Hydraulic Hose Assemblies

Hydraulic hose assemblies are flexible hoses supplied with pre-crimped end fittings, ready to connect directly into a hydraulic system without on-site crimping or fabrication. This makes them a practical, time-saving alternative to loose hose and fittings, with each assembly pressure-tested and leak-free straight out of the box. Assemblies are available in standard lengths and a range of end connection types to suit common Australian hydraulic equipment, with inner tube materials selected for compatibility with mineral oil, water-glycol and other hydraulic fluids. RS Australia stocks hydraulic hose assemblies from trusted brands including RS PRO, Parker and SKF, covering low-pressure return lines through to high-pressure industrial and press applications.

What Are Hydraulic Hoses Made From?

A hydraulic hose is a layered construction, with each layer serving a specific function in containing pressure, providing strength and protecting the assembly in service.

• Inner Tube: The inner tube carries the hydraulic fluid and must be compatible with the fluid type in the system. Synthetic rubber, commonly NBR, is the standard choice for mineral oil hydraulic systems. EPDM is used where the fluid is water-glycol based, and PTFE liners are specified for aggressive or high-temperature fluids where standard rubber would degrade.
• Reinforcement Layers: The reinforcement layer or layers give the hose its pressure rating. A single wire braid construction, as used in SAE 100R1 hose, handles low to medium pressure duties up to around 15 MPa. Double braid hose to SAE 100R2 handles standard industrial hydraulic pressures up to around 27 MPa. For hydraulic press and other high-pressure applications, multi-spiral constructions to SAE 100R9, R12 or R13 are rated for working pressures above 70 MPa.
• Outer Cover: The outer cover protects the reinforcement from abrasion, UV exposure, ozone and oil splash. Synthetic rubber compounds such as SBR and CR are standard for most applications, while polyurethane covers offer greater abrasion resistance for installations where the hose runs through or against rough surfaces.

Hydraulic Hose Fitting Types

The end fitting determines how the hose connects to the rest of the hydraulic circuit. Selecting the correct fitting type for the equipment and application is essential for a leak-free, pressure-rated connection.

• BSP (British Standard Pipe): BSP fittings are the most common thread type on Australian industrial and mobile hydraulic equipment. They are available in parallel form (BSPP, also known as G thread) and tapered form (BSPT, also known as R thread), covering connection sizes from G1/8 to G2. Most Australian-manufactured and European-sourced equipment uses BSP as the default thread standard.
• JIC (Joint Industry Council) — SAE 37° Flare: JIC fittings use a 37-degree flare cone to create the seal and are widely used on mobile hydraulic equipment, agricultural machinery and construction plants. They are a practical choice where connections need to be made and remade regularly, as the flare interface is robust and straightforward to assemble correctly in the field.
• NPT (National Pipe Thread): NPT is an American tapered thread standard commonly found on imported equipment specified to US dimensions. Where Australian or European hydraulic circuits interface with US-specification components, NPT end fittings on the hose assembly bridge the two standards without adapters.
• ORFS (O-Ring Face Seal): ORFS fittings seal on a flat face O-ring rather than a thread, making them the preferred choice for high-pressure and high-vibration applications where thread-sealed connections can work loose or leak over time. They are increasingly specified on newer industrial and mobile equipment where leak-free performance is a priority.
• SAE Flange: SAE flange connections are used on large-bore, high-pressure lines connected directly to hydraulic cylinders, pumps and motors. The bolted flange interface handles the high forces involved at large port sizes where threaded fittings would not provide sufficient holding strength.

Hydraulic Hose Standards and Pressure Ratings

SAE 100R ratings are the primary reference used by Australian buyers when specifying hydraulic hose. AS 3791 is the equivalent Australian standard and covers similar performance requirements.

