Danfoss FT1261 Hose Proof Tester Instruction Manual

: August 22, 2024
: Danfoss

Danfoss FT1261 Hose Proof Tester

INSTRUCTION MANUAL

The Danfoss FT1261 proof tester is a machine designed for hydrostatically testing Danfoss hose assemblies up to 2 inch ID, 6 wire spiral in 50-foot coil lengths. It uses tap water to prefill the assembly and an air-driven hydraulic pump to generate test pressures.

Safety Instructions

WARNING

Danfoss ﬁtting tolerances are engineered to match Danfoss hose tolerances. The use of Danfoss ﬁttings on hose supplied by other manufacturers and/or the use of Danfoss hose with ﬁttings supplied by other manufacturers may result in the production of unreliable and unsafe hose assemblies and is neither recommended nor authorized by Danfoss:

Failure to follow Danfoss process and product instructions and lim-itations could lead to premature hose assembly failures resulting in property damage, serious injury or death.

The user must exercise extreme care when operating any Danfoss assembly equipment with powered moving components. Safety glasses must be worn at all times when using any Danfoss assembly equipment.

Read and understand the owners and operators manual before at-tempting to operate any equipment.

Danfoss hereby disclaims any obligation or liability (including incidental and consequential damages) arising from breach of contract, warranty, or tort (under negligence or strict liability, theories) should

Danfoss hose, ﬁttings or assembly equipment be used with the hose, ﬁttings or assembly equipment supplied by another manufacturer or in the event that product instructions for each speciﬁed hose assembly are not followed.

CAUTION

All hoses must be dried after testing! Tested hose assemblies can be dried by blowing out with dry shop air. Any water remaining in the tested hose assembly following proof test operation may cause rust on the inside of ﬁttings or may not be compatible with the system using the hose assembly.

Introduction

The Danfoss FT1261 proof tester is especially designed to provide a practical, self contained, easy to use machine to hydrostatically test Danfoss hose assemblies.
This machine will test assemblies up to 2 inch ID, 6 wire spiral in 50 foot coil lengths.
It is designed to utilize tap water to preﬁll the assembly in conjunction with an air driven hydraulic pump to produce the desired test pressures.

INSTALLATION

Install the machine on a solid ﬂoor capable of holding 1000 pounds.

SPECIFICATIONS

Dimensions: 7’2” wide x 57” deep x 4’6” high
Weight: 800 lbs.
Test Fluid: Tap Water
Air Requirements: 70-100 psi clean dry shop air
Tooling: Adapters

INSTALLATION

Install the machine on a solid floor capable of holding 1000 pounds.

General Information

POWER UNIT

The power unit on the FT1261 hose proof tester is a compact, eco-nomical, air driven hydraulic pump. The pump operates on the simple principle of pressure magniﬁcation through the use of diﬀerential areas in which a relatively large air-operated piston drives a smaller piston which provides ﬂuid ﬂow at high pressures.

An air regulator provides the means of adjusting hydrostatic test pres-sures.

CABINET

The cabinet construction of the FT1261 proof tester is designed to withstand a hose assembly failure.

As an additional feature, the cabinet is a self-contained reservoir capa-ble of holding approximately 10 gallons of water. The cabinet may be drained into a bucket or ﬂoor drain by opening the shut-oﬀ valve at the back of the cabinet.

PREOPERATION PROCEDURES

Uncrate the FT1261 proof tester and verify that you have received the following components:

1 FT1261 Owner’s Manual
1 FC254-08 Hose Assembly
1 2021-6-8S Adapter (-6 external pipe, -8 male JIG)
1 2022-12-8S Adapter (-12 internal pipe, -8 male JIC)

Remove the clear plastic air lubricator bowl (adjacent to the air pressure regulator on the pump assembly) and ﬁll it three quarters full with SAE 30 nondetergent oil.
Connect a tap water supply line to the 1 /2” pipe port of the water shutoﬀ valve. (FT1261-3-33) located on the water pumping unit. Connect a compressed air supply line to the male air coupling attached to the air pressure regulator on the water pumping unit.

NOTE : For optimum performance, the air compressor should be capa-ble of supplying 100 psi at a rate of 20 cubic feet per minute.

