                                Internal
       Handling-
                                           locking Clamp                                         Expansion
       Cement
                         Swaged Ferrule

       Petroleum -

       Fuel Oil

       Petroleum Drop
                         Crimp
       Petroleum Vapor   Ferrule/ Sleeve                                                                     Internally
                                                                                                 Internal
       Recovery                                                                                              Expanded Short
                                                                                                 Expansion
                                                                                                             Brass
                         Swaged Ferrule
       Petroleum
       Discharge

       Petroleum
       Suction &
       Discharge

                                                                                      None
       Push On
                                                                                      Required

                                                                          None
       Sandblast
                                                                          Required

                                           Inter-
       Steam
                                           locking Clamp
              Crimp
              Ferrule/ Sleeve                   Internally
Water/Multi                     Inter-
                                                Expanded Short
Purpose                         locking Clamp
                                                Brass
              Swaged Ferrule
                                                                   Pressure Ratings Chart
                                                                                              1-     1-           2-                            Special
    Hose            Fitting         Attachment      1/4"   3/8"   1/2"   5/8"   3/4"   1"                  2"           3"    4"    5"   6"
                                                                                             1/4"   1/2"         1/2"                            Notes



     ALL
PRESSURE
  RECOM-
MENDATION
ARE "UP TO
  OR HOSE
  RATING"
WHICH EVER
 IS LOWER
 Air (assumed
                      Universal           Crimp             110    110    110    110   110
      soft wall)
 Air (assumed
                      Universal      Interlocking           110    110    110    110   110
      soft wall)
 Air (assumed                                                                                                                                   2 bands on
                      Universal       Preformed             110    110    110    110   110
      soft wall)                                                                                                                               3/4 or larger
 Air (assumed        Machined,
                                          Crimp      200    150    150    100    100   100
      soft wall)         short
 Air (assumed        Machined,
                                           Pinch     300    300    250    200    200   150
      soft wall)         short
 Air (assumed        Machined,
                                      Preformed      200    150    150    100    100   100
      soft wall)         short
                                                                                                                                              2 bands on
 Air (assumed        Machined,
                                           Pinch     220    220    300    300    300   300                                                      1/2-1; 1on
      soft wall)      medium
                                                                                                                                                 1/4 & 3/8
                                                                                                                                              3 bands on
 Air (assumed        Machined,                                                                                                                  3, 4 & 6; 1
                                      Preformed      300    300    250    200    200   150    150    150   125    125   125   125         50
      soft wall)      medium                                                                                                                 on up to 5/8;
                                                                                                                                                 2 on rest
                                                                                                                                              3 bands on
 Air (assumed        Machined,
                                    Band/ Buckle                                              225    225   200    200   175   175         75 3, 4 & 6; 2
      soft wall)      medium
                                                                                                                                                    on rest
                                                                                                                                              2 bands on
 Air (assumed
                 Machined, long            Pinch     150    150    220    220    300   300                                                      1/2-1; 1on
      soft wall)
                                                                                                                                                 1/4 & 3/8
                                                                                                                                              5 bands on
 Air (assumed                                                                                                                                  3, 4, & 6; 4
                 Machined, long       Preformed                    400    300    300   300    225    225   200    200   175   175         75
      soft wall)                                                                                                                             on 2 & 2-1/2;
                                                                                                                                                 3 on rest
                                                                                                                                              5 bands on
 Air (assumed                                                                                                                                  3, 4, & 6; 4
                 Machined, long     Band/ Buckle                                              300    300   250    250   250   200        100
      soft wall)                                                                                                                             on 2 & 2-1/2;
                                                                                                                                                 3 on rest
             Air              G/J    Interlocking    600    600    600           600   600    600    600   600    450   450   230        230
             Air   Crimp/Swage            Crimp      600    600    600    600    600   600    600    600   600    600   600   500        400

             Air   Crimp/Swage           Swage       600    600    600    600    600   600    600    600   600    600   600   500        400


 Asphalt & Hot
                              G/J    Interlocking                                      600    600    600   600    450   450   230
           Tar


     Chemical
                          C&G             Crimp                    150           250   250    250    250   250    150   125   100
       Plastic
     Chemical
                          C&G            Swage                     150           250   250    250    250   250    150   125   100
       Plastic
     Chemical
                          C&G         Preformed                    125           125   125    125    125   100     75    75    50
       Plastic
     Chemical
                          C&G       Band/ Buckle                                              150    150   125    100    75    50
       Plastic
     Chemical
                   Crimp/Swage            Crimp                    600           600   600    600    400   350    600   300   500        400
       Plastic
     Chemical
                   Crimp/Swage           Swage                     600           600   600    600    600   600    600   600   500        400
       Plastic
                                                                                                                                                3 bands on
     Chemical        Machined,                                                                                                                     3 & 4; 2
                                      Preformed                    125           125   125    125    125   100     75    75    50
       Plastic        medium                                                                                                                      bands on
                                                                                                                                                       rest
                                                                                                                                                3 bands on
     Chemical        Machined,                                                                                                                     3 & 4; 2
                                    Band/ Buckle                                              150    150   125    100    75    50
       Plastic        medium                                                                                                                      bands on
                                                                                                                                                       rest
                                                                                                                    5 bands on
  Chemical                                                                                                        3 & 4; 4 on 2
            Machined, long        Preformed     150   150   150   150   150   125   100    75    50
    Plastic                                                                                                       & 2-1/2; 3 on
                                                                                                                            rest
                                                                                                                    5 bands on
  Chemical                                                                                                        3 & 4; 4 on 2
            Machined, long      Band/ Buckle                      200   175   150   125   100    75
    Plastic                                                                                                       & 2-1/2; 3 on
                                                                                                                            rest


  Chemical
                       C&G            Crimp     150   250   250   250   250   250   150   125   100
   Rubber
  Chemical
                       C&G           Swage      150   250   250   250   250   250   150   125   100
   Rubber
  Chemical
                       C&G        Preformed     150   250   250   250   250   250   150   125   100
   Rubber
  Chemical
                       C&G      Band/ Buckle                      250   250   250   150   125   100
   Rubber
  Chemical
               Crimp/ Swage           Crimp     600   600   600   600   400   350   600   300   500         400
   Rubber
  Chemical
               Crimp/ Swage          Swage      600   600   600   600   600   600   600   600   500         400
   Rubber
                                                                                                                    3 bands on
  Chemical        Machined,                                                                                            3 & 4; 2
                                  Preformed     250   250   250   250   250   200   150   125   100
   Rubber          medium                                                                                             bands on
                                                                                                                            rest
                                                                                                                    3 bands on
  Chemical        Machined,                                                                                            3 & 4; 2
                                Band/ Buckle                      300   300   250   175   150   125
   Rubber          medium                                                                                             bands on
                                                                                                                            rest
                                                                                                                    5 bands on
  Chemical                                                                                                        3 & 4; 4 on 2
           Machined, long         Preformed     300   300   300   300   300   250   175   150   125
   Rubber                                                                                                         & 2-1/2; 3 on
                                                                                                                            rest
                                                                                                                    5 bands on
  Chemical                                                                                                        3 & 4; 4 on 2
           Machined, long       Band/ Buckle                      375   375   325   250   200   150
   Rubber                                                                                                         & 2-1/2; 3 on
                                                                                                                            rest
  Chemical
                 Internal Ex.    Internal Ex.               800   800   800   800   600   600   500         400
   Rubber


Food Grade
                    Sanitary     Internal Ex.               250         250   250   250   250   250
 Regulated


Food Grade
                       C&G            Crimp     150   250   250   250   250   250   150   125   100          75
Unregulated
Food Grade
                       C&G           Swage      150   250   250   250   250   250   150   125   100          75
Unregulated
Food Grade
                       C&G        Preformed     150   250   250   250   250   250   150   125   100          75
Unregulated
Food Grade
                       C&G Band & Buckle                          250   250   250   150   125   100          75
Unregulated
                                                                                                                   3 bands on
Food Grade        Machined,                                                                                           3 & 4; 2
                                  Preformed     250   250   250   250   250   200   150   125   100
Unregulated        medium                                                                                            bands on
                                                                                                                          rest
                                                                                                                   3 bands on
Food Grade        Machined,                                                                                           3 & 4; 2
                            Band & Buckle                         300   300   250   175   150   125
Unregulated        medium                                                                                            bands on
                                                                                                                          rest
Food Grade
               Crimp/ Swage           Crimp     600   600   600   600   400   350   600   300   500         400
Unregulated
Food Grade
               Crimp/ Swage          Swage      600   600   600   600   600   600   600   600   500         400
Unregulated
Food Grade
                 Internal Ex.    Internal Ex.               250   800   250   250   250   250   250         400
Unregulated


     Layflat           C&G        Preformed                             250   250   150   125   100    75    50

     Layflat           C&G            Crimp                             250   250   150   125   100    75    50
                                                                                                                  3 bands on
                  Machined,
     Layflat                      Preformed                             250   200   150   125   100    75    50 3, 4, 5 & 6; 2
                   medium
                                                                                                                       on rest
                                                                                                                  5 bands on
                                                                                                                3, 4, 5 & 6; 3
     Layflat Machined, long       Preformed                             300   250   175   150   125   100    75
                                                                                                                  on 1-1/2; 4
                                                                                                                       on rest
                                                                                                                    3 bands on
       Layflat            Cast      Preformed                              75    75    50    50    50    50    25 3, 4, 5 & 6; 2
                                                                                                                         on rest


     Material
                         C&G            Crimp                             250   250   150   125   100    75    75
    Handling
     Material
                         C&G           Swage                              250   250   150   125   100    75    75
    Handling
     Material
                         C&G        Preformed                             250   250   150   125   100    75    75
    Handling
     Material
                         C&G      Band/ Buckle                            250   250   150   125   100    75    75
    Handling
     Material
                    Machined,
Handling (soft                      Bolt Clamp                            250   200   150   125   100    75    75
                     medium
   wall only)
                                                                                                                    3 bands on
      Material      Machined,                                                                                     3, 4, 5 & 6; 1
                                    Preformed                             250   200   150   125   100    75    75
     Handling        medium                                                                                       on up to 5/8;
                                                                                                                      2 on rest
                                                                                                                    3 bands on
      Material      Machined,                                                                                     3, 4, 5 & 6; 1
                                  Band/ Buckle                            300   250   175   150   125   100   100
     Handling        medium                                                                                       on up to 5/8;
                                                                                                                      2 on rest
     Material
Handling (soft Machined, long       Bolt Clamp                            300   250   175   150   125   100    75
   wall only)
                                                                                                                    5 bands on
      Material                                                                                                    3, 4, 5 & 6; 4
               Machined, long       Preformed                             300   250   175   150   125   100   100
     Handling                                                                                                     on 2 & 2-1/2;
                                                                                                                      3 on rest
                                                                                                                    5 bands on
      Material                                                                                                    3, 4, 5 & 6; 4
               Machined, long     Band/ Buckle                            375   325   250   200   150   125   125
     Handling                                                                                                     on 2 & 2-1/2;
                                                                                                                      3 on rest
     Material
Handling (soft            Cast      Bolt Clamp                             75    75    50    50    50    50    25
   wall only)
     Material
                          Cast      Preformed                              75    75    50    50    50    50    25
    Handling
     Material
                          Cast    Band/ Buckle                             75    75    50    50    50    50    25
    Handling
     Material
                 Crimp/ Swage           Crimp                             600   600   600   600   500   450   400
    Handling
     Material
                 Crimp/ Swage          Swage                              600   600   600   600   500   450   400
    Handling
     Material
                   Internal Ex.    Internal Ex.                           800   800   600   600   500         400
    Handling


     Material                                                                                                        erosion is
     handling    Crimp/ Swage           Crimp                 600   600   600   600   600   600   500   450   400         very
      Cement                                                                                                          possible
     Material                                                                                                        erosion is
     handling    Crimp/ Swage          Swage                  600   600   600   600   600   600   500   450   400         very
      Cement                                                                                                          possible
     Material                                                                                                        erosion is
     handling             G/ J     Interlocking               600   600   600   600   450   450   230         230         very
      Cement                                                                                                          possible
     Material                                                                                                        erosion is
     handling      Internal Ex.    Internal Ex.               800   800   800   800   600   600   500         400         very
      Cement                                                                                                          possible


