Step 4 of 8 · Insert

How to insert fittings into hydraulic hose

Mark the insertion depth, push each fitting fully home, and set the orientation of elbow fittings before the hose goes into the crimper.

  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

A fitting that is not pushed fully onto the hose is the most common cause of a hose blowing off its fitting. The crimp looks normal from outside, but the shell is gripping less hose than it was designed for.

The safeguard is a depth mark. Before inserting, mark the hose at the insertion depth for that fitting. After inserting, the mark must sit at the edge of the shell. The mark also shows afterwards whether the hose moved during crimping.

How to do it

  1. Find the insertion depth for the fitting, or lay the fitting beside the hose with the hose end at the shell shoulder position and mark where the shell ends.
  2. Mark the depth clearly around the hose.
  3. Lubricate the insert only if the fitting manufacturer allows it, and only with the lubricant they specify.
  4. Push the fitting onto the hose until the hose bottoms against the shoulder and the mark meets the edge of the shell. Use an insertion tool on large sizes.
  5. For two-piece fittings, fit the shell (ferrule) first, then the insert.
  6. With two elbow fittings, set the displacement angle between them now, using the angle recorded from the old hose or the drawing.

Checks before moving on

  • The depth mark is at the edge of the shell on both ends.
  • The inner tube was not pushed back, cut or rolled by the insert.
  • The angle between elbow fittings matches the recorded value.
  • Overall length is checked once more before crimping.

Common mistakes

  • Crimping without a depth mark, so partial insertion goes unnoticed.
  • Using oil or grease that the manufacturer does not approve, which can let the hose creep under pressure.
  • Setting the elbow angle after the first end is crimped and twisting the hose to make it fit. A twisted hose fails early.

Equipment and consumables

  • Marker
  • Insertion depth gauge or the manufacturer depth table
  • Insertion tool or bench vice with soft jaws for large sizes
  • Approved lubricant, if specified

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 far should a fitting go into a hydraulic hose?

Until the hose bottoms against the shoulder inside the fitting. The exact insertion depth is given by the fitting manufacturer for each series and size; mark it on the hose before inserting.

Why mark the insertion depth?

The mark proves the hose is fully inserted before crimping and shows afterwards if it slipped. Partial insertion is a leading cause of hose blow-off and cannot be seen once the shell is crimped.

How do I set the angle between two elbow fittings?

Record the displacement angle from the old hose or drawing, insert both fittings, rotate them to that angle while the hose lies relaxed and untwisted, then crimp. Do not twist the hose to correct the angle afterwards.

Useful at this step

Scroll to Top