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Hydraulic hose connections in construction equipment: Common problems & Solutions

hydraulic solution for construction 1

Hydraulic hoses play a vital role in construction equipment. Construction equipment often requires delicate operation and control, and hydraulic systems can provide efficient, reliable and highly accurate force and power output. Hydraulic hoses are an important part of hydraulic systems, responsible for transferring the hydraulic transmission medium from one place to another, as well as for the task of withstanding high pressures.

The importance of hydraulic hoses is that they have a direct impact on the performance and stability of the hydraulic system. A high quality hydraulic hose can ensure the normal operation of the hydraulic system and also improve the efficiency and safety of the hydraulic system. Conversely, a faulty or improperly connected hydraulic hose can lead to reduced system performance, leaks, system instability and other problems.

Common connection issues & Prevention tips

Bending or over-bending of hard pipes

The hard tube bending or excessive bending of hydraulic hoses refers to the situation in which a part of the hydraulic hose is bent abnormally due to external forces or other factors during use. This situation may cause the performance of the hose to be reduced and even lead to hose rupture or fluid leakage.

Hydraulic hoses are usually composed of multi-layer steel wire mesh casing and rubber hose, which are pressure resistant, wear resistant and corrosion resistant. However, because the hard part of the hydraulic hose is long and the elasticity of rubber is limited, it will be restricted by bending during use. When the bending radius of the hose is less than the standard requirement or the bending angle is too large, the bending or excessive bending of the hard pipe of the hydraulic hose will occur.

Bending or over-bending of hard hoses of hydraulic hoses can lead to the following effects:

  • Reduce the hydraulic hose pressure resistance performance, may lead to hydraulic system failure.
  • Accelerate the aging of hydraulic hoses, shortening the service life of hydraulic hoses.
  • Increase the frictional resistance of the hydraulic hose, affecting the efficiency of the hydraulic system.

Therefore, when using hydraulic hoses, you should comply with the requirements of relevant standards, correctly select and install hydraulic hoses, and regularly check the state of hydraulic hoses to avoid bending or over-bending of hard pipes.

Poorly connected hydraulic tubes

Poor hydraulic hose connection usually refers to the failure to completely seal or loosen the connection of two hoses in a hydraulic system, resulting in problems such as leakage or operational failure of the hydraulic system. Poor hydraulic hose connection may be caused by the following reasons:

  • Connection damage:such as connection thread wear, bite slot deformation, etc., resulting in the connection can not be completely fit, thus causing the hydraulic hose connection is not tight.
  • Hydraulic hose aging:hydraulic hose used for too long or poor quality, the rubber or seals in the hose easily aging or hardening, so that the connection loses its sealing.
  • Improper installation:When installing the hydraulic hose, if the threaded connection is not properly installed or the connection force is not enough, it will also lead to a tight connection.

When the hydraulic hose connection is not tight, it may produce hydraulic system leakage, pressure drop, motion and other problems, and in serious cases, it may even lead to the failure of the hydraulic system. To avoid the hydraulic hose connection is not tight, the following points should be noted:

  • Choose high-quality connections and hydraulic hoses, and install them according to the relevant standards.
  • When installing hydraulic hoses, pay attention to the direction and fastening strength of the threaded connections to ensure that the connections are properly installed and fastened firmly.
  • Regularly check the state of the hydraulic hose connection, if you find that the connection is not tight or aging, etc., should be replaced or repaired in a timely manner.

Misalignment or incorrect connection of pipe fittings

Misalignment or improper connection of fittings means that the connection between two or more fittings in a hydraulic system is offset or not properly fitted, resulting in problems such as the hydraulic system not working properly or leaks. Misaligned or improperly connected fittings can be caused by the following:

  • Improper installation:When installing hydraulic system fittings, if the fittings are not properly installed or not tightened enough, they may be misaligned or not properly connected.
  • Aging or damage of fittings:Long-term use or poor quality of fittings may result in aging, deformation or damage of fittings, making them incorrectly connected or misaligned.
  • Improper operation:During the operation of the hydraulic system, such as moving, dismantling, replacing hydraulic parts, etc., failure to operate correctly or follow the protocol may result in misaligned or improperly connected fittings.