   Petroleum
                         C&G        Preformed     150   250   250   250   250   250   150   125   100    75    75
     transfer
   Petroleum
                         C&G      Band/ Buckle                      250   250   250   150   125   100    75    75
     transfer
   Petroleum
                         C&G            Crimp     150   250   250   250   250   250   150   125   100    75    75
     transfer
   Petroleum
                         C&G           Swage      150   250   250   250   250   250   150   125   100    75    75
     transfer
                                                                                                                    3 bands on
   Petroleum        Machined,                                                                                     3, 4, 5 & 6; 1
                                    Preformed     125   250   250   250   250   200   150   125   100    75    75
     transfer        medium                                                                                       on up to 5/8;
                                                                                                                      2 on rest
                                                                                                                    3 bands on
   Petroleum        Machined,                                                                                     3, 4, 5 & 6; 1
                                  Band/ Buckle                      300   300   250   175   150   125   100   100
     transfer        medium                                                                                       on up to 5/8;
                                                                                                                      2 on rest
                                                                                                                                    5 bands on
Petroleum                                                                                                                         3, 4, 5 & 6; 4
           Machined, long        Preformed                  300         300   300   300   300   250   175   150   125   100   100
  transfer                                                                                                                        on 2 & 2-1/2;
                                                                                                                                      3 on rest
                                                                                                                                    5 bands on
Petroleum                                                                                                                         3, 4, 5 & 6; 4
           Machined, long      Band/ Buckle                                         375   375   325   250   200   150   125   125
  transfer                                                                                                                        on 2 & 2-1/2;
                                                                                                                                      3 on rest
Petroleum
              Crimp/ Swage            Crimp     600   600   600   600   600   600   600   600   600   600   600   500   450   400
  transfer
Petroleum
              Crimp/ Swage           Swage      600   600   600   600   600   600   600   600   600   600   600   500   450   400
  transfer
Petroleum
                Internal Ex.    Internal Ex.                                        800   800   800   600   600   500         400
  transfer
                               Int. Ex. Short
Petroleum     Int. Ex. Short
                                       Brass/                                       300   300   300   300   300   300
  transfer            Brass
                                    Stainless


  Push-On         Push-On               N/A                 175   175   175   175   150   150   200   300   300



Sand Blast      Sand Blast              N/A                 175   175   175   175   150   150   200   300   300



    Steam               G/J     Interlocking                600         600   600   600   600   600   450   450   230         230



     Water            C&G             Crimp                 150         250   250   250   250   250   150   125   100    75    75
     Water            C&G            Swage                  150         250   250   250   250   250   150   125   100    75    75

     Water            C&G        Preformed                  150         250   250   250   250   250   150   125   100    75    75
     Water            C&G      Band/ Buckle                                         250   250   250   150   125   100    75    75

     Water        Universal      Preformed      110   110   110   110   110   110
     Water        Universal     Interlocking    110   110   110   110   110   110
                 Machined,
     Water                            Crimp     200   150   150   100   100   100
                     short
                 Machined,
     Water                            Pinch     200   150   150   100   100   100
                     short
                 Machined,
     Water                       Preformed      200   150   150   100   100   100
                     short
                                                                                                                                   3 bands on
                 Machined,                                                                                                          3, 4 & 6; 1
     Water                       Preformed      300   300   300   300   300   250   250   250   200   150   125   125    75    50
                  medium                                                                                                          on up to 5/8;
                                                                                                                                      2 on rest
                 Machined,
     Water                            Pinch     300   300   250   200   200   150
                  medium
Water (soft      Machined,
                                 Bolt Clamp     300   300   300   300   300   250   250   250   200   150   125   100    75    75
 wall only)       medium
                                                                                                                                   5 bands on
                                                                                                                                    3, 4, & 6; 4
     Water Machined, long        Preformed                  400   400   400   300   300   300   250   200   175   175   125    75
                                                                                                                                  on 2 & 2-1/2;
                                                                                                                                      3 on rest
Water (soft
            Machined, long       Bolt Clamp                 400   400   400   300   300   300   250   175   150   125   100    75
 wall only)
Water (soft
                     Cast        Bolt Clamp     200   200   150   100   100   100    75    75    75    50    50    50    50    25
 wall only)
     Water             Cast      Preformed      200   200   150   100   100   100    75    75    75    50    50    50    50    25

     Water             Cast    Band /Buckle                                          75    75    75    50    50    50    50    25
     Water    Crimp/ Swage            Crimp     600   600   600   600   600   600   600   600   600   600   600   500         400

     Water    Crimp/ Swage           Swage      600   600   600   600   600   600   600   600   600   600   600   500         400

     Water              G/J     Interlocking    600   600   600         600   600   600   600   600   450   450   230         230
The sections pertaining to industrial hose assemblies have been compiled to provide authoritative information
on assembly applications; hose, coupling and attachment selection; procedures to fabricate the assembly. This
information is intended to help those that are responsible for making assemblies as well as those responsible
for selecting the components.

The user of this document is cautioned that the information contained herein is for general guidance only. The
document reflects the most commonly used equipment and procedures to make assemblies. It does not reflect
new developments. The user is encouraged to contact the manufacturers of products in order to obtain the
latest information.

Because there are many combinations of hose, coupling and attachment methods, the user should not assume
that all combinations listed in the guide have been tested for acceptability. The information that is provided is
based on an environment of +72°F (+22.2°C). The reader is cautioned to contact the component manufacturers
when dealing with temperature extremes.

The industrial hose sections are designed to guide the user through selection of the components, fabrication of
the assembly and verification that the assembly will meet the application requirements.

Follow steps 1 through 4 to search for your fabrication procedure:




                Chemical-Plastic Lined




               Press the "Go" button to view the fabrication procedure for the selections you
               made above.
Section 7     Metal Hose

7.1 Scope

7.2 Materials

      7.2.1   Purpose
      7.2.2   General
      7.2.3   Components
      7.2.4   Component Specifics
      7.2.5   Manufacturers’ Requirements
      7.2.6   Welding and Brazing Filler Metals

7.3 Assembly Dimensions

      7.3.1   Purpose
      7.3.2   Metric/English Measurement System
      7.3.3   Inside Diameter of the Hose
      7.3.4   Developed Lengths
      7.3.5   Method of Measurement

7.4 Hose Construction

      7.4.1   Purpose
      7.4.2   Materials
      7.4.3   Types of Construction
      7.4.4   Geometrical Construction
      7.4.5   Heat Treatment
      7.4.6   Joining or Splicing Hoses

7.5 Formulas For Braid Strength And Coverage

      7.5.1   Purpose
      7.5.2   Variables for Braid Construction
      7.5.3   Theoretical Tensile Strength and Burst Strength of Braid
      7.5.4   Braid Coverage: (V)
      7.5.5   Multiple Braided Hose

7.6 Pressure Capacity Of Hose And Braid

      7.6.1 Purpose
      7.6.2 Method for Conducting a Burst Test
      7.6.3 Method for Determining MAWP and Test Pressure

7.7 Bend Radius Tests for Hose Assemblies

      7.7.1   Purpose
      7.7.2   Dynamic Bend Radius Test
      7.7.3   Static Bend Radius Test
      7.7.4   General

7.8 Hose Assembly Length Determination For Various Movements

      7.8.1   Purpose
      7.8.2   Definitions of Symbols
      7.8.3   Example Values
      7.8.4   Constant Radius Traveling Loop
      7.8.5   Variable Radius Traveling Loop
       7.8.6 Offset Motion
       7.8.7 Angular Motion
       7.8.8 Vertical Loop with Movement in Two Directions

               7.8.9 90 Degree Installation with Horizontal Movement in Horizontal Leg
               7.8.10 90 Degree Installation with Horizontal Movement in Vertical Leg
               7.8.11 90 Degree Installation with Combined Movement of Horizontal Movement in
               Horizontal Leg and Vertical Movement in Vertical Leg
               7.8.12 90 Degree Installation with Combination Horizontal and Vertical Movement in Horizontal
               Leg

7.9 Assembly Types

       7.9.1   Purpose
       7.9.2   Direct Attachment Method
       7.9.3   Neckdown Construction Method
       7.9.4   Spacer Nipples
       7.9.5   Braid Sleeves
       7.9.6   Additional Protection
       7.9.7   Assembly Method

7.10 TEMPERATURE DERATING

       7.10.1 Purpose
       7.10.2 Corrosion Factor For Metal Hose

7.1   Scope

This section specifies the methods and requirements necessary for the design, fabrication and testing of corrugated metal
hose assemblies.

This section pertains to nominal diameters from 1/4 inch (DN6) to 12 inches (DN300), except where limited by section.
The corrugated metal hose assemblies specified are suitable for the major portion of commercial and industrial
applications.
The following applications are excluded from the scope of this section: those involving extreme working pressures, or
those with design movements involving axial compression or extension.
This section is not intended to prohibit either supplier or customer from attaching additional requirements for corrugated
metal hose or hose assemblies, if necessary to satisfy the application.
Each supplier or customer should qualify these applications and its requirements separately, to ensure performance
capability.
7.2   Materials
       7.2.1    Purpose

       The purpose of this section is to identify the types of metal most frequently used in hose fabrication. This
       information will guide in the selection of the proper metal hose required for a specific application.
       7.2.2    General

       Metal hose is made from several different materials, depending on application. When selecting the material,
       proper consideration must be given to corrosion resistance, service temperature and material strength.
       7.2.3    Components

       The first step is to define each component which makes up a metal hose assembly. (See Definitions) The
       components are:
        A. A convoluted inner core,
        B. One or more layers of wire braid,
        C. Braid sleeves or ferrules (braided assemblies),
        D. Fitting(s) configuration, and
        E. Flexible casing and/or flow liner (may be optional).
7.2.4   Component Specifics

Table 7.2.1 shows the most frequently used materials. The letter in the component column refers to the
above list. The fittings or end connectors are not covered. To do so could result in some materials being left
off the list because of the many different types and styles of ends. A thorough check as to the use, strength
and weld-ability must be performed prior to using any unfamiliar material.
7.2.5   Manufacturers’ Requirements

Materials or components selected should meet or exceed Industry Standards, e.g.: UNS/ASME/SAE, etc.
(See Table 7.2.1) More stringent requirements are left to the manufacturer’s discretion.
        7.2.5.1   Welding and Brazing

        When welding and brazing processes are used by the hose assembly manufacture, it is the
        responsibility of the manufacture to perform these processes using qualified welding
        procedures and welding personnel. The qualification, documentation, and acceptance criteria
        shall meet Industry Standards, e.g.: AWS/ASME.
        A list of common weld-filler materials is listed in Table 7.2.2. When different material
        combinations are considered, care should be taken when selecting the correct weld filler
        requirement to assure material compatibility and service conditions.
Table 7.2.1 Component Specifications*
 Component                 Type                   Description             1UNS               Specification
a                 1008 AKDQ              Low Carbon Steel             G10080         2ASTM   A 620
b, d              3SAE1010               Galvanized Steel             G10100         Commercial grade
a, b, c, d        T304L                  Corrosion Resist. Steel      S30403         4SA240/A478

a, b, c, d        T304                   Corrosion Resist. Steel      S30400         SA240/A269
a, b, c, d        T316L                  Corrosion Resist. Steel      S31603         SA240/A478
a, b, c, d        T316                   Corrosion Resist. Steel      S31600         SA240/478
a, b, c, d        T316Ti                 Corrosion Resist. Steel      S31635         5DIN1.4571

a, b, c, d        T321                   Corrosion Resist. Steel      S32100         SA240/A580
a, b, c, d        MONEL 400              Nickel Copper Alloy          NO4400         4SB127/B164

a, b, c, d        INCONEL 600            Nickel Alloy                 NO6600         SB168/B167
a, b, c, d        INCONEL 625            Nickel Alloy                 NO6625         SB443/B443
a, b              CA505                  Bronze, Phosphor.            C50500         2B508

a, b              CA507                  Bronze, Phosphor.            C50700         B508
a, b              CA510                  Bronze, Phosphor.            C51000         B100/B103/B139
a, b              CA230Red Brass         C23000                       B36/B134
a, b              CA220                  Commercial Bronze            C22000         B36/B130/B131/B1344

        1    Unified Numbering System
        2    American Society for Testing Materials
        3    Society for Automotive Engineers
        4    American Society of Mechanical Engineers
        5    Standard in Germany
* Specifications listed are for strip. Other specifications may apply for wire and pipe.
7.2.6   Welding and Brazing Filler Metals

The most common filler materials are listed in the Filler Metal Table 7.2.2. Some variation may be considered
in the selection process based on required strength and corrosive applications.
Table 7.2.2 Filler Metals
            Base Metal To                          Base Metal                       Process      Suggested Filler
                                                                                                     Metal
Carbon steel hose and braid         300 series ferrules                        GTAW / GMAW       6AWS ER-308,
                                                                               Fill weld         ER-308L or
                                                                                                 ER-312
Carbon steel hose, braid and        Carbon steel end fittings                  GTAW / GMAW       same as above
ferrules                                                                       Attachment weld
T304 hose, braid and ferrules       Carbon steel or 300 series fittings        GTAW / GMAW       same as above
                                                                               All welds
Carbon steel tube or pipe           Carbon steel end fittings                  GTAW / GMAW       AWS ER70S-*
                                                                               All welds         (mild steel rod)
T304L hose, T304 or T321            Carbon steel or 300 series fittings        GTAW / GMAW       AWS ER-308L
braid/ferrules
All T316L and T316Ti                T316 or T316L fittings                     GTAW / GMAW       AWS ER-316L
All T321                            T321                                       GTAW / GMAW       AWS ER-347
All Monel 400                       Monel 400                                  GTAW              AWS ERNiCu-7
                                                                                                 (Monel 60)
All Monel 400                       Carbon steel, Inconel, Incoloy &           GTAW              AWS ERNi-1
                                    stainless                                                    (Alloy 61)
All Inconel 600                                                                GTAW              AWS ERNiCr-3
                                    Inconels, Monel 400, Carbon steel &                          (Alloy 82) or
                                    stainless                                                    ERNiCr-6 (Alloy
                                                                                                 92)
All Inconel 625                     Inconels, Monel 400, Carbon steel &        GTAW              AWS
                                    stainless                                                    ERNiCrMo-3
                                                                                                 (Alloy 625) or
                                                                                                 ERNiCr-6 (Alloy
                                                                                                 92)
A Bronze hose and braid             Bronze or copper fittings                  Torch or GTAW     7AWS    A5.27
                                                                                                 Class