Tooling

The FC254-08 hose assembly supplied with the tester is used to connect the test hose assembly to the pressure port of the tester. The end connection on the FC254-08 hose assembly is a -8 size JIC swivel ﬁtting. To connect the test assembly to the -8 JIG swivel ﬁtting will require the use of standard adapters or special proof test tooling shown in the chart on the following pages. In addition to the standard

Danfoss adapters listed, the 2021-6-8S or 2022-12-8S adapters supplied with the tester may be required to complete the connection.

Adapters listed below are special design, quick installation seal adapters or plates exclusive to the internal skive ﬁtting assemblies.

*Proof Test Tooling	Fitting Dash Size/Style
FT1236-l-l	12 Code 61 Split Flange
FT1236-1-2	16 Code 61 Split Flange
FT1236-l-3	20 Code 61 Split Flange
FT1236-l-4	24 Code 61 Split Flange
FT1236-1-5	32 Code 61Split Flange
FT1236-l-6	12 Code 62 Split Flange
FT1236-1-7	16 Code 62 Split Flange
FT1236-l-8	20 Code 62 Split Flange
FT1236-1-9	24 Code 62 Split Flange
FTl 236-1-10	32 Code 62 Split Flange
FTl 236-1-11	12 37° JIC Swivel
FT1236-1-12	16 37° JIC Swivel
FTl 236-1-13	20 37° JIC Swivel
FT1236-1-14	24 37° JIC Swivel
FT1236-l-15	32 37° JIC Swivel
FT1236-1-16	12 Male NPTF
FT1236-l-17	16 Male NPTF
FT1236-1-18	20 Male NPTF
FT1236-l-19	24 Male NPTF
FT1236-1-20	32 Male NPTF
FTl 236-1-21	12 JIC Male Flare
FT1236-1-22	16 JIC Male Flare
FTl 236-1-23	20 JIC Male Flare
FT1236-l-24	24 JIC Male Flare
FT1236-1-25	32 JIC Male Flare

*Two adapters are required to test one hose assembly.
These adapter kits are complete with all adapters and split ﬂange clamps, where applicable, to connect the hose assembly to be tested to the umbilical hose assembly of the tester.

Adapter Selection Chart

Adapters listed below are standard Danfoss adapters and may be used with Danfoss hose assemblies including internal skive where applicable.

Hose Fitting Style Fitting Adapter Pressure Port Adapter Plug or Cap and Size Part Number Part Number Part Number

SAE 37° (JIC) Swivel
-4| 2027-8-4S| | 900599-4
-5| 2021-6-5S| 2022-6-8S| 900599-5
-6| 2027-8-6S| | 900599-6
-8| 2027-8-8S| | 900599-8
-10| 2027-10-8S| | 900599-10
-12| 2027-12-8S| | 900599-12
-16| 2027-16-12S| 2022-12-8S| 900599-16
-20| 2021-16-20S| 2040-12-15S & 2022-12-3S| 900599-20
-24| 2021-16-24S| 2040-12-15S & 2022-12-3S| 900599-24
-32| 2021-16-32S| 2040-12-15S & 2023-12-3S| 900599-32
SAE 45° Swivel
-4| 2000-5-4B| 2022-5-8S| 900599-4
-5| 2000-6-5B| 2022-6-8S| 900599-5
-6| 2000-6-6B| 2022-6-8S| 2001-8-6B & 2082-8S
-8| 2000-12-8B| 2022-12-8S| 900599-8
-10| 2000-12-10B| 2022-12-8S| 900599-10
-12| 2000-12-12B| 2022-12-8S| 2001-8-12B & 2082-8S
Male Pipe
-4| 2081-8-2S| 2022-8-8S| 2046-2-2S & 2082-2S
-5| 2022-4-8S| | 2046-4-4S & 2082-4S
-6| 2022-6-8S| | 2046-6-6S & 2082-6S
-8| 2022-8-8S| | 204.6-8-8S & 2082-8S
-12| 2022-12-3S| | 2046-12-12S & 2082-12S
-16| 2040-12-16S| 2022-12-8S| 2046-16-16S & 2082-16S
-20| 2040-15-20S| 2040-12-16S & 2022-12-8| 2046-20-20S & 2082-20S
-24| 2040-20-24S| 2040-12-16S & 2040-16-20S &
2040-12-8S| 2046-24-24S & 2082-24S
-32| 2040-24-32S| 2040-16-20S & 2040-20-24S &
2022-12-8S| 2046-32-32S & 2082-32S
Adapters are available for other hose fittings styles. Contact Danfoss
ORS
Fitting Adapter Pressure Port Plug or Cap
| | |
-4| FF2031T0408S| 2022-8-8S| FF9767-04S
-6| FF2031T0608S| 2022-8-8S| FF9767-06S
-8| FF2031T0808S| 2022-8-8S| FF9767-08S
-10| FF2031T1008S| 2022-8-8S| FF9767-10S
-12| FF2031T1208S| 2022-8-8S| FF9767-12S
-16| FF2031T1612S| 2022-12-8S| FF9767-16S
-20| FF2031T2016S| 2040-12-16S & 2022-12-8S| FF9767-20S
-24| FF2031T2424S| 2040-20-40S, 2040-16-20S,
2040-12-16S & 2022-12-8S| FF9767-24S

