How to Measure and Order a Custom Hydraulic Hose Assembly

A hydraulic hose assembly is a length of hose with a fitting crimped onto each end, built to your exact spec. Getting it right means matching four things: the hose, both end fittings, and the length. Here’s how to measure and order one without guesswork.

Step 1 – Identify the hose

Note two things: the bore (dash size) and the type/rating. The dash is the inside diameter – see our dash size chart. The type (e.g. SAE 100R1, R2, R12) gives the pressure rating and construction and is usually printed along the hose cover (the “layline”). Replace like-for-like unless you’re upgrading.

Step 2 – Identify both fittings

Each end can be different. For each, record:

• Thread type – BSP, JIC, NPT, ORFS, Metric or UNO (our thread ID guide shows how).
• Male or female, and whether it’s a swivel.
• Size – the thread/seat size.
• Angle – straight, 45° or 90°.

Step 3 – Measure the length correctly

Hydraulic assemblies are quoted as overall length (OAL) – from the extreme end of one fitting to the extreme end of the other, including the fittings. For swivel and female ends, measure to the sealing face. Lay the old hose out straight (don’t measure around the bends) to get a true length, then sanity-check it against the routing on the machine, allowing a little slack for movement and a generous bend radius.

Step 4 – Clock the bent fittings

If either end is a 45° or 90° elbow, the orientation of one relative to the other matters. This “clocking” angle stops the hose twisting once it’s fitted. Note the angle between the two fitting outlets with the hose lying naturally.

Step 5 – Order it

The easiest way is our Hose Assembly Builder: pick the hose, set the length, then choose a hose tail for each end. We crimp it and ship it ready to fit. Prefer to source parts and crimp your own? Shop hose and hose tails separately.

A few good-practice tips

• Never exceed the assembly’s rated working pressure – the lowest-rated component sets the limit.
• Respect the hose’s minimum bend radius; tight bends shorten life.
• Keep assemblies clean inside – contamination is a leading cause of hydraulic failure.
• Replace damaged hoses promptly; don’t patch high-pressure hose with clamps or tape.