                                                                                                 RBCUZN-C or
                                                                                                 A5.8 Class
                                                                                                 RBCuP-2 or
                                                                                                 Sil- Fos (note
                                                                                                 that with Sil-Fos
                                                                                                 and 'sweat'
                                                                                                 joints, installer
                                                                                                 can over heat
                                                                                                 and damage
                                                                                                 joint)
       All the above including brass      Brass or copper                           Torch                  AWS BAg1-3
                                                                                                           (Silver brazing
                                                                                                           alloy) Min. of
                                                                                                           25% Silver is
                                                                                                           recommended



              6 American Welding Society
              7 This alloy has a melting point of 1590ºF
      Note:

      Above table does not include cast fittings. Consult manufacturer.
7.3   ASSEMBLY DIMENSIONS
      7.3.1   Purpose

      To establish a standard method of measurement for metal hose assemblies.
      7.3.2   Metric/English Measurement System

      The hose manufacturer shall state in its brochures or documentation which system will be employed in its
      manufacturing process. All tolerances will be applied to its system of measurement. Optional
      cross-referencing of another system will be done in brackets. [ e.g., 1/4 inch (6) means manufacture is in
      English and reference is to metric] .
      7.3.3    Inside Diameter of the Hose

      The minimum inside diameter of the hose shall be at least 98 percent of the nominal size listed by the
      manufacturer.
      7.3.4   Developed Lengths

      Tolerances for the overall length of hose assemblies shall be observed according to the following table,
      unless otherwise stated.
      Table 7.3.1 Hose Assemblies Tolerance
                             (Dimensions used are [“= in], [‘= ft] and [% = Percentage of Total length])
       Developed
       length of          0" to < = 8"   > 8” to <= 18”    >18” to <= 36”   > 3’ to <= 6’   >6’ to <= 12’      over 12’
       assembly
       Hose ID            (+)     (-)    (+)     (-)       (+)     (-)      (+)     (-)     (+)      (-)       (+)        (-)
       3/16” thru 3/4”    1/4     1/4    5/16    5/16      3/8     3/8      1/2     1/2     1        1         1%         1%
       1” thru 4”         3/8     3/8    1/2     1/2       5/8     5/8      3/4     3/4     1-1/4    1-1/4     1.5%       1.5%
       4" thru 12"        3%      1.5% 3%        1.5%      3%      1.5%     3%      1.5% 3%          1.5%      3%         1.5%

      Note: Fractions shown above are in inches
      7.3.5   Method of Measurement

      Normal length measurements shall be taken using a tape measure with the hose lying on a flat surface. If the
      centerline of the end connection is above the hose centerline, the hose should be supported accordingly. On
      most hose assemblies, the developed length is the end to end dimension at the centerline (Figure 7.3.1). End
      connections with a seating face shall be measured from the seat face and not from the end of any loose
      fitting, e.g., JIC type end fittings (Figure 7.3.2). Hose assemblies using elbows shall be measured from the
      centerlines (Figure 7.3.3).
      Figure 7.3.1    Measurement of Common Hose Assembly
Figure 7.3.2   Measurement of Hose Assembly having an End Connection with a Seating Face




Figure 7.3.3   Measurement of a Hose Assembly using Elbows
7.4   Hose Construction
      7.4.1   Purpose

      The purpose of this section is to define metal hose construction.
      7.4.2   Materials

              A. Seamless tubing
              B. Welded tubing (spiral or longitudinal)
      7.4.3   Types of Construction

      The hose shall be constructed by either of the following methods.
              A. Type A is a seamless annular hose, butt-welded annular hose, or lap welded annular hose.
              B. Type H is a helical hose that can be seamless, butt-welded or lap welded along the entire
              length of the hose.
      7.4.4   Geometrical Construction

      The hose shall consist of convolutions of uniform height and pitch continuous along its length.
      7.4.5   Heat Treatment
      When heat treatment is required by the purchaser it shall specify the process and procedures to be
      employed. All tests related to this requirement shall be done after heat treatment is concluded.
      7.4.6   Joining or Splicing Hoses

      When a manufacturer uses joints or splices to lengthen hoses it shall comply with the following:
              A. The hose can be welded with the edge weld or the butt weld processes as shown in Figure
              7.4.1 or Figure 7.4.2.
              B. Other splicing methods may be used if approved by the manufacturer.
      Note:

      Traverse joining of strip or circumferential joining of tubes prior to forming shall not be permitted.
      Figure 7.4.1 Edge Weld




      Figure 7.4.2 Butt Weld




7.5   Formulas For Braid Strength And Coverage
      7.5.1   Purpose

      The purpose of this section is to define braid coverage and its theoretical burst pressure.
      7.5.2   Variables for Braid Construction

      Variables for braid construction shall be according to the following list.

              C = Number of carriers
              W = Number of wires on each carrier
              D = Wire diameter (inches)
              A = Braid angle (degrees)
              O = Outside diameter of hose (inches) which is equal to inside diameter of braid (inches)
              I = Inside diameter of hose (inches)
              S = Tensile Strength of wire (lbs/in2)
      7.5.3   Theoretical Tensile Strength and Burst Strength of Braid
              A. Theoretical Tensile Strength of Braid(lbs):(T)

                     T = C x W x (D/2)2 x pi x S x cos(A)

              B. Theoretical Burst Strength of Braid (lbs/in2):(B)
                     B=T/E
                     Where,
                     E = the effective thrust area of the hose (in2)
                     Assume,
                     E = the cross-sectional area described by the mean diameter of the hose
                     Therefore,
                     E = ((I + O) / 4)2 x pi
      7.5.4   Braid Coverage: (V)
      Coverage = V = the percentage of the outside diameter of the hose which is covered by braid.
      Capacity = P = the percentage of the outside diameter of the hose which is covered by braid from only those
      carriers traveling in the same direction (one half of the total number of carriers).
      P = (C x W x D) / (2 x cos(A) x (O + 2 x D) x pi)
      V = 1 - (1 - P)2
      Example:
              C = 48
              W = 11
              D = 0.016 in.
              A = 45º
              O = 2.60 in.
              I = 2.00 in.
              S = 100,000 lbs/in2

      Theoretical Tensile Strength = T = C x W x (D/2)2 x pi x S x cos(A)

              T = 48 x 11 x (0.016/2)2 x pi x 100,000 x cos(45º)
              T = 7,507 lbs

      Effective Thrust Area = E = ((I + O) / 4)2 x pi

              E = ((2.00 + 2.60) / 4)2 x pi
              E = 4.15 in2
      Theoretical Burst Strength = B = T / E

              B = 7,507 lbs / 4.15 in2
              B = 1,809 lbs/in2
      Capacity = P=(C x W x D) / (2 x cos(A) x (O + 2 x D) x pi

              P=(48 x 11 x 0.016)/(2 x cos(45º) x (2.60 + 2 x 0.016) x pi
              P = 0.722 = 72.2 %

      Coverage = V = 1 - (1 - P)2

              V = 1 - (1 - 0.722)2
              V = 0.923 = 92.3 %
      7.5.5 Multiple Braided Hose
      It is inappropriate to assume that additional layers of braid will be applied with the same braid angle and/or at
      the same tension as the first.

      Note:

      Consult the manufacturer whenever multiple braids are required.
7.6   Pressure Capacity Of Hose And Braid
      7.6.1   Purpose

      The purpose of this section is to describe a method of establishing a Maximum Allowable Working Pressure
      (MAWP) for hose and braided hose assemblies based on actual burst tests conducted.
      7.6.2   Method for Conducting a Burst Test

      Burst testing shall be conducted on metal hose assemblies to verify theoretical calculations used in
      manufacturers’ published data and also to establish values when the hose and braid are not both made by
      the same manufacturer.
              A. Three assemblies having a live length of hose equal to 10 times the diameter but not less
              than 20 inches shall be fabricated using proper procedures, as recommended by the
              manufacturer for the given assemblies. (See Section 7.9.)

              B. The assemblies should be hydrostatically tested in the straight position and consideration
              should be given to personnel safety. Application of hydrostatic pressure should be done in
              increments in order to identify the hose deformation point and braid yield pressure. Initially, 10
              percent pressure increments should be applied; these increments should be reduced as the
              specimen approaches burst. During the test, the increase in volume and increase in overall
              length shall be recorded for each increment in pressure. The following acceptance criteria shall
              be satisfied for the hose:
                     1. At 1.5 times the maximum working pressure, from the manufacturer’s published
                     data, the increase in overall length shall not be greater than 3 percent of the
                     original length.

                     2. The pressure at which there is a marked permanent increase in internal volume
                     without a corresponding increase in length, i.e., the corrugation deformation
                     pressure, shall be greater than 1.5 times the published maximum working
                     pressure.
                     3. The pressure at which there is a marked permanent increase in overall length,
                     i.e., the braid yield pressure, shall be at least twice the published maximum
                     working pressure.
                     4. The average burst pressure of the three assemblies shall be greater than or
                     equal to the manufacturer’s published data:
                            (i) Should only one hose assembly burst at less than 95 percent of
                            the manufacturer’s published data, then another test assembly may
                            be fabricated and tested. The previous data should then be deleted
                            and replaced with the new test data;

                            (ii) Should more than one hose burst at less than 95 percent of the
                            manufacturer’s published data, then all three test assemblies should
                            be discarded and replaced with new ones. A new series of tests
                            should then be conducted.
      7.6.3   Method for Determining MAWP and Test Pressure

      The MAWP is defined as 25 percent of the burst pressure. The Maximum Test Pressure for the hose is the
      highest pressure an assembly can withstand without permanent deformation of the corrugations or other
      component and normally as a minimum is 1.5 times the MAWP. For example: Burst Pressure=1000 psig;
      then MAWP= 1000/4=250 psig; then Test Pressure =1.5x250=375 psig.
7.7   Bend Radius Tests for Hose Assemblies

      7.7.1   Purpose

      The purpose of this section is to establish a common method for validating bend radii.
      7.7.2   Dynamic Bend Radius Test

      For hose assemblies up to and including 4-inch nominal inside diameter, six samples of each nominal size
      shall be subjected to a dynamic bend radius test (See Figure 7.7.1). The test shall be conducted with the
      hose at the manufacturer’s maximum allowable working pressure and with the distance between the axis of
      the end fittings equal to twice the manufacturer’s minimum dynamic bend radius.
              A. Testing will be conducted at ambient temperature and the test medium will be water.

              B. The hose shall be subjected to a repeated flexing at a rate of five to 30 cycles per minute in
              a direction parallel with the axis of the hose through a movement equal to “T.”
              C. The test shall be conducted using hose assemblies mounted to form a vertical loop as
              shown in Figure 7.7.1. The live length of the assembly “L,” shall be determined by the following
      movement formula:
              L = 4R + T/2
              Where,
              R = Manufacturer’s minimum dynamic bend radius
              T = Total Travel (See Table 7.7.1).
Figure 7.7.1 Vertical Test Loop




Table 7.7.1


                      Total Travel
  Nominal Inside Diameter            "T"
              1/4                    10"
              3/8                    10"
              1/2                    10"
              3/4                    10"
               1                     10"
              1-1/4                  10"
              1-1/2                  12"
               2                     16"
              2-1/2                  20"
               3                     24"
              3-1/2                  28"
               4                     32"
        D. Failure shall be determined by the hose leaking, signs of structural damage, or permanently
        changing its shape by greater than +/- 20 percent of the minimum dynamic bend radius.
        Additional lubrication of the assembly prior to or during the testing is not permitted.

        E. Each hose size and type shall be classified relative to the number of cycles completed
        before failure. The classes will be as follows: Class A - 50,000 cycles; Class B - 20,000 cycles;
        and Class C - 5,000 cycles.
        F.In each class, the average number of completed cycles must be equal to or greater than the
        specified amount, and the minimum number of completed cycles for any hose assembly, must
        not be less than 80 percent of the specified amount.
7.7.3    Static Bend Radius Test

        For hose diameters up to and including 4-inch nominal inside diameter, two samples of each
        nominal size shall be subjected to a static bend test.
              A. Testing will be conducted at ambient temperature.
              B. The hose assembly, having one of its end fittings rigidly fixed, shall be placed
              between a cylindrical former and a fixed perpendicular restraint (See Figure
              7.7.2). The diameter of the cylindrical former shall be equal to twice the
              manufacturer’s static bend radius minus the outside diameter of the hose being
              tested. The horizontal axis of the former shall be in the same plane as the second
              hose convolution when testing unbraided hose assemblies. When testing braided
              hose assemblies the axis must be as close to the braid ferrule as possible.