• SAE 100R1: Single wire braid; up to around 15 MPa; general-purpose low to medium pressure circuits
• SAE 100R2: Double wire braid; up to around 27 MPa; standard industrial hydraulic systems
• SAE 100R4: Helical wire reinforcement; large bore; suction and return line applications
• SAE 100R7/R8: Thermoplastic construction; medium to high pressure; compact and lightweight
• SAE 100R9/R12/R13: Multi-spiral construction; rated above 70 MPa; hydraulic press and high-demand industrial applications
• SAE 100R17: Four-spiral compact construction; common in mobile equipment where space and weight are a consideration

What to Consider When Choosing a Hydraulic Hose Assembly

Choosing the right assembly comes down to matching the hose and fittings to the pressure, flow, fluid and physical demands of the installation.

• Working Pressure: Select a hose rated comfortably above the system's maximum operating pressure, typically by a factor of at least 25 to 33 percent, to account for pressure spikes that occur during normal operation. Using a hose rated at or near the system maximum leaves no safety margin for transient pressure events.
• Bore Diameter and Flow: The internal bore diameter needs to be sized for the flow rate in the circuit. An undersized bore creates excessive fluid velocity, which generates heat and pressure drop across the hose run. Common bore sizes in Australian industrial equipment range from 6 mm to 25 mm, corresponding to nominal DN6 to DN25 designations.
• Fluid Compatibility: Confirm that the inner tube material is compatible with the hydraulic fluid in the system. NBR suits mineral oil, EPDM suits water-glycol fluids, and PTFE is the appropriate choice for phosphate ester and other chemically aggressive fluids.
• Operating Temperature: Most standard flexible hydraulic hoses are rated for continuous use between minus 40°C and plus 100°C. Extended-temperature compounds are available where the system operates outside this range, such as in close proximity to engines or furnaces.
• Hose Length and Routing: Allow sufficient length for the hose to move, flex and absorb vibration without being pulled taut or kinked. Pre-made hydraulic hoses are available in standard lengths; where routing requires an exact length, confirm the measurement accounts for fitting engagement and any routing curves. Never exceed the hose's minimum bend radius, as this collapses the inner bore and accelerates wear at the bend point.

Industrial Applications of Hydraulic Hose Assemblies

Hydraulic hose assemblies are used wherever a flexible, pressure-rated fluid connection is needed between moving or fixed components in a hydraulic circuit.

• Mobile and Construction Equipment: Excavators, loaders, cranes and other mobile plants place high demands on hose assemblies, with constant movement and flexing across thousands of operating cycles. SAE 100R2 and multi-spiral constructions are standard on this equipment. Pre-made assemblies are particularly useful here because a correctly specified replacement can be fitted quickly in the field, reducing machine downtime during maintenance or emergency repairs.
• Industrial Machinery and Manufacturing: Hydraulic presses, injection moulding machines and CNC machining centres operate at high working pressures where multi-spiral industrial hydraulic hose rated to SAE 100R9 or above is the standard specification. These are demanding, continuous-duty applications where hose selection directly affects both system safety and production uptime.
• Agricultural Equipment: Tractors, harvesters and irrigation equipment across Australia rely on flexible hydraulic hoses with BSP and JIC end fittings to implement control, steering and lifting circuits. Agricultural equipment is often operated in remote locations, making the availability of pre-made hydraulic hose assemblies in standard sizes important for keeping downtime short when a hose needs replacing.
• Mining and Resources: Drilling rigs, longwall mining equipment and haul trucks operate in some of the most demanding conditions encountered across Australian industry. Heavy-duty assemblies rated for high pressure and built to resist abrasion and chemical exposure are standard across hydraulic hose applications in this sector, where equipment reliability directly affects site productivity.

Buy Hydraulic Hose Assemblies Online from RS Australia

RS Australia is a trusted hydraulic hose supplier stocking pre-made assemblies fromRS PRO,Parker andSKF, with BSP, JIC, ORFS and NPT end connections available across a range of bore sizes and pressure ratings. Whether the requirement is a replacement hose for a mobile plant or a high-pressure assembly for industrial machinery, our online range of hydraulic hose assemblies covers the key specifications in use across Australian industry.

Complementary products includinghydraulic fittings and couplings, hydraulic tubes andpneumatic hose and fittings are also available from a single supplier. Browse the full range of hydraulic hose online and order with fast, Australia-wide delivery. For more details on delivery services and fees, please refer to ourDelivery page.