Critical Mistakes in Hydraulic Hose Selection | Ahmet İpek

Critical Mistakes in Hydraulic Hose Selection | Ahmet İpek

Critical Mistakes in Hydraulic Hose Selection

(Details That Silently Kill the System)

A significant part of the malfunctions in hydraulic systems are caused not by the pump, valve or cylinder, but  by incorrectly selected or incorrectly applied hydraulic hoses. Whereas, hydraulic hoses are not just a fitting but the pressure-bearing active components of the system.

In this article, I discuss the most common hydraulic hose-related errors in  the field and the technical problems caused by these errors with application examples.

 

Hose selection based on price, not working pressure

The most common mistake is selecting the hydraulic hose based  solely on its rated pressure rating.

❌ Mistake:

Failure to account for impact pressures

Ignoring the safety coefficient

"This hose is enough" approach

✅ The right approach:

Hose selection  should be based on pulse + peak pressures, not maximum system pressure

Compliance with EN and SAE standards should be checked

Result: The wrong pressure class leads to hose bursts and serious occupational safety risks.

 

Incorrect Hose Bend Radius (Minimum Bend Radius)

A large proportion of hydraulic hose failures are  caused by running the hose below the minimum allowable bend radius.

❌ Mistake:

Installation by forcing the hose in tight spaces

Changing direction by bending the hose instead of the elbow

✅ The right approach:

The minimum bending radius in the manufacturer's catalogs  must be taken into account

At the necessary points, the transition should be made with elbows or pipes

Result: The process that is invisible from the outside but leads to a sudden explosion → inner wire breakage.

 

Ignoring Ambient Conditions

Hydraulic hoses are challenged not only by pressure but  also by environmental factors.

❌ Mistake:

High-temperature standard rubber hose use

Unprotected hoses in chemical, UV or corrosive environments

✅ The right approach:

Ambient temperature, oil type and external factors should be analyzed

If necessary, stainless steel spiral or PTFE hoses should be preferred

The result: External coating cracking, premature aging and sudden failures.

 

Incorrect Gland and Connection Selection

As critical as the hydraulic hose,  the fittings and fittings that complement it  are also critical.

❌ Mistake:

Use of fittings incompatible with the hose

Taper–straight thread incompatibilities

Incorrect tightening torques

✅ The right approach:

Hose-fitting compatibility should be done according to manufacturer recommendations

Torque values must be applied during assembly

The result: micro-leaks, → oil loss, → reduced system performance.

 

Considering the Hose Independently of System Design

In many projects, the hose is handled at the last stage of design. This approach is a serious engineering error.

❌ Mistake:

Not planning the tornado route in advance

Ignoring vibration and moving parts

✅ The right approach:

Hose route should be determined at the design stage

If necessary, clamp, spiral guard and vibration allowance should be added

The result: hose friction, outer sheathing damage and ruptures.

 

Conclusion: Hydraulic Hoses Are Not the "Weak Link"

A properly selected and correctly applied hydraulic hose can be one of the most reliable components of the system. However, improper selection and installation will soon disable even the most powerful hydraulic systems.

Ahmet İpek considers hoses not only as fittings but also  as the pressure and safety carrier of the system in industrial and OEM hydraulic projects  .

 

Author

Ahmet İpekHydraulic Systems Specialist – HidromanIndustrial & OEM Hydraulic Solutions