Operating Instructions

PREFILLING

1. Close the air shut-oﬀ valve and cabinet drain valve. Adjust the air regulator to zero pressure by turning the valve handle on top of the regula- tor in a counterclockwise direction until no turning resistance is felt.
2. Open the cabinet of the tester and place the hose assembly to be tested on the ﬂoor of the tester. The umbilical hose assembly can be removed if necessary to provide unobstructed loading of hose assemblies on skids.
3. Connect the umbilical hose assembly to the hose assembly to be tested using the appropriate adapter combination or proof test tooling listed on pages 7-10 of this manual.
4. Reattach the coupling of the umbilical hose to the pumping unit if necessary.
5. Ensure that the high pressure dump valve is completely closed.
6. Open the water shut-oﬀ valve and ﬁll the assembly allowing the tap water to force the air from the hose assembly through the non-capped end.
7. When the sample is completely ﬁlled, shut oﬀ the water and cap or plug the open end of the hose assembly.

PRESSURIZING

1. Close the cabinet and insert the “T” pin to connect both doors together. DO NOT ATTEMPT TO PRESURE TEST THE HOSE ASSEMBLY WITH THE CABINET DOORS OPEN OR WITH THE PIN NOT SECURE.
2. Reopen the water shut-oﬀ valve to supply ample water to the pumping unit during pressurization.
3. Open the air shut-oﬀ.
4. While monitoring the test pressure gauge, adjust the air regulator valve clockwise allowing the pumping action to begin. Steadily increase air pressure until the test pressure is approaching, then back oﬀ the air pressure until the pumping slows greatly. When the test pressure is reached, back oﬀ the air pressure just enough to stop the pumping action.
5. The test assembly should remain pressurized at the proof test pressure for one minute. During this time the assembly should be observed through the transparent Lexan lid. Pinhole leaks or seeping ﬁttings may not be immediately apparent, so careful observation is important.
6. Once the test pressure has been obtained, tighten the locknut on the regulator. Subsequent assemblies can be pressurized to the test pres-sure by merely opening the air shut-oﬀ valve on the pump. The air regulator will only require readjusting when a new test pressure is required.

PRESSURIZING

(Test pressures under 2000 psi)

1. Close the cabinet and insert the “T” pin to connect both doors together. DO NOT ATTEMPT TO PRESSURE TEST THE HOSE ASSEMBLY WITH THE CABINET DOORS OPEN OR WITH THE PIN NOT SECURE.
2. Open the water shut-oﬀ valve to amply supply water to the pumping unit during pressurization.
3. With the air shut-oﬀ valve closed, adjust the air pressure regulator to provide an inlet pressure of 15-20 psi.
4. Carefully open the air shut-oﬀ valve very slightly while observing the test pressure gauge. The pressure will rise slowly. When the desired test pressure is indicated on the gauge, close the air shut-oﬀ valve. The pressure will remain constant in the test assembly for the duration of the test provided there are no leaks in the system.
5. Hold the test pressure for approximately one minute while observing the hose assembly through the transparent Lexan lid for pinhole leaks or seeping ﬁttings.

