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Proper Hydraulic Hose Installation and Routing: the Best Practices

Proper Hydraulic Hose Installation and Routing: the Best Practices


At Cylinders, Inc., we’re more than familiar with the vital role that hydraulic cylinders play in a wide variety of industries. For optimal performance and longevity, you can’t overlook the importance of hydraulic hose installation. Proper hydraulic hose routing is the cornerstone of efficient hydraulic cylinder repair.

In this blog post, we’ll guide you on how to install a hydraulic hose effectively. Whether you're a seasoned professional or new to the world of hydraulics, these guidelines will help you maintain the integrity of your hydraulic system and ensure smooth operations.

Proper Hydraulic Hose Routing in 10 Steps

Proper Hydraulic Hose Routing in 10 Steps

Proper hydraulic hose routing is essential to ensure hydraulic equipment runs efficiently. Here are ten crucial steps to follow:

#1. Select the Right Hydraulic Hose

Selecting the right hydraulic hose is a critical aspect of proper hydraulic hose installation, particularly when dealing with hydraulic cylinders. It's essential to consider factors like pressure rating, temperature range, compatibility with hydraulic fluids, and the specific requirements of the hydraulic cylinder. Equally important is proper hydraulic hose routing to prevent kinks, abrasion, or other damage.

#2. Choose Proper Hose Length

It's essential to ensure that the hose's overall length provides enough flexibility and slack for the hydraulic system to operate smoothly without placing undue stress on the hose. Having adequate length allows for natural movements and adjustments within the system. However, it's equally critical not to have too long of a hose, as this can lead to tangling, increased cost, and potential safety hazards.

#3. Avoid Hose Twist

It is essential to follow guidelines that prevent hose twisting during installation, as a twisted hose can result in decreased flow rates, elevated friction, and the risk of damage to the hydraulic cylinder system. To prevent twists, meticulous routing, and securement are vital, avoiding sharp bends or kinks.

#4. Accommodate Movement During Hydraulic Hose Installation

#4. Accommodate Movement During Hydraulic Hose Installation

Hydraulic systems frequently encounter dynamic forces, vibrations, and temperature variations that induce hose movement. To ensure dependable performance and prevent potential damage, it's imperative to account for this movement. This can be achieved by opting for flexible hoses, securing them using suitable clamps and supports, and avoiding rigid connections that hinder their ability to flex. Incorporating these measures not only enhances the hydraulic system's performance but also significantly reduces the risk of hose failure, ultimately extending the service life of the hydraulic cylinder and related components.

#5. Use the Proper Bend Radius

To ensure the proper functioning and longevity of hydraulic hoses, adhering to guidelines for the correct bend radius is essential. Each specific hose type has a designated minimum bend radius, which should not be exceeded during installation. Going beyond this limit can lead to hose failure due to kinking or internal damage. It's crucial to consult the manufacturer's specifications to determine the appropriate bend radius for the particular hose you are using.

#6. Use Clamps to Secure the Hose

Again — make sure to carefully plan and secure the hose routes, avoiding sharp bends, kinks, or contact with abrasive surfaces. Adequate clamping with appropriate supports helps maintain hose integrity and prevents vibration-induced damage. By using clamps when installing hydraulic hoses, you can enhance the overall reliability and safety of your hydraulic equipment, minimizing the risk of hose failure and system downtime.

#7. Prioritize Abrasion Resistance

The longevity and reliability of hydraulic hoses, especially in systems involving a hydraulic cylinder, hinge on prioritizing abrasion resistance during installation. Preventing abrasion is essential to avoid premature wear and potential hose failure. To achieve this, hoses should be properly routed and secured, avoiding contact with sharp edges, surfaces, or other moving components that could cause friction or wear. The use of protective covers or shields in high-risk areas can further enhance abrasion resistance.

#8. Clean Hydraulic Hoses

#8. Clean Hydraulic Hoses

When installing hydraulic hose assemblies, especially in systems involving a hydraulic cylinder, cleanliness is paramount. Guidelines for proper hydraulic hose installation stress the importance of clean hoses to prevent contamination within the system. Before assembly, ensure that both the interior and exterior of the hydraulic hoses are free from dirt, debris, and contaminants. Contaminants can compromise the integrity of the hydraulic system, potentially causing damage to components like the hydraulic cylinder.

#9. Check the Pressure

During the installation of hydraulic hoses, especially in systems involving a hydraulic cylinder, it's crucial to connect the hoses to the hydraulic components carefully and check the pressure. Ensuring a secure and proper connection helps prevent unnecessary pressure losses, maintaining the hydraulic system's efficiency. Be sure to confirm that the working pressure of the hydraulic hose matches the requirements of the hydraulic cylinder and other components.

#10. Use Elbow Fittings

Use elbow fittings or adapters when necessary, especially when connecting hoses to hydraulic cylinders or other components. This practice is vital for a smoother hose assembly, reducing the risk of kinking or excessive bending. Properly aligned tube fittings and adapters not only improve the performance of the hydraulic system but also extend the hose's life by minimizing stress and wear.

How to Install Reusable Hydraulic Hose Fittings

Installing reusable hydraulic hose fittings is a critical task to ensure the proper functioning of hydraulic systems, including those involving a hydraulic cylinder.

To guide you through the process, here's a checklist:

  • Inspect components: Examine the hose, fittings, and adapters for any damage or defects before installation.
  • Cut the hose: Use a hose cutter to make a clean, perpendicular cut to the desired length.
  • Select fittings: Choose the appropriate reusable fittings for your hose size and application.
  • Assemble fittings: Follow the manufacturer's instructions to assemble the reusable fittings onto the hose, ensuring a secure fit.
  • Apply lubrication: Apply a recommended lubricant to the threads and sealing surfaces of the fittings.
  • Tighten fittings: Use a wrench or socket to tighten the fittings to the specified torque, following the manufacturer's guidelines.
  • Inspect for leakage: Conduct a thorough inspection to check for any leaks at the fittings or connections.
  • Securely attach: Properly secure the hose to the hydraulic cylinder, ensuring it's routed to avoid sharp edges or potential abrasion points.
  • Test operation: After installation, test the hydraulic system to ensure it functions correctly.

With this checklist, you can effectively install reusable hydraulic hose fittings and contribute to the reliable operation of hydraulic systems, including those associated with a hydraulic cylinder.


By following these guidelines, you significantly reduce the risk of hydraulic cylinder failures and costly operational downtime. Regular inspections and a robust maintenance plan are essential components of keeping your equipment in prime condition for extended periods. Moreover, having a reliable hydraulic cylinder repair partner like Cylinders, Inc. in your corner for hydraulic hose replacement can offer invaluable support when issues arise.

With our expertise in industrial cylinder rebuilds and repairs, you can trust that your equipment is in safe hands when something does go wrong. Don't hesitate to contact us for all your hydraulic needs and enjoy the peace of mind that comes with a well-maintained hydraulic system.

Cylinders inc. team



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