500 SERIES HOSE
Step 1 Once the exact length of the hose has been ascertained - allowing for bends, obstructions, etc - wrap the hose tightly with one or two turns of masking tape. Mark the exact point at which the cut is to be made. Using a bench mounted shear, fine toothed cutting wheel, or fine toothed hacksaw cut through the hose cleanly and squarely. Remove any loose strands of wire and loose rubber liner.
Step 2 Remove the masking tape and place the collar onto the hose (you may need to "screw" it on). Ensure that the hose butts up against the internal shoulder of the collar, and then pull the hose back until there is a gap of 1/16" - 1/8" (1.6mm - 3.2mm) between the end of the hose and the shoulder. Mark the outside of the hose with a felt tip pen or a turn of masking tape.
Step 3 Lubricate the inside of the hose, collar and fitting with a light engine oil. Place the fitting in a vice (using soft jaws or a vice with surface ground jaws). Push the hose onto the nipple of the fitting (this may require some force) and begin screwing the collar onto the fitting by hand. Ensure that the fitting is not cross threaded and there are no pieces of steel braid getting caught in the threads.
Step 4 With the fitting held in the vice, push the hose onto the fitting with one hand and, with the other hand screw the collar down using a suitable spanner (in fact a good adjustable spanner with deep jaws is ideal). Continue tightening until the collar is within 1/16" (1.5mm) of the fitting.
Step 5 Check the mark you were advised to make in step 2 of these instructions. During assembly there is often a tendency for the hose to back out of the fitting. If this has happened a gap will be apparent between the hose and the mark. If this gap is more than 1/16" you must re-assemble the hose.
Step 6 Clean off any excess oil used in step 3, and test the assembly before installation.
*NOTE - It is a good idea to pressure test all assemblies before use. EXACT can supply, or advise on construction of, a test rig for this purpose. Please ensure that there is no foreign matter inside the hose. Blow out with an air line (dry air) before use.