              C. Note: Care shall be taken to insure that the corrugations are not crushed or
              damaged.

              D. The hose assembly shall be bent over the former, making contact with 90
              degrees of its circumference.
              E. One cycle includes one 90 degree bend and the return movement to the
              perpendicular position. The test shall consist of the assembly being flexed through
              10 cycles at a rate of 10 to 30 cycles per minute, without internal pressure.
              F. At the conclusion of the bend test, the assembly shall be hydrostatically tested
              at a pressure equal to manufacturer’s maximum allowable working pressure.
              There shall be no leakage, cracking, or substantial change in shape of
              convolutions after the test.
              G. The length of unbraided hose assemblies shall be sufficient to insure contact
              with 90 degrees of the circumference of the cylindrical former.

              H. Braided hose assemblies shall be of such a length that there is at least one
              complete revolution of braid wire along the live length of hose.
        Figure 7.7.2 Bend Test for Static Radius
      7.7.4   General

      The bend tests specified in Section 7.7.2 and 7.7.3 should not be considered as an all-encompassing test for
      all metal hose assembly applications. Passing the bend tests does not imply that the minimum or average
      cyclic lifetime can be reached in circumstances other than those specified in the test procedures. For
      applications where fatigue lifetime is important or where high temperature occurs, it is essential that the
      manufacturer be consulted when establishing the design requirements, along with a mutually acceptable
      factor of safety.
7.8   Hose Assembly Length Determination For Various Movements
      7.8.1   Purpose

      The information in this section is provided as a guide for the determination of minimum developed length of
      hose assemblies for the conditions shown. All formulas determine the minimum live length required. To
      obtain the overall length, the length of the fittings including braid sleeves, must be added to the live length.
      7.8.2   Definitions of Symbols

      The following definitions of symbols shall be used in all formulas.
              T = Travel in inches
              R = Manufacturer’s recommended minimum bend radius
              L = Live length
              H = Minimum height of loops in both vertical and horizontal movements
      7.8.3   Example Values

      In all calculations the following example values are assigned.
              Hose inside diameter (ID)= 2.00"
              Hose outside diameter (OD) = 2.75"
              Minimum bend radius = 14"
              Fitting length including braid sleeve = 3.50"
      7.8.4   Constant Radius Traveling Loop
      Figure 7.8.1 Constant Radius Traveling Loop - Vertical Travel
Figure 7.8.2 Constant Radius Traveling Loop - Horizontal Travel




        Formula:

        L = 4(R) + 1/2T
        Assume: Travel = 6.00"

        L = 4(14) + 1/2(6)
        L = 59.00"
        Developed length = 59.00 + 2(3.5) = 66.00"
7.8.5   Variable Radius Traveling Loop
Figure 7.8.3 Variable Radius Traveling Loop - Vertical Travel
Figure 7.8.4 Variable Radius Traveling Loop - Horizontal Travel




        Formula:

        L = 4(R) + 1.57(T)

        Assume: Travel = 6.00"
        L = 4(14) + 1.57(6)
        L = 65.42"
        Developed length = 65.42 + 2(3.5) = 72.42"
7.8.6   Offset Motion
Figure 7.8.5 Offset Motion
        Formula:

        L = (20R x T)1/2

        Assume, Travel = 3.00"

        L = (20 x 14 x 3)1/2

        L = 28.98"

        Developed length = 28.98 + 2(3.5) = 35.98"

        Live Straight Length = Lp

        Lp = (L2 x T2)1/2

        Lp = (28.982 - 32)1/2

        Lp = 28.82"

        Overall straight installed length = 28.82 + 2(3.5) = 35.82"

Note 1:

When the offset motion occurs to both sides of the hose centerline, use total travel in the formula; i.e. two
times "T."
Note 2:

The offset distance "T" for constant flexing should never exceed 25 percent of the centerline bend radius "R."
7.8.7   Angular Motion
Figure 7.8.6 Angular Motion
        Formula:

        L = 2(S) + (Ø/57.3)R
        Note: S = Outside Diameter of Hose
        Assume - = 15 Degrees
7.8.8   Vertical Loop with Movement in Two Directions
Figure 7.8.7 Vertical Loop with Movement in Two Directions




        Formula:

        L = 4(R) + 1.57(T1) + (T2/2)

        H1 = 1.43(R) + 0.785(T1) + (T2/2)
        H2 = 1.43(R) + (T1/2)

        Example:

        R = 14 T1 = 6 T2 = 8

        L = 4(14) + 1.57(6) + (8/2)
        L = 69.42"

        Developed length = 69.42 + 2(3.5) = 76.42"
        H1 = 1.43(14) + 0.785(6) + (8/2) = 28.73"
        H2 = 1.43(14) + (6/2) = 23.02"
7.8.9   90 Degree Installation with Horizontal Movement in Horizontal Leg

This installation is for low frequency movement (such as thermal expansion).
Figure 7.8.8 90 Degree Installation with Horizontal Movement in Horizontal Leg




        Formula:

        L = 0.035Ra + 1.57R
        A = R + 2R(SINa)
        B = R + R(0.035a- 2SINa)

        a = T/R Take value from the bend angle Table 7.8.1.
        Note:

        The bend angle a must not exceed 60 degree maximum.
        Example: T = 3.00"
        a = 3/14 = 0.214 25 degrees SIN25 = 0.423
         L = (0.035 x 14 x 25) + (1.57 x 14) = 34.23"
         A = 14 +[ (2 x 14) x 0.423] = 25.84"
         B = 14 + 14[(0.035 x 25) - (2 x 0.423)] = 14.41"
7.8.10     90 Degree Installation with Horizontal Movement in Vertical Leg

This installation is for low frequency movement (such as thermal expansion).
Figure 7.8.9 90 Degree Installation with Horizontal Movement in Vertical Leg




         Formula:

         L = 0.035Ra + 1.57R
         A = R + 2RSINa
         B = R + R(0.035a - 2SINa)

         a = T/R Take value from the bend angle Table 7.8.1.
         Note:

         The bend angle a must not exceed 60 degrees maximum.
         Example: T = 3.00"

         a = 3/14 = 0.214 25 degrees SIN25 = 0.423
         L = (0.035 x 14 x 25) + (1.57 x 14) = 34.23"
         A = 14 + [(2 x 14) x 0.423] = 25.84"
      B = 14 + 14[(0.035 x 25) - (2 x 0.423)] = 14.41"
7.8.11 90 Degree Installation with Combined Movement of Horizontal Movement in Horizontal Leg
and Vertical Movement in Vertical Leg

This installation is for low frequency movement (such as thermal expansion).
Figure 7.8.10 90 Degree Installation with Combined Movement of Horizontal Movement in Horizontal
Leg and Vertical Movement in Vertical Leg




      Formula:

      L = 0.035Ra + 0.035Rb +1.57R
      A = R + 2RSINa + R(0.035b - 2SINb)

      B = R + 2RSINb + R(0.035a - 2SINa)
      a = T1/R Take the value from Table 7.8.1.

      b = T2/R Take the value from Table 7.8.1.

      Note:

      The bend angles a and b must not exceed 45 degrees maximum each.
      Example: T1 = 3.00" T2 = 2.00"
      a = 3/14 = 0.214 25 Degrees Sin25 = 0.423

      b = 2/14 = 0.143 20.5 Degrees Sin20.5 = 0.350
      L = (0.035 x 14 x 25) + (0.035 x 14 x 20.5) + 1.57(14) = 44.28"
      A = 14 + (2 x 14 x 0.423) + 14[(0.035 x 20.5) - (2 x 0.035)] = 28.29"

      B = 14 + (2 x 14 x 0.423) = 14[(0.035 x 25) - 2 x 0.423)] = 24.21"
7.8.12     90 Degree Installation with Combination Horizontal and Vertical Movement in Horizontal Leg

This installation is for low frequency movement (such as thermal expansion).
Figure 7.8.11 90 Degree Installation with Combination Horizontal and Vertical Movement in Horizontal
Leg




         Formula:

         L = 0.035Ra + 0.035Rb + 1.57R
         A = R + 2RSINa + R(0.035b - 2SINb)
         B = R + 2RSINb + R(0.035a - 2SINa)
         a = T1/R Take the value from Table 7.8.1.

         b = T2/R Take the value from Table 7.8.1.
         Note:

         The bend angles a and b must not exceed 45 degrees maximum each.
         Example: T1 = 2.00" T2 = 1.00"
         a = 2/14 = 0.143 20.5 degrees SIN20.5 = 0.035
         b = 1/14 = 0.071 14.75 degrees SIN14.75 = 0.255

         L = (0.035 x 14 x 20.5) + (0.035 x 14.75) + (1.57 x 14) = 39.25"
         A = 14 + (2 x 14 x 0.035) + 14[(0.035 x 14.75) - (2 x .255)] = 23.87"
         B = 14 + (2 x 14 x 0.255) + 14[(0.035 x 20.5) - (2 x 0.035)] = 21.39"
Table 7.8.1 Bend Angles

   Bend                                                            Travel/Bend
              Travel/Bend Radius(T/R)    Bend Radius
   Angle                                                           Radius(T/R)
 Deg./Min.        0'           30"         Deg./Min.          0'                 30'
        0       0.0000       0.0001           30            0.3151          0.3263
        1       0.0003       0.0007           31            0.3377          0.3493
        2       0.0012       0.0019           32            0.3611          0.3731
        3       0.0028       0.0038           33            0.3853          0.3977
        4       0.0050       0.0063           34            0.4104          0.4232
        5       0.0078       0.0095           35            0.4363          0.4495
        6       0.0113       0.0133           36            0.4630          0.4767
        7       0.0155       0.0179           37            0.4906          0.5048
        8       0.0204       0.0231           38            0.5191          0.5337
        9       0.0259       0.0289           39            0.5484          0.5634
     10         0.0322       0.0355           40            0.5786          0.5940
     11         0.0391       0.0428           41            0.6096          0.6255
     12         0.0468       0.0509           42            0.6415          0.6578
     13         0.0551       0.0596           43            0.6743          0.6910
     14         0.0643       0.0690           44            0.7079          0.7250
     15         0.0741       0.0793           45            0.7424          0.7599
     16         0.0847       0.0903           46            0.7777          0.7957
     17         0.0961       0.1020           47            0.8139          0.8323
     18         0.1082       0.1145           48            0.8510          0.8698
     19         0.1211       0.1278           49            0.8889          0.9082
     20         0.1347       0.1418           50            0.9277          0.9474
     21         0.1491       0.1567           51            0.9673          0.9874
     22         0.1644       0.1723           52            1.0078          1.0284
     23         0.1804       0.1887           53            1.0491          1.0701
     24         0.1972       0.2059           54            1.0914          1.1128
     25         0.2148       0.2239           55            1.1344          1.1563
     26         0.2332       0.2428           56            1.1783          1.2006
     27         0.2525       0.2624           57            1.2230          1.2457
     28         0.2725       0.2829           58            1.2686          1.2918
     29         0.2934       0.3042           59            1.315           1.3386

Note:

To determine the bend angle for calculating 90 degree bends to absorb movement. Bend Angle = T/R
Note:
      The bend angle must not exceed 60 degrees max. When absorbing movements from two directions the bend
      angle must not exceed 45 degrees max.
      Note:

      If the calculated value of T/R exceeds 1.3623, a new bend angle must be calculated with a correspondingly
      larger radius R.
7.9   Assembly Types
      7.9.1   Purpose

      The purpose of this section is to identify the most common types of assembly construction.
      7.9.2   Direct Attachment Method

      Attachment of the hose, braid, and braid sleeve shall be made first, and the fitting attachment second (See
      Figure 7.9.1).
      7.9.3   Neckdown Construction Method

      The fitting shall be first attached to the hose ends. The braid and braid sleeve shall then be applied and
      clamped to the fitting directly above the first weld. The braid and braid sleeve attachment shall then be made
      to the fitting (See Figure 7.9.2a).
      7.9.4   Spacer Nipples

      Spacer nipples shall be used for flanged or similar assemblies when neckdown construction is used or when
      bolt circles may interfere with the hose outside diameter.
      Note: With all assembly types, care should be taken to select the most appropriate method to maximize
      flexible lengths and application requirements.
      7.9.5   Braid Sleeves

      Braid sleeves shall be used to facilitate the attachment of braid and hose and to prevent the heat affected
      zone (HAZ) from flexing. Braid sleeves should cover approximately three convolutions and shall not be less
      than 3/8 inch long and are not required to be greater than 1 inch long.
      7.9.6   Additional Protection

      When stated by the purchaser, assemblies shall be provided with a metallic or non-metallic protective cover
      to shield against possible abrasion or mechanical damage. Acceptable types of protective covers are, but not
      limited to: interlock, wire wrap, PVC, rubber, fiberglass, and firesleeve.
      7.9.7   Assembly Method
      Fabrication Procedures:
      Note:

      If neckdown construction is desired for braided assembly, make an unbraided assembly and then continue
      with Steps 10 through 13.
                   1. Cut the hose.
                   2. Trim the hose.