TEST PRESSURE RELEASE

1. Close the air shut-oﬀ valve on the water pump.
2. Close the water shut-oﬀ valve located on the water pump.
3. Open the high-pressure dump valve to release the water pressure from within the hose assembly.

REMOVING THE ASSEMBLY

1. WAIT UNTIL ALL PRESSURE IS REMOVED FROM THE SAMPLE! This will be indicated by zero pressure indicated on the pressure gauge and no water draining from the pressure discharge port in the tester.
2. Open the cabinet and remove the umbilical hose and test tooling from the tested assembly.
3. Drain the remaining water from the tested assembly. It is recommended that all hose assemblies be blown dry with compressed air. Any moisture left in the assembly may cause ﬁtting corrosion or may be incompatible with the ﬂuid system on which the hose assembly will be used.

Maintenance

Normal maintenance requires periodic reﬁlling of the lubricator on the water pump and cleaning the see-through lid with clean, soapy water. NOTE: Do not use petroleum or chemical solvents on the see-through lid. Use only mild detergent.

Troubleshooting

PROBLEM	SOLUTION
Desired pressure not obtained while power unit is operating.	1. Check all

connections of tooling and hose assemblies for leaks. See that high pressure dump valve is closed.
2. Open the water shut-oﬀ valve to supply ample water to the power unit.
3. Too much air in test sample.
Power unit not operating when adjusting the regulator.| 1. Supply air not connected or air shut-oﬀ valve not open.
Excess water not draining from the cabinet with the shut-oﬀ valve open.| 1. Check for obstruction in the valve or bottom of the cabinet.

Proof Tester

FT1261 Parts List

Detail Number	Part Number	Description	Number Required
1	FT1261-3-1	Tank	1
2	FT1261-3-2	Sheave	2
3	FT1261-3-3	5/32 Dia. x 4.00 Aircraft Cable	2
4	FT1261-3-4	Alumetal Cable Clips	4
5	FT1261-3-5	5/16-18 x .63 Hex Head Bolt	14
6	FT1261-3-6	5/16-18 x .88 Flat Hd Soc Cap Screw	13
7	FT1261-3-7	5/16-18 Hex Nut	29
8	FT1261-3-8	5/16 Lock Washer	29
9	FT1261-3-9	Door	1
10	FT1261-3-10	Cable	1
11	FT1261-3-11	Latch .62 x 2.25 x 4.25	1
12	FT1261-3-12	5/16-18 x .88 Hex Head Bolt	2
13	FT1261-3-13	Deck	1
14	FT1261-3-14	Stiffener	2
15	FT1261-3-15	Front Door	1
16	FT1261-3-16	Rubber Bumper	2
17	FT1261-3-17	5/8-11 x 1.00 Soc Hd Cap Screw	2
18	FT1261-3-18	Counterbalance	3
19	FT1261-3-19	5/16 Flat Washer	3
20	FT1261-3-20	1 /2-13 x 1.00 Soc Hd Cap Screw	2
21	FT1261-3-21	Sheave Support L.H.	1
22	FT1261-3-22	Sheave Support R.H.	1
23	FT1261-3-23	3/8-16 x 1.00 Soc Hd Cap Screw	6
24	FT1261-3-24	Track	2
25	FT1261-3-25	1/4-20 x .75 Flat Hd Soc Cap Screw 1/4	12
26	FT1261-3-26	Lock Washer	16
27	FT1261-3-27	1/4-29 Hex Nut	15
28	FT1261-3-28	Slide	2
29	2083-8-8S	Pipe Nipple Assembly	1
30	FT1264	Power Unit	1
31	2024T-4-4S	Danfoss Elbow	1
32	FT1261-3-32	Hydraulic Tubing	1
33	FT1261-3-33	Valve	2
34	2083-8-6S	Danfoss Pipe Nipple	1
35	2083-6-4S	Danfoss Pipe Nipple	1
36	FD69-1001-06-08	Danfoss Coupling Female Half	1
37	FD69-1002-06-08	Danfoss Coupling Male Half	1
38	FT1261-3-38	Spacer	4
39	FT1261-3-39	5/16-18 x 1.25 Hex Head Bolt	4
Detail Number	Part Number	Description	Number Required
40	FT1261-3-40	T-Pin	1
41	FT1261-3-41	1 /4-20 Eye Bolt	2
42	FF96505-4	Danfoss Ferrule	1
43	FC2875-4	Danfoss Nut	1
44	FT1261-3-43	Cover Canvas	1
45	FT1261-3-44	Crate	1
46	FA7082HHH0360	Hose Assembly	1
47	2021-08-08	Danfoss Adapter	1
48	FT1261-3-48	3/8-16 x .50 Hex Head Screw	3
49	FT1261-3-49	3/8-16 Hex Nut	3
50	SC2307	ID Tag	1
51	FT1065	Name Tag	1
52	FD41-1014-04-04	Danfoss Male Air Coupling Nipple	1

