Hydraulic hose failures are a main cause of downtime at every job site using heavy-duty equipment. While replacing hydraulic hoses is inescapable, following these five steps to prevent hydraulic hose failure, can help delay those failures and save your customer money and time.
- Construct the Hydraulic Hose Correctly.
- Hydraulic hoses have a three part construction: tube, reinforcement and cover. The tube is rubber and transports the fluid. Reinforcement is the less flexible braided wire that is wrapped around the tube. The cover surrounding both is the final protection from the elements, adding strength to the hydraulic hose as well.
- Most manufacturers will list hose identifying information on the layline of the hose. Always check to be sure the hydraulic hose being considered is the right size (length and diameter) for the application.
- Always follow the manufacturer’s recommendation for the correct construction. Use the proper fittings that are designed to work with the hydraulic hose being used.
- Before the assembly is crimped, be sure the fitting is pushed on the hydraulic hose all the way to prevent the end from blowing off during operation.
- Be sure to use the right crimp specs when crimping the end form to the hose. Over crimping can crush the hydraulic hose, blocking the fluid and weakening the hose. Under crimping can cause the end to blow off during operation. Crimping errors aren’t always visible to the naked eye, so be sure to check the crimp specs with a caliper before approving the finished product.
- Route the Hydraulic Hoses Properly
- After the hose assembled correctly it’s ready to be put back on the equipment. Routing is how the hydraulic hoses are positioned in regard to the equipment design. Incorrect routing can cause abrasion and weakening of the hose. Using clamps and pivot points can keep the hose from rubbing against the machine, furthering the life of the hydraulic hose. Using 45 degree or 90 degree fittings is common to help route the hydraulic hose more efficiently.
- After the hose assembled correctly it’s ready to be put back on the equipment. Routing is how the hydraulic hoses are positioned in regard to the equipment design. Incorrect routing can cause abrasion and weakening of the hose. Using clamps and pivot points can keep the hose from rubbing against the machine, furthering the life of the hydraulic hose. Using 45 degree or 90 degree fittings is common to help route the hydraulic hose more efficiently.
- Use an Appropriate Bend Radius
- Manufacturers provide the maximum bend radius information, and it should be followed to improve routing. The bend radius needs of your hydraulic hose needs to be kept as large as possible to avoid flow restrictions and prevent kinking or flattening. Allow for some slack on the length of the hydraulic hose to counterbalance the movement caused by the fluid moving thru the system.
- Be Mindful of Extreme Temperatures
- Extreme temperatures have sometimes critical effects on the life of a hydraulic hose assembly. Outside temperatures, as well as heat sources from the machine being used, or those around it can cause weak spots in the construction of the hose. This is why proper routing techniques are imperative. Hydraulic hose should be kept away from the hot parts of the mechanism as well as any additional places extreme heat is present. If this is impossible, use heat resistant sleeves.
- Maintain Proper Operating Pressure.
- The last step in preventing hydraulic hose failure is to avoid moving fluids at or above the operation pressure of the hose (PSI). Continuously using hydraulic hoses at their maximum
pressure can cause blowouts and leaks. Some hydraulic systems are susceptible to dangerous pressure surges, if this is the case us a hydraulic hose with a higher PSI for normal flow. Pressure rating information should be listed on the layline of the hose.
- The last step in preventing hydraulic hose failure is to avoid moving fluids at or above the operation pressure of the hose (PSI). Continuously using hydraulic hoses at their maximum
All hydraulic hose assemblies will fail eventually but delaying the process can save money and time. Following these steps can help keep your hydraulic hose assemblies strong for the extent of their service life.
"I found a way to offer a very unique service with virtually no competition with Tubes n' Hoses. The bender and end forming capabilities are unmatched at this price point. Only industrial high production manufacturing equipment can top it. The hydraulic shops in the area refer their customers to me for the impossible. We have expanded from just doing a/c hose to so much more, and it's fun. I would highly recommend the Tubes n' Hoses system. Especially if in a rural location or area that has heavy concentrations of agricultural/mining activity. We have a huge competition in the hydraulics here so we concentrate on automotive, and the hydraulic shops hate to deal with automotive, so they refer customers here daily. Auto parts stores even bring us hoses to have made for their customers. For my business, they system has changed our situation. We've been able to scale the system to provide us with a solid income that allows us to provide a very unique service to our existing customers and open avenues to new ones." -Bob Steinmann, Century Auto Air
"Like many folks, I am resistant to change. I looked at the Tubes n' Hoses system for 5 years before I made the commitment to myself and the shop that this could be good. With the addition of the system to our shop, we have been able to diversify our client base. We are now doing many jobs, which before we had to turn away. With the constant expansion of our city and counties, we have had an influx of heavy equipment. Nearly all heavy equipment relies on hydraulic systems. My customers know that when I use my Tubes n' Hoses equipment, they are getting a superior product hand made to the exact specifications they request. Customers and shops around the country are noticing what we do. Our out of state customers have never been displeased with the turnaround time, thanks to the Tubes n' Hoses system. Owning this system can be a life changing decision and I highly recommend making the upgrade to your own shop to serve your customers in ways you could not before. After years of looking at just about every system on the market I have not found any to compare with this one. Minute for minute this can and will improve your productivity and bottom line. I wholeheartedly recommend Tubes n' Hoses!"
"When first looking at the Tubes n' Hoses system there were a couple of obstacles; one being lack of knowledge on knowing how to utilize everything the machine offers, and the second being the cost of the machine itself. When we made the decision to purchase, we found out how much the machine offers, how much it helped our customer's needs, and it felt good to be self sufficient! We like all the features of the machine, but the tube bending station really helps out, especially when you are bending the bigger sized tubing. Again, it goes back to satisfying our customers needs. As I mentioned before there are many things the machine offers. It is capable of upsizing/downsizing, beading, and flaring multiple sized tubing. Crimping standard and reduced barrier A/C hose. The list goes on! I would recommend this system. The machine is capable of doing so many things. Basically, it comes down to being self-sufficient and satisfying our customer needs, which is our NUMBER ONE PRIORITY!"