                          a) For helical hose: flatten the first convolution.
                          b) For annular hose: trim end to desired plane perpendicular the
                          axis of the hose.

                   3. Apply braid sleeve (ignore if unbraided).
             4. Trim the braid so that the end of the braid, hose, and sleeve are on the same
             plane.
             5. Weld the cap (ignore if unbraided). See Figure 7.9.1(a).
             6. Weld the hose, braid, and sleeve together using the appropriate welding rod.
             See Table 7.2.2.
             7. Attach the fitting. See Figure 7.9.1(b) for braided assembly. See Figure 7.9.2(a)
             for unbraided assembly.
             8. Weld the fitting to the end of the hose using the appropriate welding rod. See
             Table 7.2.2.
             Note:

             For neckdown construction only, continue with Steps 10 through 13.
             9. Put braid over the unbraided assembly.
             10. Put braid sleeve over the braid and fitting as close as possible to the hose.
             11. Trim the braid off that is exposed past the braid sleeve.

             12. Weld the braid, sleeve, and fitting together [See Figure 7.9.2(b)] using the
             appropriate welding rod (See Table 7.2.2).
Testing:

Perform pneumatic pressure test at the appropriate pressure. See Section 9.
Figure 7.9.1 (a, b) Direct Attachment Method
           (a) Step 1                   (b) Step 2




Figure 7.9.2 (a, b) Neckdown Construction Method
           (a) Step 1                   (b) Step 2
7.10   TEMPERATURE DERATING
       7.10.1     Purpose

       The purpose of this section is to identify pressure correction factors to compensate for elevated
       temperatures.
       7.10.2     Corrosion Factor For Metal Hose

       Consult:
                National Association of Corrosion Engineers Handbook
                1440 South Creek Drive
                Houston, TX 77084
       Table 7.10.1 Derating Factors

       Apply to pressure rating for elevated temperatures.

                                                     Materials
           Temperature Fº        Stainless Steel       Steel     Monel      Bronze
                   70                  1.00            1.00       1.00       1.00
                  150                  .97              .99       .93         .92
                  200                  .94              .97       .90         .89
                  250                  .92              .96       .87         .86
                  300                  .88              .93       .83         .83
                  350                  .86              .91       .82         .81
                  450                  .81              .86       .77         .75
                  500                  .78              .81       .73
                  600                  .74              .74       .72
                  700                  .70              .66       .71
                  800                  .66              .52       .70
                  900                  .62              .50
                  1000                 .60
               1100                    .58
               1200                    .55
               1300                    .50
               1400                    .44
               1500                    .40

             Note:

             This table is for operating temperatures in excess of 70ºF.
             Note:

             The tabulated catalog pressures must be decreased in accordance with the conversion factors
             in the table above.
             Note:

             Consult the metal hose manufacturer whenever the service is at an elevated temperature.

>> continue to Section 8
Section 8 Hose of Teflon® (PTFE)

8.1 Scope

8.2 Materials

      8.2.1 Purpose
      8.2.2 General
      8.2.3 Components

8.3 Assembly Dimensions

      8.3.1   Purpose
      8.3.2   Metric / English Measurement System
      8.3.3   Inside Diameter of the Hose
      8.3.4   Developed Lengths
      8.3.5   Method of Measurement

8.4 Hose Construction

      8.4.1   Purpose
      8.4.2   Types of construction
      8.4.3   Metallic Hose with a Smooth Liner of Teflon® (PTFE)
      8.4.4   Geometric Construction

8.5 Performance Characteristics

      8.5.1   Purpose
      8.5.2   Maximum allowable Working Pressure (MAWP)
      8.5.3   Temperature
      8.5.4   Chemical Compatibility
      8.5.5   Minimum Bend Radius
      8.5.6   Vacuum Rating

8.6 Hose Assembly Length Determination For Various Movements

      8.6.1   Purpose
      8.6.2   Definitions of Symbols
      8.6.3   Example Values
      8.6.4   Constant Radius Traveling Loop
      8.6.5   Variable Radius Traveling Loop
      8.6.6   Offset Motion
      8.6.7   Angular Motion
      8.6.8   Vertical Loop with Movement in Two Directions

8.7 Assembly Methods

      8.7.1   Purpose
      8.7.2   Crimp Method
      8.7.3   Swage Method
      8.7.4   Flared Over Tubes of Teflon® (PTFE) (convoluted & smooth)
8.8 Assembly Testing

       8.8.1 Purpose
       8.8.2 General
       8.8.3 Leakage Test

8.1   Scope

This section specifies the methods and requirements necessary for the design, fabrication and testing hose of
Teflon® (PTFE) assemblies.

This document pertains to nominal diameters from 1/4 inch (DN6) to 4 inches (DN100), except where limited by
section.

The hose of Teflon® (PTFE) assemblies specified are suitable for the major portion of commercial and
industrial applications.

The following applications are excluded from the scope of this document: those involving extreme working
pressures, or those with design movements involving axial compression or extension.

This document is not intended to prohibit either supplier or customer from attaching additional requirements for
hose of Teflon® (PTFE) or hose of Teflon® (PTFE) assemblies, if necessary to satisfy the application.
8.2   Materials

       8.2.1   Purpose

       The purpose of this section is to identify the types of liners/inner cores most frequently used in the
       fabrication of hoses of Teflon® (PTFE). This information will guide you in the selection of the
       proper hoses of Teflon® (PTFE) required for a specific application.
       8.2.2   General

       Hoses of Teflon® (PTFE) are manufactured in several different configurations depending on the
       application. When selecting the hose, consideration must be given to corrosion resistance,
       service temperature, pressure ratings, end fittings, and exterior environmental conditions.

       8.2.3   Components

       The following components comprise a hose of Teflon® (PTFE) assembly. It is necessary to select
       the appropriate construction materials for the specific application.

               a) Innercore (tube)

                      1. PTFE
                      2. PFA
                      3. FEP

               b) Reinforcements

                      1. Braided, metallic.
                      2. Braided, non-metallic
                      3. Rubber, with/without wire/ fabric ply-core.
                      4. Stainless Steel Housing

               c) Fittings

                      1. Type 316 Stainless Steel
                    2. Type 304 Stainless Steel
                    3. Type 303/302 Stainless Steel
                    4. Brass
                    5. Carbon Steel (plated)
                    6. Aluminum
                    7. Non-Metallic

              d) Collars/Ferrules

                    1. Stainless Steel
                    2. Carbon Steel (plated)
                    3. Brass

      The preceding specifications should be considered minimal and each manufacturer may suggest
      additional requirements to assure best results in fabrication, testing and service life.
8.3   Assembly Dimensions

      8.3.1   Purpose

      The purpose of this section is to establish a standard method of measurement for hose of Teflon®
      (PTFE) assemblies.
      8.3.2   Metric / English Measurement System

      The hose manufacturer shall state in their brochures or documentation which system will be
      employed in their manufacturing process. All tolerances will be applied to their system of
      measurement. Optional cross-referencing of another system will be done in brackets. [e.g., 1/4
      inch (6) means manufacture is in English and reference is to metric.]
      8.3.3   Inside Diameter of the Hose

      The inside diameter of the hose may be true bore or nominal bore as specified by the
      manufacturer.
      8.3.4   Developed Lengths

      Tolerances for the overall length of the hose assembly shall be observed according to the
      following table unless otherwise stated.
      Table 8.5.1 Tolerances

      This chart is intended for smooth bore hose. For other styles of hose, consult your manufacturer
      for actual tolerances.
                                ASSEMBLY LENGTH TOLERANCES
                           INCHES                                 MM
                   Up to 18"        ± .125" (3.2mm)        Up to 450 mm        ± 3 mm
                   18" to 36"                ± .25"    450 mm to 900 mm        ± 6 mm
                   36" to 50"                 ± .5"   900 mm to 1270 mm        ± 13mm
                    Over 50"                  ± 1%        Over 1270 mm            ± 1%

      8.3.5   Method of Measurement

      Normal length measurements shall be taken using a tape measure with the hose laying on a flat
      surface. If the centerline of the end connection is above the hose centerline, the hose should be
      supported accordingly. On most hose assemblies the developed length is the end to end
      dimension at the centerline (Figure 8.3.1). End connections with a seating face shall be measured
      from the seat face and not from the end of any loose fitting (e.g. JIC type end fittings) (Figure
      8.3.2). Hose assemblies using elbows shall be measured from the centerlines (Figure 8.3.3).
      Figure 8.3.1 Measurement of Hose Assembly




      Figure 8.3.2 Measurement of Hose Assembly having an End Connection with a Seating
      Face




      Figure 8.3.3 Measurement of Hose Assembly having an Elbow Fitting




8.4   Hose Construction

      8.4.1   Purpose

      The purpose of the section is to define various hose of Teflon® (PTFE) construction methods.
      8.4.2   Types of construction

      The hose construction may consist of one or more of the components listed below. Typically
      hoses of Teflon® (PTFE) are reinforced by one of the following outer covers, however some
      applications do not require any exterior reinforcement and the inner core alone may be adequate.
      (Consult manufacturer for specific limits.)
              8.4.2.1   Innercores (tube)

                    a) Smooth tube, extruded

                    b) Convoluted
                           1. Extruded, formed construction

                           2. Tape wrapped, Fiberglass backed, molded
                           convolution
              8.4.2.2   Reinforcements

                    a) Metallic (braided on, slip braided)

                           1. CRES (300 series)
                           2. Bronze
                           3. Monel.
                           4. Hastalloy
                           5. Others (consult manufacturer)

                    b) Non-Metallic (braided on)

                           1. Polypropylene
                           2. PVDF
                           3. Nylon
                           4. Fiberglass
                           Others available. Consult the manufacturer.
      8.4.3   Metallic Hose with a Smooth Liner of Teflon® (PTFE)

      These are reinforced metal (stainless steel) corrugated hose assemblies designed to incorporate
      smooth liners of Teflon® (PTFE) throughout the inside diameter of the hose and extending over
      the sealing surfaces of the fitting connections.
      8.4.4   Geometric Construction

      A. The hose liner should consist of a smooth bore tube, concentric with consistent wall thickness
      throughout its length.
      B. Hose shall consist of convolutions of uniform height and pitch continuous along its length.
8.5   Performance Characteristics

      8.5.1   Purpose

      The purpose of this section is to establish various performance characteristics of hoses of
      Teflon® (PTFE) assemblies.
      8.5.2   Maximum allowable Working Pressure (MAWP)

      The MAWP for an assembly is 25% of it’s burst pressure.
      8.5.3   Temperature

      Unless otherwise stated, hose of Teflon® (PTFE) assemblies are suitable for applications to
      400ºF. Most manufacturers rate maximum operating pressures at ambient temperatures. If a hose
      is to be considered for use in an application that exceeds 400ºF, consult manufacturer for any
      pressure de-rating of the hose of Teflon® (PTFE) assembly.
      8.5.4   Chemical Compatibility

      For the corrosion resistance of the non-Teflon® (PTFE) components of a hose assembly, consult:

              National Association of Corrosion Engineers Handbook
              1440 South Creek Drive
              Houston, TX 77084
      8.5.5   Minimum Bend Radius

      A sphere with a diameter equal to 85% of the internal diameter of the hose must be able to roll
      freely (from end to end) in an unpressurized assembly bent 180 degrees at the hose’s stated
      minimum bend radius.
      8.5.6   Vacuum Rating

      The maximum amount of vacuum that can be drawn on the inside of a hose assembly without
      causing the assembly to fail the minimum bend test.
8.6   Hose Assembly Length Determination For Various Movements

      8.6.1   Purpose

      The information in this section is provided as a guide to determine the overall length of hose
      assemblies for the conditions shown. All formulas determine the minimum live length required. To
      obtain the overall length, the length of the fittings including braid sleeves, must be added to the
      live length.
      8.6.2   Definitions of Symbols

      The following definitions of symbols shall be used in all formulas:

              T = Travel
              R = Radius of the installation.
              L = Live length
              S = Outside diameter of the hose
              OAL = Overall length of the assembly
              MBR = Minimum bend radius of the hose
      8.6.3   Example Values

      In all calculations, the following example values are assigned:

      Hose outside diameter (S) = 2.75”
      Minimum bend radius of hose (MBR) = 14”
      Fitting length including braid sleeve = 3.50”
      8.6.4   Constant Radius Traveling Loop
      Figure 8.6.4.1 Constant Radius Traveling Loop - Vertical Travel
Figure 8.6.4.2 Constant Radius Traveling Loop - Horizontal Travel




      Formula:

      L = 4(R) + (T)/2

      Example: Travel (T) = 6.00”

      2R = 40”
        R = 40”/2 = 20”

        L = 4(20”) + (6”)/2

        L = 83.00”

        OAL = 83.00” + 2(3.5”) = 90.00”
        Note:

        For metal hose, R must be > or = MBR
        For hose of Teflon® (PTFE), R must be > or = (MBR + S/2)
8.6.5   Variable Radius Traveling Loop
Figure 8.6.5.1 Variable Radius Traveling Loop - Vertical Travel




Figure 8.6.5.2 Variable Radius Traveling Loop - Horizontal Travel




        Formula:

        L = 4(R) + 1.57(T)

        Example: Travel (T) = 6.00”
      2R = 40”

      R = 40”/2 = 20”

      L = 4(20”) + 1.57(6”)

      L = 89.42”

      OAL = 89.42” + 2(3.5”) = 96.42”
      Note:

      For metal hose, R must be > or = MBR
      For hose of Teflon® (PTFE), R must be > or = (MBR + S/2)
8.6.6 Offset Motion

Figure 8.6.6.1 Offset Motion




Formula:

L = (20RxT)1/2

For metal hose, R = MBR

For hose of Teflon® (PTFE), R = (MBR) + S/2)
Example:

Travel (T) = 3.00”

Metal Hose

R = MBR = 14”

L = (20x14”x3”)1/2
L = 28.98”

OAL = 28.98” + 2(3.5”) = 35.98”

Live Straight Length – Lp

Lp = (L2 – T 2)1/2

Lp = (28.98” 2)1/2 – 3” 2

Lp = 28.92”

Overall straight installed length = 28.82” + 2(3.5”) = 35.82”
Note 1:

When the offset motion occurs on both sides of the centerline, T = total travel = (T1+T2).

