Step 2 of 8 · Cut

How to cut hydraulic hose

Cut the hose to cut length, not assembly length, with a square end and as little heat and debris as possible.

  1. 1 Select
  2. 2 Cut
  3. 3 Skive
  4. 4 Insert
  5. 5 Crimp
  6. 6 Clean
  7. 7 Test
  8. 8 Inspect

What this step does

The hose is cut shorter than the finished assembly because each fitting adds length. Hose cut length = finished assembly length − the cut-off allowance of each fitting. The allowance is published for each fitting in the manufacturer catalogue.

The cut must be square to the hose axis. An angled cut leaves part of the hose short of the fitting shoulder, which reduces the grip of the crimp and can cause a leak or a blow-off.

How to do it

  1. Calculate the cut length from the finished length and the two fitting allowances.
  2. Measure and mark the hose. Lay it straight without stretching it.
  3. Choose the blade for the hose construction. Wire-braid and spiral-wire hoses are cut with an abrasive or toothed cut-off blade on a hose saw; textile-braid and thermoplastic hoses can be cut with a sharp hose knife or shear.
  4. Clamp or hold the hose against the saw guide so it meets the blade at a right angle, then cut in one steady pass.
  5. Let the blade do the work. Forcing the cut overheats the rubber, melts it onto the wire and leaves burnt residue inside the tube.
  6. Deburr loose wire ends and blow or brush away cutting dust from the end before the next step.

Checks before moving on

  • The cut is square and the wire reinforcement is not frayed or flared.
  • The measured length matches the calculated cut length.
  • The inner tube is not burnt, torn or glazed at the cut.
  • Loose rubber and metal particles have been removed from the bore.

Common mistakes

  • Cutting to the finished assembly length, which makes the assembly too long by both fitting allowances.
  • Using a worn or wrong blade that tears the cover and flares the wire.
  • Skipping cleaning because the assembly will be cleaned later — cutting debris pressed under a fitting stays there.
  • Measuring a hose that is still coiled or under tension.

Equipment and consumables

  • Hose cut-off saw with a blade suited to the hose construction
  • Measuring bench or tape
  • Marker
  • Dust extraction, eye and hearing protection

Settings such as crimp diameter, skive length, insertion depth and test pressure are specific to the hose and fitting manufacturer. Use their current specification.

Frequently asked questions

How do I calculate hydraulic hose cut length?

Subtract the cut-off allowance of both fittings from the finished assembly length. For a 1,000 mm assembly with two fittings of 55 mm allowance each, the cut length is 890 mm. Use the allowance published for your exact fitting.

Can I cut hydraulic hose with a hacksaw or angle grinder?

It is possible in an emergency but not recommended. A hacksaw frays the wire and rarely cuts square; an angle grinder overheats the rubber and fills the bore with debris. A hose saw gives a square cut with controlled heat.

Why must the cut be square?

The fitting shell compresses the hose against the insert over a fixed length. If the end is angled, part of the hose does not reach the shoulder and that side has less grip, which can leak or pull out under pressure.

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