How to Calculate the Correct Length on a Hydraulic Hose Assembly


Calculating the correct length of a hydraulic hose assembly is essential to ensure proper fit, functionality, and safety in hydraulic systems. Here’s a step-by-step guide on how to calculate the correct length for a hydraulic hose assembly.

Measure the Distance:

Determine the exact distance between the two points where the hose assembly will be installed. Measure from the center of the hose’s connection points. Make sure to account for any bends, twists, or movements that the hose might undergo during its operation.

Factor in Allowance:

Add a reasonable allowance for movement, vibration, and potential changes in the system. A common rule of thumb is to add around 10-15% to the measured distance to account for hose flexing, expansion, and contraction.

Account for Hose Ends:

Take into consideration the length of the hose fittings (couplings) at both ends of the hose. This length varies based on the type and style of fittings. Typically, you’ll need to account for an additional length of hose equal to the length of the fittings combined.

Check Manufacturer Guidelines:

Refer to the hose manufacturer’s guidelines, technical specifications, and installation instructions. Manufacturers often provide recommendations on the optimal hose length based on the specific hose type, diameter, and application.

Consult Industry Standards:

Follow industry standards and guidelines for hydraulic hose assemblies. Organizations like the Hydraulic Hose Safety Institute (HHSI) and the Society of Automotive Engineers (SAE) provide standards that can help you determine the appropriate hose length.

Consult Hydraulic System Designer/Engineer:

If you’re unsure about the proper hose length, it’s advisable to consult with a hydraulic system designer, engineer, or a technical expert who can provide insights based on the specific requirements of your system.

Consider Hose Routing and Flexibility:

Take into account the routing of the hose within the system. Ensure that the hose is routed in a way that avoids sharp bends, kinks, and potential abrasion points. Adequate hose flexibility is essential for proper operation.

Order Custom-Length Hoses:

If the required hose length is not a standard size, consider ordering custom-length hoses from a reputable supplier. This ensures that the hose is precisely tailored to your system’s needs.

Test Fit:

Before finalizing the hose length, it’s a good practice to perform a test fit of the hose assembly in the actual system. This allows you to verify that the hose fits comfortably without excessive tension, bending, or interference.

Ensure Safety and Compliance:

Ensure that the chosen hose length and assembly meet safety standards and industry regulations. Hydraulic systems involve high pressures, and using the correct hose length is crucial for maintaining the integrity and safety of the system.


Remember that selecting the correct hose length involves careful consideration of various factors, including system design, application requirements, and safety considerations. If in doubt, it’s always better to consult with professionals who have expertise in hydraulic systems and components.

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