Note 2:

The offset distance “T” for constant flexing should never exceed 25% of the hoses stated
minimum bend radius.

8.6.7   Angular Motion
Figure 8.6.7.1 Angular Motion




Formula:

L = 2(S) + (0/57.3)R

For metal hose, R = MBR

For hose of Teflon® (PTFE), R = (MBR + S/2)

Example: Ø = 15 Degrees

Metal Hose

R = MBR = 14”
      L = 2(2.75)” + (15/57.3)14”

      L = 9.17”

      OAL = 9.17” + 2(3.5”) = 16.17”
      8.6.8 Vertical Loop with Movement in Two Directions
      Figure 8.6.8.1 Vertical Loop with Movement in Two Directions

      (Graphic missing)
      Formula:

      L = 4(R) + 1.57 (Th) + (Tv)/2

      Example: 2R = 40"

              Th = 6

              Tv = 8"

      R= 40"/2 = 20"

      L = 4(20") + 1.57(6") + (8")/2

      L = 93.42"

      OAL = 93.42" + 2(3.5") = 100.42"
      Note:

      For metal hose, R must be > or = MBR

      For hose of Teflon® (PTFE), R must be > or = (MBR + S/2)
8.7   Assembly Methods

      8.7.1   Purpose

      The purpose of this section is to identify the most common types of assembly methods typically
      used to fabricate hose of Teflon® (PTFE) assemblies.

      8.7.2   Crimp Method

      This method utilizes a machine that reduces the diameter of the fitting collar or sleeve
      simultaneously along its length. The sizing die set usually consists of eight or ten “fingers” that are
      machined to a prescribed diameter. When placed in a series inside the throat of the crimper the
      reduced diameter can usually be adjusted with minor changes to the crimper. Crimp diameters
      are established by the hose manufacturer based on the successful completion of a series of
      qualification tests. When crimping the collar, the fitting remains stationary to the die set and is
      reduced through radial loading of the fingers. It is anticipated that the resulting outside surface of
      the collar or sleeve will exhibit multiple axial tool marks along its length. Care should be exercised
      to insure that the tooling does not leave deep marks that could be detrimental.
      Figure 8.7.2.1 Typical Crimped Collar
      8.7.3   Swage Method

      This method utilizes a machine that reduces the diameter of the fitting collar or sleeve
      progressively along its length. The sizing die set usually consists of two halves that are machined
      to a prescribed diameter and cannot be adjusted. Swage diameters are established by the hose
      manufacturer based on the successful completion of a series of qualification tests. When swaging
      the collar, the fitting is pushed progressively into the stationary die thus reducing the collar to a
      prescribed diameter. It is anticipated that the resulting outside surface of the collar or sleeve will
      exhibit two axial tool marks along its length.
      Figure 8.7.3.1 Typical Swaged Collar




      8.7.4   Flared Over Tubes of Teflon® (PTFE) (Convoluted & Smooth)

      Typically, these types of hoses feature a heavy wall Teflon® (PTFE) tube (either smooth or a
      straightened portion of the convoluted hose) extending through the fitting. The liner is then formed
      over the fitting sealing surface to provide an area for sealing against a mating fitting.

      Metallic hose with a smooth inner liner of Teflon® (PTFE) should meet the following criteria:

              A. Metal hose assembled to NAHAD Flexible Metal Hose Standard.

              B. Hose must incorporate a smooth transition from the convoluted I.D. to the Fitting
              with vent hole(s) burr free, no sharp edges, no metal chips, machined radii transition
              at the fitting sealing surface

              C. Hose features same flared over Teflon® (PTFE) liner per Section 8.7.3.

      Consult manufacturer for actual fabrication /assembly features. (This type assembly is usually a
      factory produced item due to the requirements of liner fit.)
8.8   Assembly Testing

      8.8.1   Purpose

      The purpose of this section is to define minimum test requirements and identify other types of
      tests. This is inclusive of leak and proof pressure testing.
      8.8.2   General

      All hose of Teflon® (PTFE) assemblies shall be tested in a condition such that the end fittings and
      the section of hose immediately behind the fittings is visible. Do not obstruct the access to these
      areas with any type of optional chafe or fire sleeve that may be required to complete the
      assembly.
      8.8.3   Leakage Tests

      After fabrication, each hose assembly shall be subjected to a leakage test during which there
      shall be no signs of leakage or other modes of failure. As a minimum, the assembly should be
      hydrostatically tested followed by other tests as defined by the contract.
              8.8.3.1   Hydrostatic Proof Pressure

              The hose assembly shall be subjected to a proof pressure test at a value defined by
              the contract or 1.5 times the maximum working pressure, using water as the media.
              Any evidence of leakage or permanent deformation is cause for rejection. Leakage
              is defined as a continuous stream of water droplets emitted from a single or multiple
              locations.

              All entrapped air residing within the hose assembly should be removed prior to
              testing. This may be accomplished by having a vent port to relieve the entrapped air
              while filling the assembly with water.
              8.8.3.2   Pneumatic Proof Pressure

              The hose assembly shall be subjected to a proof pressure test at a value defined by
              the contract or the maximum working pressure using gaseous nitrogen as the media
              while the assembly is immersed in a bath of water. An alkaline wetting agent should
              be added to the water bath to assist in defining the leakage. Any evidence of
              leakage or permanent deformation is cause for rejection. Leakage is defined as a
              continuous stream of bubbles emitted from a single or multiple locations.

              Care should be exercised to remove all entrapped air residing under the braid
              during the test so as not to confuse it with actual leakage. This may be
              accomplished using a water pick device while the assembly is immersed in the
              water bath.
              8.8.3.3   Other

              When so requested by the contract, other test media such as hydraulic oils may be
              used during the proof pressure testing. Consult the manufacturer for proven
              methods and procedures should these types of special requirements apply.

>> continue to Section 9
Section 9 Testing Procedures

9.1 Purpose

9.2 Hydrostatic Proof Pressure Tests

9.3 Pneumatic Proof Pressure Test - Metal and Hose of Teflon

9.4 Other Leakage Tests

9.5 Electrical Continuity Test

9.6 Electrical Resistance Test - UL330 Testing Method for an Assembly

9.7 Visual Inspection

9.8 Elongation Length Measurement - COMPOSITE HOSE Only

9.9 Calibrations

9.10 Test Documentation

9.11 Other Documentation

       9.11.1   Certificate of Conformance
       9.11.2   Test Report
       9.11.3   Certified Material Test Reports
       9.11.4   Third Party Certification

9.1   Purpose

The following testing methods may or may not be required. Refer to the customer requirements and/or the
appropriate assembly data sheets for recommended testing and documentation needed.
9.2   Hydrostatic Proof Pressure Tests

A proof test is usually conducted applying the following criteria:
       Composite Hose -

       Hose assemblies with 25mm to 100mm (1 inch to 4 inches) nominal bore standard duty oil and
       chemical hose should be tested to a minimum of one and a half times the rated working pressure
       of the assembly for a minimum period of five minutes.

       Hose assemblies with 100mm nominal bore heavy duty and 150mm to 250mm (6 inches to 10
       inches) nominal bore composite hose should be tested to one and a half times the rated working
       pressure of the assembly for a minimum period of 30 minutes.
       Hydraulic Hose -

       This proof pressure test is conducted at twice the working pressure of the hose unless otherwise
       specified by the customer.

       The test pressure shall be maintained for a period of not less than 30 seconds and no more than
       60 seconds. There shall be no indication of failure or leakage.
       Industrial Hose -
A proof test is usually conducted at 50% of the minimum burst pressure or twice the working
pressure for a new hose assembly and one and a half times the working pressure for used
assemblies. The test is usually conducted for a minimum of 5 minutes under pressure.
Metal Hose -

The assembly shall be pressurized to the maximum test pressure of the assembly and maintained
for a sufficient length of time to permit a visual examination of all surface joints. The minimum
testing time should be one minute.
Hose of Teflon -

The hose assembly shall be subjected to a proof pressure test at a value defined by the contract
or 1.5 times the maximum working pressure, using water as the media
Recommended Procedure

For Composite, Hydraulic and Industrial hose assemblies, it is strongly recommended to use
hydrostatic pressure test methods instead of pneumatic proof testing!

A hydrostatic pressure test requires either a hand pump, a power driven hydraulic pump, or an
accumulator system. Connect the hose assembly to the test pump in a straight fashion, assuring
a leak tight connection. It is extremely important that fittings, adapters, and any other mating
components are rated for the pressure value of the test. It is recommended that the hose
assembly be secured in an encapsulated tank that will withstand the pressure, and secure it with
steel rods or straps close to each end and at ten-foot intervals along the length of the hose. This
will prevent it from “whipping" if a failure occurs. The securing rods or straps must be anchored
firmly to the test structure, but should not contact the hose. The hose must be free to move
slightly when pressure is applied.

An outlet valve should be applied to the hose end of the assembly that opposes the test pump
end of the assembly. Unless otherwise specified by the customer, the test media should be water.
Fill the hose with water while the outlet end is raised and the valve slightly opened to bleed all of
the air from the system. Use the outlet valve to bleed all air remaining in the hose. When all the
air has been expelled, close the outlet valve and lower the raised end.
***This is very important as a safety measure because expansion of air compressed in the hose,
when suddenly released by bursting or other failure, might result in a serious accident. ***

Next for reference, mark a line behind the couplings which is at the end of the ferrule, clamp,
band, etc. Then gradually raise the pressure to the desired pressure rating. Hold the pressure at
for time dictated by hose type and conduct a visual inspection. As the pressure is raised, watch
for visual indications of permanent deformation, leakage, and coupling slippage. If any of these
are noted it is cause for rejection. After the test is complete, relieve the test pressure before
disconnecting the hose assembly from the test equipment and drain the water from the hose. The
hose may be flushed with alcohol if all of the water must be removed.
WARNING**WARNING**WARNING**WARNING**WARNING

Wherever particular skills are required, only specially trained persons should engage in those
applications or testing procedures. Failure to do so may result in damage to the hose assembly or
to other personal property and, more importantly, may also result in serious bodily injury.

Hoses must be properly cleaned prior to inspection and testing. This will prevent unexpected
reactions between conveyants and the test media. Always wear safety glasses, gloves, and
protective clothing to protect from leaks or high pressure spray. Also, use shields to protect
people in the work area in the event of a hose burst, spray, or coupling blow-off.
        It is recommended to never stand in front of, over, or behind the ends of a hose assembly during
        pressure testing. Also make sure that the hose is sufficiently shielded during pressure testing to
        stop a coupling in case of a coupling blow-off.
9.3   Pneumatic Proof Pressure Test - Metal and Hose of Teflon® (PTFE)

When required by the customer, the hose assembly shall be subjected to a pneumatic proof pressure test at a
value defined by the contract or the maximum working pressure. Using a gaseous media, the assembly is
immersed in a bath of water for a sufficient length of time to permit visual examination of all surface joints.
Typical gas testing media are air, nitrogen, and helium. An alkaline wetting agent should be added to the water
bath to assist in defining the leakage. Minimum testing time should be one minute. Any evidence of leakage or
permanent deformation is cause for rejection.
Any failure during testing is likely to be of an explosive nature!

