{"entries":[{"name":"page_advice_hydraulic_hoses","type":"advice_page","contents":{"body":{"unwrappable_entries":[{"name":"Body","type":"modular_content","contents":{"untitled_content_item_62b91e2":{"unwrappable_entries":[{"name":"text_wrapper_advice_hydraulic_hoses_intro","type":"text_flavour","contents":{"structure__structure":{"unwrappable_entries":[{"name":"Structure","type":"multiple_choice","date_time":{},"options":{"alternative":"alternative"}}]},"text":{"unwrappable_entries":[{"name":"Text","type":"modular_content","contents":{"text_intro_advice_hydraulic_hoses":{"unwrappable_entries":[{"name":"text_intro_advice_hydraulic_hoses","type":"text_flavour_test","contents":{"button":{"unwrappable_entries":[{"name":"Button","type":"modular_content","date_time":{}}]},"image":{"unwrappable_entries":[{"name":"Image","type":"asset","date_time":{}}]},"text":{"unwrappable_entries":[{"name":"Text","type":"rich_text","text":"

Hydraulic hoses and couplings are used in many different applications. When it comes to replacing a hose, you should be trying to replace like for like – a new hose with the exact same characteristics. For this reason, it is important to find out the technical data of the hose you are replacing and compare it against the hose you are considering. The exact application is also important, so you need to be sure that the function, liquids it can channel (sometimes known as the medium), material, inner diameter, minimum bend radius, length, temperature ranges and pressure loads are all correct.
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About hydraulic hoses

A hose is composed of several layers, each of which has a particular purpose.

The inner layer is known as the inner jacket and can help indicate for which uses the hose is suitable.
Surrounding that inner jacket are one or more reinforcement layers, so-called pressure carriers, which can consist of different types of material, and which help the hose withstand particular pressures.
The outer jacket is made of a strong, wear-resistant layer which offers the hose protection from the outside. It is usually made of rubber or plastic.

Characteristics of hydraulic hoses

Hoses are flexible, can absorb movements and vibrations and have a damping effect. A hose may look simple, but it forms a carefully designed connecting link in any hydraulic system. Even having the correct angles when routing a hose can have a dramatic effect on the performance of the hydraulic system and the lifespan of the hose itself. Making the right choice of hose and couplings is very important. It is worth remembering that a hydraulic hose is sensitive to wear and tear and has a limited service life – they must always be replaced after a certain period of time, before they begin to show signs of cracking, abrasion or blistering.

Types of hoses

SAE standard hose: A high-pressure hose used with petroleum or water-based fluids designed for industrial applications. It is made of single steel, wire-braided tubing and suited to temperatures from -40°C to 100°C.
Standard high-pressure hose: Flexible hoses used in the mining, oil, construction and agricultural industries to carry hydraulic oils and water-oil emulsions.
Low-pressure hose: Used for return lines, anti-static delivery lines, air or lube lines and not suited to use in any safety-related or high-pressure application. They are extremely flexible and textile-braided.
Thermoplastic hydraulic hose: The inner and outer layers are made of thermoplastic, surrounding a synthetic fibre mesh reinforcement layer. Capable of resisting external abrasion and working in a very low temperature environment, they are found in for heavy construction machinery, hydraulic lift equipment, and lubrication lines.
Steel wire-braided hose: Typically used in mining, oil and heavy industry or other industries, they can be single or double wire-braided and are designed to withstand extreme temperatures and pressures.
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What is the quickest way to find out this information?

All the information you need should be printed on the hose itself. This information is sometimes known as the hose layline. It should always include the maximum working pressure, size and the product number, and may also include manufacturer and model details. Most hydraulic hoses are provided with an EN, ISO or SAE standard number, which indicates the uses and pressures they have been made to withstand. These numbers are international standards and apply to all hydraulic hoses, irrespective of brand.

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External material

The outer jacket, made of rubber or plastic, protects the hose against external influences, such as high and low temperatures, wear and tear, abrasion, chemicals, animal fats and weather.

The type of outer jacket depends on the situation. This additional protection can be particularly useful in fertilizer silos, spraying on liquid fertilizer, in a seawater environment or on the road (transport vehicles). Most rubber hoses can perform at temperatures from -40°C (-40°F) to 100°C (212°F). Thermoplastic hoses are lighter in weight, may last longer than rubber hoses, and are typically more flexible at temperatures below -40°C.

Inner jacket material

The inner jacket transports the fluid, which in most cases is a hydraulic oil. Nowadays, however, there are also many biodegradable liquids. Whatever liquid is used, bear in mind that the material of the inner jacket must be resistant to it. This is also true of the often high temperatures for that given medium and application.

