Eleven Tips for Hydraulic Hose Laying and Installation

When using hydraulic hoses, safety and performance are paramount considerations. Proper installation is crucial to ensuring productivity and preventing potential hazards in the working environment. Both a safe working environment and ideal performance depend on proper hydraulic hose routing. The following practical installation tips help ensure efficiency and prevent premature hose failure.

The routing of hose assemblies and their operating environment directly affect their service life. Proper hose assembly routing maximizes service life and ensures safe operation.

1. Allow for slack.

When connecting hoses in a straight line, sufficient slack must be ensured to accommodate length changes under pressure. Depending on the structure, hydraulic hoses can vary in length from -4% to 2%. When determining the hose length, ensure the hose assembly has sufficient slack to prevent tension on the hose during system component movement or vibration. If the hose assembly cannot bend sufficiently or accommodate length changes due to thermal expansion and contraction, the hose’s lifespan will be shortened. Under pressure, an excessively short hose may cause stress at the hose joint or detach from the joint, leading to premature failure of metal fittings or seals. At the same time, avoid leaving excessive slack to prevent the hose from being snagged by other equipment or rubbing against other components.

2. Do not exceed the minimum bending radius.

When installing hoses, avoid exceeding their minimum bending radius. Bending the hose beyond the recommended minimum bending radius applies excessive stress to the hose reinforcement layer (wire layer), causing larger gaps between the wires and severely reducing the hose’s pressure resistance. Exceeding the minimum bending radius may cause the hose to burst. The minimum bending radius for each type of hose can be found in the technical parameter list in its catalog.

3. Avoid twisting the hose

Twisting the hose during installation should be avoided, as this can cause misalignment of the reinforcing layer and reduce the hose’s pressure resistance. A simple way to identify twisting is to observe the “marking lines,” which are continuous information lines printed on the hose containing part numbers, pressure ratings, and other information. If the marking lines are twisted like a spiral, it indicates that the hose was twisted during installation, which may lead to premature hose failure.

4.Use non-straight hose fittings or transition fittings if necessary.

The general principle for hose installation is that if the hose needs to be bent immediately before the hose fitting, its straight section length should be at least twice the outer diameter (some sources suggest 1.5 times). If this is not possible, use a 90° or 45° hose fitting. This prevents high-pressure, high-speed fluid from directly impacting the inner tube, thus avoiding hose aging and premature failure. Transition fittings simplify interface connections and hose installation and can be used to transition threaded connections. However, transition fittings should be used sparingly to minimize the number of components, thereby avoiding prolonged installation time, increased costs, and reducing potential leak points in the hose assembly.

5.Avoid wear and tear

Avoid placing hoses near any objects with sharp or rough surfaces, or too close to other hoses, as direct contact with equipment parts, hoses, or materials in the working environment can cause wear on the outer sheath, potentially exposing the reinforcement layer. However, if contact cannot be avoided in the application scenario, a hose with higher abrasion resistance should be selected, or a protective sleeve should be added.

6.The plane of motion must be considered.

The hose assembly must not be laid out in more than one plane of motion. If there are multiple planes of motion, it should be disassembled into multiple independent hose assemblies or fixed into a hose assembly with only one plane of motion by hose clamps.

7.Allow sufficient length for moving parts.

The hoses connected to the moving parts must be long enough to accommodate their entire range of motion. If the hoses are too short, the moving parts connected to them will not be able to move as required.

8.Do not mix hoses and connectors.

To ensure maximum service life and safe operation of hoses and fittings, do not mix hoses and fittings from different manufacturers. Maintaining consistency with the manufacturer of hoses and fittings, and strictly following the manufacturer’s recommended equipment, components, and operating procedures during assembly, is crucial for guaranteeing performance and safety. Proper fitting selection avoids hose twisting and wasted hose length, while reducing the number of connections required.

9.Methods for securing the hose

When securing hoses, it is crucial to take precautions against mechanical movement and vibration. Crossing or securing high-pressure and low-pressure hoses together can cause wear on the hose sheath due to their different rates of length change, reducing production efficiency and creating safety hazards. Proper securing methods should ensure the hose is securely positioned in the designated location and prevent contact with potentially damaging surfaces. Of course, when using hose clamps to secure hoses, it is essential not to sacrifice the hose’s flexibility under movement and pressure.

10. Temperature directly affects hose lifespan.

Hydraulic hoses should be kept away from external heat sources, as excessively high ambient temperatures can cause hoses to crack, thus shortening their lifespan. When ambient temperatures are extremely high (whether high or low), appropriate protective measures should be taken, such as durable hose sheaths. Another method is to install sleeves, which can help protect the hose from high-temperature equipment components and other potentially hazardous heat sources.

11. Balancing functionality with aesthetics, practicality, and ease of maintenance.

While prioritizing functionality in the design, the aesthetics and practicality of the piping, as well as the ease of future maintenance, should also be considered. Nothing is more frustrating than having to disassemble adjacent components to maintain a single flexible hose. To avoid this, staggered combinations of hose fittings and connectors can be used, such as short straight pipes and long straight pipes, or short elbows and long elbows. Taking this step during hose installation reduces maintenance workload and downtime. Using non-straight hose fittings and transition joints simplifies piping layout, avoids unnecessary stress on the hoses, and enables clean and easy-to-handle installation. Therefore, overly complex hose assembly layouts should be avoided to accommodate potential future inspections and maintenance.