When testing braided metal hose, care should be exercised to remove all entrapped air residing under the braid
during the test so as not to confuse it with actual leakage. This may be accomplished using a water pick device
while the assembly is immersed in the water bath.
Note:

When testing Metal Hose, use Tables 9.3.1 to determine the test pressure for the assembly.
Table 9.3.1 Metal Hose ONLY
                         Unbraided Assemblies Test Pressures
Nominal I.D.                                             Pressure
1/4" through 1/2" (6.35mm through 12.7mm)                25 psig (171.25 kPa)
3/4" through 1" (33.87mm through 25.4mm)                 10 psig (68.95 kPa)
1 1/4" through 3" (31.75mm through 76.2mm)               5 psig (34.48 kPa)
3 1/2" through 4" (88.9mm through 101.6mm)               3 psig (20.68 kPa)
                          Braided Assemblies Test Pressures
Nominal I.D.                                             Pressure
1/4" through 4" ((6.35mm through 101.6mm)                75 psig (517.125 kPa)



Note:

If higher test pressures are to be used consult the manufacture's catalog for maximum test pressures.

Note:

Due to the corrosive considerations, attention is drawn to the need to control the chloride content of the water
used for testing of austenitic stainless steels to below 50 ppm (parts per million).
9.4   Other Leakage Tests

When leak rates are critical, consult the manufacturer for more sensitive testing methods. These may include
but are not limited to the following: Mass Spectrometer Leak Testing, Pressure Decay, Vacuum Decay, Mass
Flow, and Halogen Leak Test.
9.5   Electrical Continuity Test
There are two types of electrical grounding paths for hoses: metallic and non-metallic. Hoses should be tested
with a calibrated multi-meter from end fitting to end fitting to determine if the assembly is electrically continuous.
Note:

All lengths of Composite Hose that have been fitted with electrically conductive end fittings must be tested.
9.6   Electrical Resistance Test - UL330 Testing Method for an Assembly

The maximum resistance for a hose assembly is determined by the standard that the assembly is made to
conform, such as the requirement of 70,000 ohms/ft. per the UL 330 specification.

Hoses that are metallically grounded have a static wire, metal helical wire, or wire braid that is connected to the
coupling on each end of the hose. Per the UL 330 specification, the electrical resistance of a metallic grounded
hose can be measured with a standard low-voltage ohmmeter. Hoses which have grounding paths that have
resistance greater than 1000 ohms require electrical continuity testing to be done with an ohmmeter that has an
internal resistance of 100,000 ohms +/- 10 percent, with an open circuit potential of 500 volts, D.C.

Hoses that are non-metallically grounded utilize a conductive material to achieve electrical continuity. These
hoses require electrical continuity testing to be completed with an ohmmeter that has an internal resistance of
100,000 ohms +/- 10 percent with an open circuit potential of 500 volts, D.C.

The electrical resistance of the hose is measured from coupling connection to the other end coupling
connection while pressurized with air, nitrogen, or kerosene at 75 psig. During the electrical continuity testing, if
there is a swivel coupling present, the swivel must be rotated 360 degrees while the ohmmeter leads are
attached and the hose is under 75 psig pressure. The highest reading during the test is considered to be the
electrical resistance of the hose assembly.
Note:

Unless otherwise specified, all lengths of Composite Hose that have been fitted with electrically conductive end
fittings must have an electrical resistance not exceeding 10 ohms.
9.7   Visual Inspection

All sample assemblies should be visually inspected for substandard quality conditions in the hose or couplings.
Each assembly should be visually inspected for kinks, loose covers, bulges or ballooning, soft spots, cuts,
broken wires, or any obvious defect in the hose. The fittings and attachments should be inspected for any type
of visible defects that may affect the performance of the assembly.

        A. Visual inspection checkpoints should include but are not limited to the following:

        B. Hose Identification - Size and type must correspond to the fabrication order (work order).

        C. Coupling Identification - Coupling size, type, and product number must correspond to
        information on the fabrication order (work order) and specifications. Identified with date code, part
        number, etc. when required.

        D. Inspection Items -

               Bulge behind the coupling.
               Cocked couplings.
               Cracked couplings .
               Exposed reinforcement.
               Freedom of swivels.
               General appearance of the assembly.
               Hose cover pricked if required.
               Internal contaminants.
                 Protective caps or plugs.
                 Restriction in the tube.
                 Rusted couplings.
9.8    Elongation Length Measurement - COMPOSITE HOSE Only

A characteristic of composite hose is elongation. This characteristic should not be used solely as an
assessment of the condition of the hose or an indication of failure. Because of the elongation under pressure,
the check with the manufacturer when length in application is critical.

In the event that elongation length measurement is required, the following is an accepted process and may be
incorporated into your test procedure.
Pressurize the hose to one time working pressure, hold for 30 seconds, release pressure to 10 psi and take the
initial length measurement at 10 psi. Lo=____.

Measure the hose length under pressure (Test Pressure Length), Lt=_____. Calculate the temporary elongation
as follows: Lt - Lo x 100 = ____% Lo.
Release the pressure, wait 30 seconds, measure and record the Over All Final Length, and drain hose.
9.9    Calibrations

Inspection and testing equipment used in the production or testing of coupled hose assemblies should be
calibrated at prescribed intervals according to written procedures. All gauging equipment shall be calibrated
regularly by means traceable to NIST (National Institute of Standards and Technology). The tag giving date of
last calibration, next calibration due date and signature of the inspector shall be attached to the gauge and a
record filed for future reference.
9.10    Test Documentation

If required by the customer, a test certificate may be issued to provide written confirmation that the assembly
has been tested, and conforms to certain performance criteria. If a test certificate is not supplied, test results
should be maintained and kept on file for five years.

Each test certificate should bear a unique number for traceability.

Test certificates should include the following information as a minimum:

        A. Test Certificate Number
        B. Customers Name and Purchase Order Number
        C. Suppliers Name and Job Number
        D. Hose Serial Number(s)
        E. Hose details including length, type of hose and diameter
        F. End fitting details with types of ferrules and seals used
        G. Test Date
        H. Test Pressure
        I. Electrical Continuity Conformance
        J. Suppliers Authorization Signature
9.11    Other Documentation

Other types of documentation may be requested by the customer. All certificates and reports required should
accompany the shipment, unless otherwise specified.
        9.11.1     Certificate of Conformance

        When required, a Certificate of Conformance (C of C) shall be supplied with the order, confirming
        in the form of a text, and without expressed mention of the test results, that the product being
        supplied meets the requirements of the customers purchase order, as agreed upon order
      acceptance. The C of C should have the following information, if applicable:
         a.    Customer's Name
         b.    Customer's Address
         c.    Customer's Purchase Order
         d.    Customer's Contract Number
         e.    Customer's Specification Number
         f.    Customer's Drawing Number
         g.    Supplier's Name
         h.    Supplier's Address
         i.    Supplier's Order Number
         j.    Supplier's Drawing Number
         k.    Quantity
         l.    Description
        m.     Additional Information
         n.    Supplier's Authorization Signature
         o.    Date

      9.11.2    Test Report

      A request for a C of C may require that actual test results be included.
      9.11.3    Certified Material Test Reports

      When required, a Certified Material Test Report (CMTR) shall be supplied showing the materials
      meet the requirements of the customer's purchase order. These may be supplied as copies of the
      raw material CMTR's provided by the materials supplier or on the manufacturer's form providing
      certified test results.
      9.11.4    Third Party Certification

      When required by the customer, an authorized inspection party shall inspect and certify that the
      product being supplied meets the requirements of the customer's purchase order as agreed upon
      order acceptance. Upon request, copies of these certifications shall be supplied.

>> continue to Section 10
Section 10 Quality Plan

10.1 Purpose

10.2 Sampling Plan

10.3 Material Receiving Inspection

       10.3.1 Couplings
       10.3.2 Hose

10.4 Storage (Labeling, Environment, Time)

10.1   Purpose

The purpose of this section is to outline a quality plan for fabricating hose assemblies. The assurance of an
acceptable hose assembly reaching the customer depends upon the quality of the components and the
workmanship of the fabricator.

An effective quality control plan is based on statistical sampling principles. Responsibility for supervising the
quality plan must be designated. Corrective action procedures must be formalized to deal with
nonconformance.
10.2   Sampling Plan

An effective sampling plan is based on the statistical history of a design that demonstrates quality performance
and sets confidence levels.

Sampling is performed in an effort to statistically evaluate a product or process against tolerances that are
considered acceptable as determined by national standards, customer requirements, etc. This monitoring of
product or process with an adequate sampling plan is done in an effort to provide 100% acceptable product to
the customer. In an ideal world, if inspection capability is 100% effective, then the only way to assure 100%
acceptable product is to inspect everything 100%. Due to practical considerations of time and resources (both
manpower and financial), 100% inspection will probably not occur as a standard method of operation.

There are many areas or processes that may be sampled. These may vary from operation to operation, but
there are some constants that should probably apply no matter what the operation.

       A. Inspection of incoming material – You cannot guarantee the quality of the outgoing product, if
       the quality of incoming materials has not been verified.

       B. In process inspection – This may be as simple as inspection of the first assembly produced. Or
       it may be quite complicated, such as doing a complete dimensional audit on so many pieces per
       production run and plotting these results on Statistical Process Control (SPC) charts in order to
       track trends and potential problems.

       C. Final Inspection – This may be relatively simple, such as verifying piece counts before shipping
       to the customer, or as complicated as checking specific criteria to ensure compliance with the
       customer’s requirements. Regardless of what is being sampled, inspection characteristics, the
       corresponding documentation and the personnel responsible for carrying for inspecting these
       characteristics, must be defined.

When establishing the frequency of sampling, there are many factors that need to be considered. These
include but are not limited to:

       1. Cost
       2. Complexity of process
        3. Application
        4. Liability
        5. Stability of procedure

If a process is very stable as indicated by past performance, the frequency of sampling can be decreased.
There is no specific sampling plan that can be considered best suited to all applications.
10.3    Material Receiving Inspection

        10.3.1     Couplings

                 1. Upon receipt of a shipment of couplings, the assembly fabricator should perform,
                 at minimum, the following inspection steps:

                 2. Compare the couplings received with the purchase order by making sure part
                 numbers agree between order and packing slip.

                 3. Check the count between packing slip and actual quantity received.

                 4. Check the product in the package to make sure it agrees with the part number on
                 the package. Supplier catalogs are a good reference.

                 5. When possible, leave the couplings in the original container with the original date
                 code. If a coupling problem arises later, all the couplings of that size and date code
                 can be separated out for 100% inspection purposes.

                 6. At least one coupling from every box should be inspected for dimensions,
                 defective plating, concentricity, snap rings attached to the swivels, any damage from
                 shipping.
        10.3.2     Hose

        Upon the receipt of a shipment of hose, the assembly fabricator should perform, at a minimum,
        the following inspection steps:

                 1. Check product numbers on the packing list with numbers on the packages of the
                 actual merchandise.

                 2. Check total footage against the packing slip, making sure they agree.

                 3. Check the product, making sure it agrees with the label on the packaging.

                 4. Check the hose inside diameter, outside diameter and reinforcement, and verify
                 against the manufacturer’s product information.

                 5. All hose should be visibly inspected for damage due to shipping, kinks, loose
                 cover, bulges, ballooning, cuts, crush, and tears. A certificate of conformance may
                 be requested with the hose, couplings, and attachments.
10.4    Storage (Labeling, Environment, Time)

Proper storage will maximize hose shelf life. All hose should be stored in such a manner to protect them from
degrading factors such as humidity, temperature extremes, ozone, sunlight, direct light from fluorescent or
mercury lamps, oils, solvents, corrosive liquids, insects, rodents, and any other degrading atmosphere.

Care should be taken when stacking hose, as its weight can crush hose at the bottom of the stack. The stack
could also become unstable, creating a safety hazard.
Note:
The ideal storage temperature for rubber hose is +50°F to +70°F with the maximum of +100°F. Care should be
taken to keep rubber hoses from being stored next to heat sources. Rubber hose should not be stored near
electrical equipment that generates ozone. Exposure to high concentrations of ozone will cause damage to the
hose.

Store components in a cool, dry area. If stored below freezing, pre-warming may be required prior to handling,
testing and placing into service.

Components should be stored in original date-coded containers. Steps should be made to rotate inventory on a
first-in, first-out basis, to insure that the products are exposed to the shortest shelf time possible.

>> continue to Section 11
Section 11 Assembly Identification, Cleaning and Packaging

11.1 Purpose

11.2 Hose Assembly Markings

       11.2.1 Method of Marking

11.3 Cleaning

11.4 Packaging

11.1   Purpose

This section is intended to establish methods and content of applying hose assembly identification markings
and identify minimum cleaning and packaging requirements.
11.2   Hose Assembly Markings

       11.2.1     Method of Marking

       The marking of hose assemblies may be achieved in two ways:

                a. Information pre-stamped in legible characters on metal tag or band affixed to the
                assembly by approved durable method.

                b. Information in legible characters stamped directly onto the ferrule or fitting.
11.3   Cleaning

Each assembly shall be supplied to the customer free of water, debris, metal shavings, dirt or any foreign
material that may cause problems to the application. Air may be blown through the assembly to remove loose
particles. Some customers have stringent cleanliness requirements that may require flushing the assembly.