Misaligned or improperly connected fittings can seriously affect the efficiency and safety of the hydraulic system and may lead to leakage, pressure drop, mechanical failure and other problems. To avoid misalignment or improper connection of fittings, the following points should be noted:

  • Choose high-quality fittings, and install and fasten them according to relevant standards.
  • When installing the hydraulic system, attention should be paid to the direction and position of the fittings to ensure that they are properly installed and tightened firmly.
  • When operating the hydraulic system, follow the relevant regulations to properly operate and maintain the hydraulic components to avoid damage to the fittings.
  • Regularly check the connection of the hydraulic system’s fittings, and if you find that the fittings are misaligned or not properly connected, they should be repaired or replaced in a timely manner.

Damage or aging of the rubber layer of the hydraulic hose

Damage or aging of the rubber layer of hydraulic hoses usually refers to the wear, cracking or aging of the rubber layer in the hydraulic hose, which affects the normal operation of the hydraulic system. Damage or aging of the rubber layer of the hydraulic hose may be caused by the following reasons:

  • Hydraulic hose use too long: With the increase of hydraulic hose use time, the rubber layer may appear aging, wear or deterioration, thus affecting the service life of the hose.
  • Improper operation of hydraulic system:In the process of hydraulic system operation, such as too high or too low temperature, too high or too low pressure, etc., may cause damage to the rubber layer of the hydraulic hose.
  • Improper installation:When installing the hydraulic hose, such as tightening strength is not enough or the connection is not properly installed, it can also cause damage to the rubber layer.

When the rubber layer of hydraulic hose is damaged or aging, it may produce hydraulic system leakage, pressure drop, mechanical failure and other problems. To avoid damage or aging of the rubber layer of hydraulic hoses, the following points should be noted:

  • Choose high-quality hydraulic hoses and rubber materials, and install and use them in accordance with relevant standards.
  • When operating the hydraulic system, attention should be paid to controlling the temperature, pressure and other parameters of the hydraulic system to avoid damage to the rubber layer of the hydraulic hose.
  • When installing hydraulic hoses, ensure that the connections are properly installed and tightened with appropriate strength, and pay attention to the bending radius and bending angle of the hoses to avoid damage to the rubber layer.
  • Regularly check the state of the rubber layer of the hydraulic hose, if the rubber layer is found to be worn, aging or deteriorated, it should be replaced or repaired in time.

Dirt accumulation or blockage inside the pipe

The accumulation of dirt or blockage inside the hydraulic system piping is usually caused by improper use, improper maintenance, etc. The accumulation of dirt or blockage inside the piping can affect the normal operation of the hydraulic system, such as reducing the flow rate, increasing the pressure, affecting the sensitivity of the hydraulic components, and even causing system failure. Common causes include:

  • Poor quality of hydraulic oil or pollution:impurities, water or gas contained in the hydraulic oil will deposit on the inside of the pipe, and a long time accumulation will form sediment or dirt, thus blocking the pipe.
  • Unreasonable design of pipeline:unreasonable design of pipeline, small inner diameter of pipeline or too many elbows will slow down the flow of liquid, thus making it easy to accumulate dirt inside the pipeline.
  • Improper maintenance: Improper maintenance of the hydraulic system can cause impurities and contaminants in the hydraulic oil to exist for a long time, thus increasing the risk of dirt accumulation or blockage inside the pipeline.

To avoid the accumulation of dirt or blockage inside the pipes, the following measures can be taken:

  • Select high quality hydraulic oil and replace the hydraulic oil regularly according to the specified replacement cycle to avoid hydraulic oil pollution.
  • When designing the hydraulic system piping, the inner diameter of the piping and the number of elbows should be reasonably selected according to the liquid flow and working pressure.
  • Regular maintenance of the hydraulic system, such as regular replacement of hydraulic oil, cleaning the interior of the pipeline, etc.
  • When using the hydraulic system, overuse and excessive working pressure should be avoided to reduce the risk of dirt accumulation inside the pipes.
  • If it is found that more dirt has accumulated inside the pipes, the inside of the pipes should be cleaned in time to avoid any impact on the normal operation of the hydraulic system.

In construction equipment, hydraulic systems are widely used, such as cranes, excavators, loaders, road rollers, etc.. These equipments need high strength and high reliability hydraulic system to support their operation and running. Hydraulic hoses, as an important part of the hydraulic system, must be kept properly and stably connected to ensure efficient and stable operation of the hydraulic system.

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