FT1261 Hose Proof Test Stand

The FT1261 hose proof test stand is designed for easy and economical hydrostatic testing of hydraulic hose assemblies.
Proof testing at twice the recommended working pressure is an easy nondestructive way to test hose assembly reliability before it leaves the shop.
Practical and self-contained, the FT1261 machine has an air driven power unit that can develop a maximum of 22,000 psi hydraulic pres-sure using 100psi clean, dry shop air. The power unit (FT1264) can be ordered separately.

The FT1261 hose proof test stand will proof test assemblies up to 2 inches inside diameter, 6-spiral wire in 50 foot coil lengths.

Two types of tooling are available for proof testing with the FT1261 machine. Standard Danfoss adap ters may be used with any Danfoss hose assembly. Special proof test adapters with O-Ring seals are available for internal skive crimp hose assemblies. Proof test adapters must be ordered separately

FEATURES

Designed to use tap water, eliminating the need for a special test ﬂuid.
Compact power unit is air driven.
Tests assemblies up to 2 inches inside diameter, 6-spiral wire in 50 foot coil lengths.
Cabinet construction withstands hose assembly failures and func-tions as a 10 gallon reservoir.
Air regulator and gauge provide easy pressure adjustment and monitoring.
Tough transparent Lexan lid resists impact resulting from assembly failure.

SPECIFICATIONS

Dimensions: 8 feet wide × 7 feet deep × 4 ½ feet high
Weight: 800 pounds
Test Fluid: Tap water
Pump: Air driven hydraulic
Air Requirements: 70-100psi clean, dry shop air
Pressure Capabilities Variable: to 15,250 psi with 70 psi clean, dry shop air, to 22,000 psi maximum with 100 psi clean, dry shop air
Tooling: Standard adapters or special; O-Ring seaI proof test adapters

POWER UNIT

The power unit of the FT1261 tester is a compact, economical air driven hydraulic pump. It will provide suﬃcient hydraulic pressure to proof test any Danfoss hose assembly.
The pump operates on a simple principle of pressure magniﬁcation through use of diﬀerential areas in which a relatively large air operated piston drives a smaller piston to provide ﬂuid ﬂow at high pressures.

FT1261 Standard Adapter Selection Chart

Hose Fitting Style
and Size| Fitting Adapter
Part Number| Pressure Port Adapter
Part Number| Plug orCap
Part Number
---|---|---|---
SAE 37° (JIC) Swivel
-4| 2027-8-4S| | 900599-4
-5| 2021-6-5S| 2081-12-6S| 900599-5
-6| 2027-8-6S| | 900599-6
-8| 2027-8-8S| | 900599-8
-10| 2027-10-8S| | 900599-10
-12| 2027-8-12S| | 900599-12
-16| 2021-12-16S| | 900599-16
-20| 2021-16-20S| 2040-12-16S| 900599-20
-24| 2021-16-24S| 2040-12-16S| 900599-24
-32| 2021-16-32S| 2040-12-16S| 900599-32
SAE 45° Swivel| | |
-4| 2000-6-4B| 2081-12-6S| 900599-4
-5| 2000-6-5B| 2081-12-6S| 900599-5
-6| 2000-6-6B| 2081-12-6S| 2001-6-6B&
| | 2082-6S
-8| 2000-12-8B| 900599-8
-10| 2000-12-1OB| 900599-10