End connection openings should be sealed or capped to assure that cleanliness is maintained.

Consult the customer information for specific cleaning requirements.
11.4   Packaging

Hose assemblies shall be packaged in such a manner to insure that external abuse during shipping and
handling does not damage the hose or fittings.

Hose shall be packed in a clean and dry state.

Containers, boxes, banding and pallets shall be of sufficient size and strength to withstand handling and transit
without failure.

When packaged, hose assemblies should not be coiled tighter than the specified minimum bend radius.

Check customer information for any specific labeling or packaging requirements.

>> continue to Section 12
Section 12 Installation and Handling

12.1 Purpose

12.2 General

12.3 Safety Considerations

       12.3.1 Media Permeation
       12.3.2 Fluid Injections
       12.3.3 Whipping Hose
       12.3.4 Fire and Explosions from Conveyed Fluids
       12.3.5 Fire and Explosions from Static-Electric Discharge
       12.3.6 Burns from Conveyed Fluids
       12.3.7 Electrical Shock
       12.3.8 Fluid Controlled Mechanisms
       12.3.9 Air and Gaseous Applications
       12.3.10 Hand-held Hydraulic Operated Tools

12.4 Hose Installation and Replacement

       12.4.1   Pre-Installation Inspection
       12.4.2   Handling During Installation
       12.4.3   Torque
       12.4.4   Hose Routing
       12.4.5   Securement and Protection
       12.4.6   System Checkouts

12.5 Maintenance Inspection

       12.5.1   Inspection Frequency
       12.5.2   Visual Inspections
       12.5.3   Visual Inspections for All Other Components
       12.5.4   Functional Tests
       12.5.5   Composite Hose – Special Cleaning Instructions After Use

12.1   Purpose

The purpose of this section is to increase awareness on the proper installation and handling of hose
assemblies, and to alert fabricators, installers and end-users to the safety hazards in the field.

Hoses and hose assemblies are used interchangeably in this document. Hoses are used to convey fluids,
gases and other media. Hose constructions are available in a variety of materials and styles depending on the
intended application.
12.2   General

All hose has a finite life and there are a number of factors, which will reduce its life. The design and use of
systems, which contain hoses, require consideration of factors related to specific application requirements.
12.3   Safety Considerations

Below are some potential conditions that can lead to personal injury and property damage. This list is not
inclusive. Consider reasonable and feasible means, including those described in this section to reduce the risk
of injuries or property damage.

Employers with hose assemblies in fluid systems are encouraged to provide training, including the information
in this document, for maintenance personnel and other employees working with and around hoses under
pressure.
      12.3.1   Media Permeation

      Hoses should always be used in well-ventilated areas. Certain media will permeate through hoses
      that can displace breathable air in confined spaces. Consult the manufacturer if in question.
      12.3.2   Fluid Injections

      Fine streams of pressurized fluid can penetrate skin and enter a human body. Fluid injection
      wounds may cause severe tissue damage and loss of limb. Consider the use of guards and
      shields to reduce the risk of fluid injections.

      If a fluid injection occurs, contact a doctor or medical facility at once. Do not delay or treat as a
      simple cut. Fluid injections are serious injuries and prompt medical treatment is essential. Be sure
      the doctor knows how to treat this type of injury.

      Avoid all contact with escaping fluids. Treat all leaks as though they are pressurized and hot or
      caustic enough to burn skin.
      12.3.3   Whipping Hose

      If a pressurized hose or hose fitting comes apart, the loose hose end can flail or whip with great
      force, and fittings can be thrown off a high speed. This is particularly true in compressible gas or
      fluid systems. If the risk of hose whipping exists, consider the use of guards and restraints.
      12.3.4   Fire and Explosions from Conveyed Fluids

      All hydraulic fluids, including many designated as “Fire Resistant”, are flammable (will burn) when
      exposed to the proper conditions.

      Fluids under pressure which escape from system containment, may develop a mist or fine spray
      that can explode upon contact with a source of ignition (e.g.; open flames, sparks, hot manifolds.)
      These explosions can be very severe and could cause extensive property damage, serious injury
      or death. Care should be taken to eliminate all possible ignition sources from contact with
      escaping fluids, fluid spray or mist, resulting from hydraulic system failures. Select and route
      hoses to minimize the risk of combustion.
      12.3.5   Fire and Explosions from Static-Electric Discharge

      Fluid passing through hose can generate static electricity, resulting in static-electric discharge.
      This may create sparks that can ignite system fluids or gases in the surrounding atmosphere. Use
      hose rated for static conductivity or a proper grounding device. Consult manufacturer for proper
      hose and coupling selection.
      12.3.6   Burns from Conveyed Fluids

      Fluid media conveyed in certain applications may reach temperatures that can burn human skin.
      If there is risk of burns from escaping fluid, consider guards and shields to prevent injury,
      particularly in areas normally occupied by operators
      12.3.7   Electrical Shock

      Electrocution could occur when a hose assembly conducts electricity to a person. Most hoses are
      conductive. Many have metal fittings. Even nonconductive hoses can be conduits for electricity if
       they carry conductive fluids.

       Certain applications require hose to be nonconductive to prevent electrical current flow. Other
       applications require the hose to be sufficiently conductive to drain off static electricity. Hose and
       fittings must be chosen with these needs in mind. Consult manufacturer with any questions.
       Note:

       Metal hoses are conductive. Always use proper grounding to minimize the risk of electrical
       discharge.
       Note:

       Be aware of routing hydraulic hose near an electrical source. When this cannot be avoided,
       nonconductive hoses should be considered. SAE J517-100R7 and 100R8 hoses with orange
       covers marked “Nonconductive” are available for applications requiring nonconductive hose.
       12.3.8     Fluid Controlled Mechanisms

       Mechanisms controlled by fluids in hoses can become hazardous if a hose fails. For example,
       when a hose bursts, objects supported by the fluid pressure may fall. If mechanisms are
       controlled by fluid power, use hose with design characteristics sufficient to minimize the potential
       risks of property damage or injury.
       12.3.9     Air and Gaseous Applications

       Consult manufacturer for proper hose and coupling selection. The covers of hose assemblies that
       are to be used to convey air and other gaseous materials must be pin perforated.
       CAUTION: Exercise care not to perforate beyond the cover. These perforations allow gas that has
       permeated through the inner tube of the hose to escape into the atmosphere. This prevents gases
       from accumulating and blistering the hose.
       12.3.10     Hand-held Hydraulic Operated Tools

       Extreme care is necessary when connecting hand-held or portable hydraulic powered tools to a
       hydraulic power source with a hose assembly.

                a. Always use a strain reliever at both ends of the hose assembly to prevent
                excessive bending, kinking and stress at the coupling to hose interface.

                b. Never use the hose assembly as a means to carry, pull, lift or transport the
                hydraulic tool or power unit.

                c. Exposed hose near the operator should be covered with a fluid deflection
                apparatus such as nylon sleeving, for protection against injection injuries should a
                hose rupture occur.

                d. Operators should be protected with the proper safety equipment such as face
                masks, leather gloves and safety clothing as dictated by the job, fluid and tools
                being used.

                e. If the connecting hose assembly could be subjected to external forces that may
                inflict damage, an appropriate guard should be used.
12.4   Hose Installation and Replacement

The following practices shall be used when installing hose assemblies in new systems or replacing hose
assemblies in existing systems.
       12.4.1     Pre-Installation Inspection

       Before installing hose assemblies, the following shall be examined:

                a. Hose length and routing for compliance with original design.

                b. Correct style, size, length, and visible non-conformity of assembly.

                c. Fitting seats for burrs, nicks or other damage.

                d. Kinked, crushed, flattened, or twisted hose.
       12.4.2     Handling During Installation

       Handle hose with care during installation; bending beyond the minimum bend radius will reduce
       hose life. Sharp bends at the hose to fitting juncture should be avoided.
       12.4.3     Torque

       Hose assemblies shall not be installed or operated in a twisted or torqued condition. Swivel
       fittings or a lay line may be used to aid in torque-free installation.
       12.4.4     Hose Routing

       When planning the hose routing use the following practices for optimum performance and more
       consistent and predictable service live.

       Routing at less than minimum bend radius, will reduce the service life of the hose. Use the static
       or dynamic minimum bend radius according to service conditions. Sharp bends at the hose to
       fitting juncture should be avoided

       Hose assemblies subject to movement while operating should be installed in such a way that
       flexing occurs in the same plane.
       12.4.5     Securement and Protection

       Necessary restraints and protective devises shall be installed. Such devices shall not create
       additional stress or wear points.
       12.4.6     System Checkouts

       In some liquid systems, it may be necessary to eliminate all entrapped air after completing the
       installation. Follow manufactures’ instructions to test the system for possible malfunctions and
       leaks.

       To avoid injury during system checkouts, do not touch any part of the hose assembly when
       checking for leaks and stay out of potentially hazardous areas while testing hose systems. (See
       Safety Considerations.)
12.5   Maintenance Inspection

A hose and fitting maintenance program can reduce equipment down time and maintain peak operating
performance.
       12.5.1     Inspection Frequency

       The nature and severity of the application, past history and manufacturer’s recommendations
       shall be evaluated to determine the frequency of the visual inspections and functional tests.

       However, in the absence of this information, we recommend a visual inspection be conducted
      before each shift or at least once a day.

      To avoid injury during system checkouts, do not touch any part of the hose assembly when
      checking for leaks and stay out of potentially hazardous areas while testing hose systems. (See
      Safety Considerations.)
      12.5.2     Visual Inspections

      The hose and fittings shall be visually inspected for:

               a. Leaks at the hose fittings or in the hose.
               b. Damaged, abraded, or corroded braid; or broken braid wires.
               c. Cracked, damaged, or badly corroded fittings.
               d. Other signs of significant deterioration.

      If any of these conditions exist, the hose assemblies shall be evaluated for replacement.
      12.5.3     Visual Inspections for All Other Components

      Hose and fittings shall be visually inspected for:

               a. Leaking ports.
               b. Damaged or missing hose clamps, guards, or shields.
               c. Excessive dirt and debris around hose.
               d. System fluid.
               e. Level, type, contamination, condition, and air entrapment or blockage.

      If any of these conditions are found, appropriate action shall be taken.
      12.5.4     Functional Tests

      Functional tests shall be conducted to determine if systems with hose are leak-free and operating
      properly. Such tests should be conducted in accordance with the manufacturers’
      recommendations.
      12.5.5     Composite Hose – Special Cleaning Instructions After Use

      It is important that any media be thoroughly drained prior to cleaning to avoid chemical or
      exothermic reactions when the hose is returned into service.

      Typically, composite hose assemblies are cleaned by flushing thoroughly with clean water. Other
      media which can be used, depending on the media that has been passing through the hose,
      include hot water, sea water, detergents and common solvents at ambient temperature. If sea
      water is used, the hose must be well drained after cleaning to minimize corrosion.

      Due to the inherent nature of the hose internally, any form of mechanical method of cleaning such
      as pigging should not be used under any circumstances.

      Also, due to the fact that the hose is constructed using plastics which tend to weaken at elevated
      temperatures, care must be taken when cleaning with hot water so as not to exceed the maximum
      working temperature of the hose. If steam is to be used, contact the manufacturer for any
      recommended practices.

      Compressed air may be used but the hose must be open-ended.

      During any cleaning operation, the assembly must be electrically grounded to avoid build up of
      static charge.

>> continue to Appendix A
Appendix A Pressure Conversion Chart
    psi         Atms       inches    inches        mm      mbar     bar          Pa      kPa       MPa
                             H20       Hg          Hg                          (N/m^2)
                                                  (Torr)
          1     0.0681      27.71      2.036 51.715        68.95    0.0689        6895   6.895      0.0069
     14.7              1    407.2      29.92        760    1013      1.013     101,325   101.3      0.1013
   0.0361     0.00246           1     0.0735      1.866    2.488   0.00249       248.8   0.249     0.00025
   0.4912     0.03342       13.61             1    25.4    33.86    0.0339        3386   3.386     0.00339
  0.01934 0.001316          0.536     0.0394           1   1.333 0.001333        133.3 0.1333 0.000133
   0.0145 0.000987         0.4012     0.0295       0.75       1      0.001         100     0.1      0.0001
   14.504        0.987      401.9      29.53        750    1000            1   100,000    100          0.1
0.000145      0.00001 0.00402 0.000295 0.0075               0.01   0.00001           1   0.001 0.000001
  0.14504     0.00987       401.9      0.295       7.50      10       0.01        1000         1     0.001
   145.04        9.869       4019      295.3       7500 10,000            10 1,000,000   1000            1

To use chart:

      1. Locate the column with the units you want to convert from.
      2. Move DOWN that column until you locate