Reasonable Arrangement of Hydraulic Hoses for Construction Machinery

Reasonable Arrangement of Hydraulic Hoses for Construction Machinery

hydraulic hose layout on the machine
hydraulic hose layout on the machine

The hydraulic system is an essential part of construction machinery; the machine will generate power to the end of the actuator, drive the specific parts to do the corresponding movement, and complete a specific task via the hydraulic system. The hydraulic assembly is a vulnerable part of the hydraulic system that requires not only regular inspection and replacement but also proper maintenance. Proper maintenance can extend the life of the hydraulic assembly, reducing downtime, improving productivity, and even protecting personal property from damage.

This article describes three methods for laying out, installing, and protecting hydraulic hoses on construction machinery.

The hydraulic hose has excellent anti-disturbance, can absorb hydraulic shock, and is easy to replace, and is widely used in construction machinery. Hydraulic hose, as a hydraulic system auxiliary component, its layout, installation, and protection directly affect the dynamics of construction machinery, safety, and reliability.

Layout

Hydraulic hose selection and installation are primarily influenced by the overall layout of each component in the hydraulic system. The hydraulic hose layout for construction machinery should meet the four requirements listed below.

First, reducing resistance loss of hydraulic oil along the hydraulic line and sectional energy loss, in order to decrease the internal stress in the hydraulic hose.

Second, the hoses should be arranged neatly, simply, smoothly, aesthetically pleasing, and generously, evoking a sense of time, beauty, and safety.

Third, the hydraulic hose should be set up so that it can turn, move, and overhang without causing wear, extrusion, stalling, or interference in the operation of construction machinery.

Fourth, the hydraulic valve manipulation mechanism, high-pressure filter, and pressure test points through the hydraulic hose facilitate the location’s operation, so as to make routine maintenance, inspection, repair, and replacement of wearing parts more convenient.

hydraulic fittings
Hydraulic fittings

Hydraulic fittings

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Installation

The quality of hydraulic hose installation determines its dependability and service life, and its installation should adhere to the three fundamental principles outlined below.

First, hydraulic hose mounting brackets should be used for multiple hydraulic hoses installed in the same direction, and ties should be used to ensure that multiple lines are installed parallel and equidistant to ensure that they do not cross-wear.

hydraulic hose bracket on the construction machine
hydraulic hose bracket on the construction machine
hydraulic hose clamp on the construction machine
hydraulic hose clamp on the construction machine

Second, when hydraulic hoses are installed, the bending radius should be greater than nine times the outside diameter of the hydraulic hose, and the distance from the bend to the pipe joint should be greater than six times the outside diameter of the hose. Additionally, you should avoid using hoses with a minimum radius of curvature that is less than the recommended value in order to prevent excessive energy loss or shortened hose life.

Third, the length of the hydraulic hose should be reasonable; because the hose is made of rubber, its shrinkage rate is affected by temperature, so the length of the hose should not be too short, leaving a small margin to adapt to hydraulic oil temperature changes and the need to withstand tension and vibration, but the hose should not be too long; otherwise, it will detract from the beauty of the hydraulic system and reduce pressure loss, resulting in adverse consequences.

Fourth, the hydraulic hose installation should avoid distortion, as hose distortion reduces pressure-bearing capacity and service life; therefore, in frequently moving parts, the length, direction, flexibility, and possible distortion of the hose should be adapted to the actual requirements of the work.

Protection

According to some estimates, external wear and tear accounts for about 80% of hydraulic hose failures. Hydraulic hoses should be properly protected to avoid wear, and the following are the main measures to take.

First, when assembling the hydraulic pipeline, try to avoid cross-connections; it’s best to keep the hoses parallel to each other, with a distance of more than 100mm between them, so that it’s not only easy to disassemble the pipe joint, but also to avoid hose collisions due to vibration.

Second, if the hydraulic hose is excessively long or appears to be overhanging, it should be secured with a hose holder or hose clamp alignment. (As illustrated in the diagram above)

Third,when working on construction machinery, the installation of multiple hydraulic hose bundles that are not directly tied with a tie should be padded with burst protection sleeves for hydraulic hoses to prevent friction between the hoses (as shown in Figure below easy to damage parts of the hose should be equipped with a protective cover)

Nylon cable tie for hydraulic hose
Nylon cable tie for hydraulic hose
Hydraulic hose protection sleeves
Hydraulic hose protection sleeves
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