How to optimise hydraulic hose assemblies

9 tips for installing and maintaining hydraulic hose assemblies

1. Arrange hoses so they aren’t touching other parts

Hoses should be installed in such a way that they aren’t rubbing against other parts of the machine, especially moving parts and corners that might cut into the hose over time. Clamps are often required to keep hoses in position. Make sure the clamps are the right size. If a clamp is too big, the hose will rub inside the clamp, causing the exact problem you’re trying to avoid: abrasion.

2. Aim for a neat and tidy appearance

The appearance of the hose assembly is important. It shouldn’t look like a jumble of hoses put together haphazardly. Only use the length of hose that’s needed. Extra-long hoses take up unnecessary space, risk causing abrasion by being in contact with other parts of the machine and can affect pressure and performance. Use 45° and/or 90° angle adapters, clamps and other fittings to route hoses efficiently.

3. Pay attention to the bend radius

The bend radius is a measurement of the inside curvature of a bend in the hose. To prevent flow being restricted as fluid passes through these bends, the bend radius should be kept as large as possible. If it’s too small, it can cause the hose to collapse. Check the manufacturer’s specifications for the minimum bend radius for specific hose types.

4. Keep hoses away from heat

Powerful machinery generates a lot of heat. High temperatures can damage hoses and shorten their lifespans. Hose assemblies should be installed in a way that keeps the hoses away from hot parts of the machine. If that’s not possible, insulate the hoses with protective sleeving to keep them in good condition for as long as possible.

5. A little slack is necessary for straight hoses

When hoses are installed in a straight line, without any bends, they shouldn’t be stretched tightly between the couplings on either end. Leave a small amount of slack. This allows the hose to cope with the pressure that’s applied when the hydraulic system is active. Without this slack, the hose could burst or break away from its couplings.

6. Allow enough length for moving parts

Hoses that are connected to moving parts need to be long enough to handle the full range of movement. If they’re too short, the machine parts they’re connected to won’t be able to move in the ways they need to.

7. Use hydraulic adapters instead of pipe fittings

Excessive use of threaded pipe joints can interfere with the integrity and function of the hose assembly. Keep things as simple as possible and use hydraulic adapters. They optimise the performance of the hydraulic system and offer better protection against corrosion.

8. Minimise hose strain

Elbows and angle adapters let you get around corners without creating sharp bends in the hose. This protects the hose assembly from unnecessary strain and creates a neater installation that’s easier to inspect and maintain.

9. Don’t let hoses get twisted

If pressure is applied to a twisted hose, it can lead to hose failure, loose connections and shortened hose lifespan. When bending hoses, keep them in the same plane. If this isn’t possible, install a clamp between bends, with enough hose length on each side to allow for pressure changes.