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How hose length makes a difference

Hoses change in length under pressure - up to 4% - which means that there needs to be sufficient extra length to accommodate contraction without placing stress at the fittings and on the hose itself.
It is important to use angled connections and pipe brackets that ensure that this extra length is safely and securely guided and contained. The aim is to avoid wear, crushing and too small a bending radius.
Look for the minimum bend radius in the manufacturer’s guidelines when installing; too tight a bend can cause turbulence in the flow, which will affect performance and can be damaging.
When the hose is attached to moving parts, the guidance and length are both vitally important.
The images below illustrate good practice for avoiding tight bends and maintaining straight flow where possible.

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Inner diameter measurements

When replacing the hose, the inner diameter can usually be determined by the print on the hose. This is indicated in inches (1/4 \", 3/8\", 1/2 \", 3/4\" etc) or in millimetres (DN06, DN10, DN13, DN20 etc.). The so-called \"Dash Size\" is also often printed. This number represents the number of sixteenths of an inch. For example, -8 corresponds to 8/16 and is the same as 1/2 \" or DN13.

The outer diameter

Size tables often also show the outer diameter of the hose. This can help to identify a hose, but wear and tear may make this a less reliable method of sizing. Referring to the inner diameter is a far more reliable way to identify the correct hose.

Length

The hose must be long enough to allow correct and stress-free. A hose that is too short will not bend, or may not bend sufficiently, under the influence of pressure impulses. Hoses that are too long, on the other hand, can rub against each other or against nearby components or get stuck behind them, as well as increase system pressure and reduce efficiency.

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Sometimes the burst pressure (BP) is also shown. When this pressure is reached, the hose can burst, with sometimes catastrophic results. The permitted working pressure also applies to the hose couplings, although this is not mentioned on the coupling itself due to lack of space. The permissible working pressure of the hose assembly is the lowest value of hose and coupling and is often engraved on the sleeve or indicated on a label permanently attached to the hose.

The pressure carrier

The reinforcement layers in a hydraulic hose consist of steel or synthetic threads, applied in a cross-woven or spiral-woven bandage. These layers ensure that when the hose comes under pressure, the material and structure can withstand it. The number of layers is often found in the imprint on the hose (2SN, 1ST, 4S, 6S etc). In addition to the number of layers, the material and the structure of the layers are also important. In the case of frequent and high-pressure peaks, it is best to choose hoses with spiral-wound inlays.

Inner diameter

The inner diameter of the tubing is important because the fluid flow rate needs to be within the recommended range. If the tubing selected is too small, it will increase flow rate, friction and turbulence, resulting in high system pressure. Manufacturers usually supply a table or nomograph, allowing you to work out the ideal diameter for a particular hose length and flow rate.

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You need to know:

The purpose/function/application
Pressure rating and maximum working pressure
Maximum flow (through hose)
Inner diameter
Length
Material: inner material, outer material, pressure carrier

Below, we explore the importance of each factor.

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The maximum working pressure is critically important:

The hose construction must be able to withstand the pressure in the system. You must choose a hose with a maximum working pressure (WP) that is at or above the maximum pressure for the hydraulic system. The hose is often marked with Bar, mPa or PSI value to indicate the allowable working pressure. The relationship between them is as follows: 1 mPa = 10 bar. 1000 PSI = 69 bar. 1000 PSI is also indicated as 1K. 6000 PSI (~ 420 bar) is then indicated as 6K.

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What if the EN/ISO and other hose layline information is no longer visible?

You can identify the hose by sawing through it. Make a note of the number of steel inlays and measure the inner diameter precisely. In combination with the working pressure of the machine and the function of the system, you should be able to identify a suitable replacement by looking at a new product’s technical data. If you know the type and size of the hose nipple, you can also find out the inner diameter of the hose. The EN number makes identifying the hose easier, but these other methods can also be used.

Pressure rating and maximum working pressure

The flow rate for a hose is affected by the inner diameter and volume. Above a certain flow rate, you will get a turbulent flow, which means more resistance and less efficiency.

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The best-case scenario for choosing the wrong hydraulic hose is that your machine underperforms, because the hose cannot provide the correct flow rate, and the hose fails faster because it is not designed for the purpose you are using it for. You might experience environmental contamination from leaks or suffer damage to your equipment.

The worst-case scenario is a fatality. If a hose or a hose coupling breaks, the pressure can cause “hose whip”, which can seriously injure, maim and even kill.

Never cut corners on safety and never choose a hose based on its price, rather than its suitability.

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Hoses Plastic