In any hydraulic or pneumatic system, the integrity of your hoses is essential to performance, safety and system longevity. Preventive maintenance practices not only reduce downtime and costly repairs but also enhance overall fluid flow efficiency.
Here are best practices in five critical areas: fluid flow preventive maintenance, proper hose installation, abrasion protection, hose storage and regular visual inspections.
Fluid Flow Preventive Maintenance
Maintaining steady and unrestricted fluid flow is fundamental to the operation of hydraulic and pneumatic systems. Poorly maintained hoses can lead to excess restrictions, overheating and equipment failure. To prevent these issues:
- Schedule regular inspections: Check hoses for signs of wear, twisting or leaks.
- Follow correct routing practices: Improper routing can restrict flow or cause hoses to kink, collapsing the internal diameter and affecting performance.
- Use bend radius guidelines: Following catalog specifications for minimum bend radius helps prevent hose collapse, damage and ensures smooth fluid flow.
Incorporating these routine checks can help your systems perform at peak efficiency while reducing the risk of unexpected failures.
Proper Hose Installation
Correct hose installation is key to avoiding mechanical failure, leaks and unnecessary downtime. Follow these best practices:
- Provide slack for length changes: Hoses should allow for expansion or contraction due to pressure changes (plus 2% to minus 4%).
- Avoid twisting: Install hoses with the printed lay line straight to prevent twisting, which can cause failure at fittings.
- Protect from heat: Keep hoses away from hot components or insulate them to prevent degradation.
- Reduce mechanical strain: Use elbows and adapters to ease stress on hose ends and connectors.
- Observe proper bend radius: Avoid tight bends that can restrict flow. Use the formula B ÷ 2 to determine the minimum bend radius.
- Secure runs: Use hose clamps to minimize vibration and rubbing that can lead to wear.
- Plan for movement: Route hoses so that any flexing occurs in the same plane as the equipment’s motion to reduce stress.
These strategies support reliable operation, extend hose service life and contribute to a cleaner, more professional setup.
Abrasion Protection / Hose Protectors
Hoses and cables are often exposed to abrasive surfaces and harsh environments that can shorten service life. Hose protectors offer a simple and effective solution.
- Abrasion and chemical resistance: Protects against rubbing, friction and exposure to chemicals in a wide range of environments and temperatures.
- Reduces downtime: Extends the life of hoses and prevents premature failure.
- Easy installation: Most styles of hose protection can be added to hose assemblies while they are installed on equipment.
- High visibility: Some hose protectors are available in black, orange and yellow to increase awareness and promote safety.
- Versatile application: Suitable for hydraulic lines, brake hoses, wiring, heater hoses and more.
Used properly, hose protectors not only enhance system longevity but also improve safety and reduce overall maintenance costs.
Hose Storage
Proper storage is essential to preserving hose condition and streamlining operations. Kimball Midwest’s hydraulic hose cabinets and racks, such as the 636, 746 and 811 series, are engineered to store a wide variety of hose sizes and types.
- Space efficiency: Vertical and horizontal compartments allow easy separation by size or use.
- Modular flexibility: Components such as end compartments, single and double-bin units and adjustable bases can be configured to suit your shop layout.
- Durable construction: Powder-coated 16-gauge steel ensures long-term, rugged performance.
- Improved accessibility: Clearly organized storage reduces handling time and limits damage due to improper stacking or bending.
Well-structured hose storage protects your investment, supports a cleaner workspace and minimizes operational slowdowns.
Be on the Lookout – Cracks, Leaks, UV Damage and More
Even with proper installation and protection, hoses are vulnerable to environmental and operational wear. Stay alert for signs of trouble:
- Cracking: May indicate UV exposure or heat damage, especially near engines or outdoor setups.
- Leaks: Look for oil spots, pressure drops or hissing sounds; signs that fittings or seals may be compromised.
- UV degradation: Prolonged exposure to sunlight weakens hoses over time. Consider rerouting or shielding.
- Stiffness or brittleness: Loss of flexibility can signal aging or chemical degradation.
- Use proper sealants: Apply high-performance thread sealants such as Torque-Lok™ hydraulic and pneumatic sealants. These sealants handle pressures up to 10,000 psi and resist temperatures from minus 60 to 300 degrees Fahrenheit.
Products like Torque-Lok™ gel and pump applicators ensure leak-free, vibration-resistant seals for a wide range of hydraulic and pneumatic fittings.
Proactive maintenance through proper hose installation, secure storage, abrasion protection and regular visual checks helps ensure reliable system performance. With the right tools, such as hose cabinets and high-performance sealants, you can reduce unplanned downtime, extend equipment life and keep fluid flow optimized across your operation. Contact your sales representative to learn more. If you do not have a sales rep, we can help you