Hose Fitting Style
and Size| Fitting Adapter
Part Number| Pressure Port Adapter
Part Number| Plug orCap
Part Number
---|---|---|---
Male Pipe| | |
-2| 2081-8-2S| 2081–12-8S          2046-2-2S &
2082-2S
-4| 2081-8-4S| 2081–12-8S          2046-4-4S &
2082-4S
-6| 2081-8-6S| 2081-12-8S           2046-6-6S &
2082-6S
-8| 2081-12-8S| 2046-8-8S &
2082-8S
-12| | 2046-12-12S &
2082-12S
-16| 2040-12-16S| 2046-16-16S&
2082-16S
-20| 2040-16-20S| 2040-12-16S       2046-20-20S &
2082-20S

FT1261 Special O-Ring Seal Proof Test Adapters for Internal Skive

Fittings Only

Proof Test Tooling*	Fitting Dash Size/Style
FT1236-l-l	-12 Code 61 Split Flange
FT1236-l-2	-16 Code 61 Split Flange
FT1236-l-3	-20 Code 61Split Flange
FT1236-1-4	-24 Code 61 Split Flange
FT1236-1-5	-32 Code 61Split Flange
FT1236-1-6	-12 Code 61 Split Flange
FT1236-1-7	-16 Code 61Split Flange
FT1236-1-8	-20 Code 61 Split Flange
FT1236-1-9	-24 Code 61 Split Flange
FT1236-1-10	-32 Code 61 Split Flange
FT1236-1-11	-12 37° JICSwivel
FT1236-1-12	-16 37° JIC Swivel
FT1236-1-13	-20 3T JIC Swivel
FT1236-l-14	-24 3T JIC Swivel

Proof Test Tooling*	Fitting Dash Size/Style
FT1236-1-15	-32 37° JIC Swivel
FT1236-l-16	-12 Male NPTF
FT1236-l-17	-16 Male NPTF
FT1236-l-18	-20 Male NPTF
FT1236-l-19	-24 Male NPTF
FT1236-l-20	-32 Male NPTF
FT1236-1-21	-12 JIC Male Flare
FT1236-l-22	-16 JIC Male Flare
FT1236-1-23	-20 JIC Male Flare
FTl 236-1-24	-24 JIC Male Flare
FTl 236-1-25	-32 JIC Male Flare

*Two adapters are required per hose assembly to be tested.

CAUTION : High pressure water can be dangerous. Read all Operat-ing and Safety Instructions in Owner’s Manual before attempting to operate.

About Danfoss Power Solutions FC

Danfoss hoses, ﬁttings, and tooling provide the ultimate ﬂuid conveyance solutions for a variety of equipment and applications around the world. We proudly engineer to support a sustainable future for tomorrow.

To learn more please visit: http://www.danfoss.com/en/about-danfoss/our- businesses/power-solutions

Danfoss Power Solutions

14615 Lone Oak Road
Eden Prairie, MN 55344, USA
Phone: 952-937-9800

Danfoss Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515-239-6000

Danfoss Power Solutions GmbH & Co.OHG
Krokamp 35
D-2439 Neumünster, Germany
Phone: +49 4321 871 0

Danfoss Power Solutions ApS
Nordborgveg 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222

Danfoss Power Solutions Trade (Shanghai) Co. Ltd.
Building #22, No 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 3418 5200w

Danfoss can accept no responsibility for possible errors in catalogs, brochures, and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed. All trademarks in this material are the property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

Specifications:

Dimensions: 7’2″ wide x 57″ deep x 4’6″ high
Weight: 800 lbs.
Test Fluid: Tap Water
Air Requirements: 70-100 psi clean dry shop air
Tooling: Adapters

FAQ:

Q: Can I use Danfoss fittings with hoses from other manufacturers?

A: Danfoss recommends using Danfoss fittings with Danfoss hoses to ensure reliability and safety. Using fittings from other manufacturers may result in unsafe assemblies.

Q: How should I dry hoses after testing?

A: Tested hose assemblies should be dried by blowing out with dry shop air to prevent rust or compatibility issues with the system.

Q: What should I do before operating the equipment?

A: Before use, read and understand the owner’s and operator’s manual for the equipment. Wear safety glasses when operating any Danfoss assembly equipment with powered moving components.