When using the poly braided ultra pro hose begin by tightly wrapping the braid with high
quality ptfe
tape, better known as plumbers tape, at the location of the desired cut.
Use a utility knife with a new razor blade to ensure sharpness and a clean cut.
Never use a hose cutter or
saw to cut poly braided ultra pro hose.
Start by puncturing the hose with the blade near the top or 12 o clock position.
Once you have
punctured the hose, slowly rotate the hose while firmly holding the blade in the 9 o
clock position.
Cut approximately 90 % of the way around the hose leaving a small portion of the inner
hose and outer
braid uncut.
Finish the cut with a sharp pair of scissors.
If you are installing stainless steel ultra pro hose start by wrapping the hose at the
desired cut location
with high quality masking tape or duct tape.
Do not wrap the duct tape more than 1 1/2 to 2 times
around the hose braid.
Anymore than this can cause difficulty when installing the collars.
Only use Earls’ professional hose cutting machine, part# D100ERL, or a band saw to
cut stainless braided
Ultra pro hose.
Never use a hacksaw, cutoff wheel or shears to cut ultra pro hose , doing so can damage
the liner of the hose causing leaks and/or pressure failure.
Once your cut is complete install the correct crimp collar over the tape and onto the hose.
Be sure to
position the grooved end of the collar so that it faces toward the fitting you are crimping.
When installing the collar on a stainless steel hose you can use one of 2 methods.
Method one is the same as the
poly braid installation.
Slide the collar over the tape left over from the initial cutting process.
Method number 2 is to remove the tape and lightly secure the collar in a vice.
Be sure you have the
grooved end of the collar facing the correct way.
Now slowly twist the hose as you work the braid into
the collar with the assistance of a pair of pliers.
Continue twisting until the hose is completely through the collar.
Next you will need to expand the hose.
This step is only necessary for -10 and larger Ultra Pro hose.
This expansion process allows for easier installation and a more consistent higher quality crimp..
This step is not required when using -6 or -8 ultra pro hose.
The -6 and -8 dies included with the
expander tool, part # 600ERL, are for use with other Earl’s product lines.
Install the appropriate expander die to your earls expander tool.
Place the hose onto the expander
making sure you slide the crimp collar back 2-3” away from the end of the hose that
is going to be
expanded. Never attempt
to expand the hose with a crimp collar in place. Pull the lever 90 degrees from the
resting
position to expand.
Return the lever to the resting position and rotate the hose slightly in the die and
expand a second time.
There are 3 methods you can use to secure a fitting in the vice depending on the which
one you are
installing.
When installing a straight fitting you can secure a weld in bung in the vice that corresponds
with your hose end.
Simply twist your fitting onto the weld in bung and push the hose on.
One method of securing tube fittings is to lightly tighten the tube section of the
fitting directly in
the vice.
Be careful not to crush the tube by over tightening your vice.
Keep the jaws of the vice from
contacting the brazed joint area where the tube meets the fitting.
Earls vice jaws, part # 1044ERL AND 1004ERL, work best to secure all types of fittings
and are easy to
use.
Simply insert your fitting in to the Earl’s jaws and tighten.
Now your ready to install your hose onto the secured fitting.
Apply a couple of drops of Earl's assembly lubricant to any thread surfaces and the nipple to aid in assembly and prevent galling
When installing the hose onto the fitting be sure it is pushed up until it butts against
the step of the
fitting.
Carefully slide the crimp collar towards the fitting making sure that no braid material
is sticking
past the collar when it is full installed.
Ensure that the braid is not bunched or twisted before
proceeding.
If necissary slide the collar back away from the fitting, adjust your braid and re install the
collar.
Crimp all Ultra Pro hose and fittings using the Earls D100 crimp machine.
Follow the setup instructions
included with your machine before performing any crimping.
It may be necessary to adjust the factory
settings on your machine due to variations in the manufacturing and assembly process.
Using the crimping machine setting chart, determine the correct setting and set the
micro adjustable
stop accordingly.
Ensure that the dies you are using are correct for the hose you are crimping.
If you are
using anodized collars applying a light film of earls assembly oil to the exterior of the
collar will help
prevent galling and discoloration of your collar.
Insert the hose and fitting assembly into the crimper making sure that the top of the
collar is flush with
the top of the die.
If the collar is too deep in the die the crimper can crush the fitting destroying it.
If it
is too shallow the collar will not get a sufficient crimp and possibly leak.
For Ultra pro -6 crimped fittings you must double crimp the collar.
After the preliminary crimp is
complete, rotate the collar in the machine so that the newly formed ridges are now centered
on the flat
spots of the die and re-crimp using the same settings.
Remove the hose assembly from the machine, now using calipers measure the outside diameter
of the
crimped collar at the low points , never on the ridges formed by the die.
Refer back to the crimping
machine setting chart for the correct final crimp O.D. range and compare.
If the o.d. measurement is
larger than the spec you will have to reset the micro adjustable stop accordingly and
re crimp.
If the o.d.
measurement is more than 1/15000ths of an inch smaller than the spec, the assembly has been over crimped and should be discarded.
Every Ultra Pro hose assembly must be tested using our Earls pressure test kit part # D016
before
installation due to variances that occur during the manufacturing and assembly process.
The assembly process is now complete and ready to install.