Understanding and Optimizing Airline Routing in Heavy Equipment

[MikePhua]

Airlines are critical components in the operation of heavy equipment, ensuring that compressed air is delivered where it is needed for functions such as lifting, clamping, or controlling various mechanical movements. The proper routing of airline systems plays a significant role in the performance and reliability of these systems. Improper routing can lead to inefficiency, reduced performance, and even safety hazards.
This article will explore the key aspects of airline routing in heavy equipment, common issues, and how to ensure that your air systems operate at peak performance.
Why Proper Airline Routing Matters
In heavy equipment, air systems are used for a wide range of functions, including but not limited to powering attachments, operating brakes, controlling movement mechanisms, and even for climate control in the operator’s cabin. The efficiency of these systems depends heavily on how the airlines are routed. Misrouted, pinched, or poorly secured airlines can cause:

• Air loss
  
• Reduced performance of equipment
  
• Increased wear on the components
  
• Potential for safety hazards
  

Ensuring that airlines are routed in an optimal manner will contribute to the longevity and efficiency of the equipment, reduce downtime, and improve safety for operators.
Common Issues in Airline Routing
While routing airlines seems straightforward, there are a number of common issues that can arise in the process. Here are some of the most frequent concerns:
1. Airline Kinking and Bending
Airlines that are routed too tightly or with sharp bends can become restricted, reducing air flow and causing pressure issues. In the worst cases, they can kink and prevent air from flowing completely, rendering the system ineffective.

• Example: A hydraulic system on a backhoe loader began to perform poorly, with the controls feeling sluggish and unresponsive. Upon inspection, a kinked airline was discovered where it had been routed too tightly around a corner. Re-routing the airline alleviated the issue and restored normal performance.
  

Solution: Always ensure that airlines have enough slack to avoid sharp bends. When routing airlines, try to keep the bends as gentle as possible to prevent restricting air flow. Additionally, use airlines with reinforcement, such as braided steel, if they need to be routed in areas where they might be subject to bending.
2. Airline Exposure to Heat or Abrasion
Airlines that are exposed to extreme temperatures or abrasive surfaces can deteriorate more quickly. Heat from engine components, friction from moving parts, or exposure to harsh outdoor environments can wear down the material of the airline, causing cracks, leaks, and air loss.

• Example: An excavator’s air system began losing pressure intermittently. Upon inspection, the airline routed too close to the engine block had developed cracks due to heat exposure. The airline needed to be replaced with a more heat-resistant material, and a protective sleeve was added for extra protection.
  

Solution: Be mindful of where airlines are routed, avoiding areas with high heat or exposure to friction. Use heat-resistant and abrasion-resistant airlines in areas where the equipment is exposed to such conditions. Protective sheaths or sleeves can also be added to protect airlines from abrasions.
3. Airline Clutter and Poor Securing
In some cases, airlines may be routed in a cluttered or disorganized manner, which can lead to tangling, rubbing, or even damage. Airlines that are not securely fastened can also vibrate, rubbing against other parts or moving components, leading to wear and leaks.

• Example: A loader with multiple attachments was experiencing intermittent air pressure problems. The cause was traced to airlines that were routed haphazardly and were rubbing against metal parts, causing slow leaks. Properly securing the airlines and organizing them helped solve the issue.
  

Solution: Ensure that airlines are routed neatly and securely. Use cable ties, clips, or brackets to secure airlines in place and prevent them from moving around or rubbing against other components. Consider adding protective covers or routing airlines through protective tubes in areas where they may come into contact with sharp edges or moving parts.
4. Leaks in Airline Connections
Leaky connections are one of the most common issues with air systems in heavy equipment. These can occur at coupling points, where airlines are connected to pneumatic tools or attachments. If connections are loose or improperly sealed, they can lead to a gradual loss of air pressure and performance.

• Example: A forestry machine was struggling with air-powered attachments not operating at full capacity. The issue was traced to a leaky airline connection where it was connected to an attachment. Replacing the O-ring and tightening the connection restored full air pressure.
  

Solution: Regularly inspect all airline connections for signs of leakage. Make sure that O-rings, seals, and couplings are in good condition and replaced when necessary. Tighten connections securely but avoid overtightening, which can damage components or cause stress on the airline itself.
Best Practices for Routing Airlines in Heavy Equipment
Proper airline routing is more than just making sure the airlines are connected. It’s about ensuring that they are routed in such a way that maximizes their performance and longevity, while reducing the risk of failure. Here are some best practices to keep in mind when routing airlines in heavy equipment:
1. Plan the Route
Before installing or rerouting airlines, take time to plan their paths carefully. Avoid routes that cross moving parts or areas where they might be exposed to heat, abrasive surfaces, or excessive vibrations. Use routing guides or diagrams when available, as they can provide helpful guidance for optimal placement.
2. Use the Right Materials
Not all airlines are created equal. Depending on the environmental conditions of the job site—whether it’s high heat, exposure to chemicals, or abrasive materials—make sure to select airlines made from materials that can withstand these conditions. High-temperature rubber, braided steel, and abrasion-resistant hoses are often suitable for harsh environments.
3. Secure and Protect the Airlines
Once the airlines are routed, make sure they are securely fastened using clips, brackets, or cable ties to prevent them from moving around. In high-risk areas, consider using additional protective sleeves or coatings to shield the airlines from heat, abrasions, or impacts.
4. Regular Inspections
Conduct regular inspections of the air system, particularly around connection points and areas where airlines may be subject to wear. Catching issues early—such as a small leak or a worn connection—can prevent larger problems down the road.
5. Train Operators and Maintenance Teams
Operators and maintenance personnel should be trained to recognize the signs of airline issues, such as decreased air pressure, unusual sounds, or sluggish performance. Knowing what to look for can help catch problems early, ensuring minimal downtime.
Conclusion
Airline routing plays a crucial role in the performance, safety, and longevity of heavy equipment. Proper routing ensures that the air system operates efficiently, reducing downtime and preventing costly repairs. By paying attention to common issues such as kinking, heat exposure, and poor securing, and by following best practices for routing and maintenance, operators and maintenance teams can keep air systems in optimal condition.
The importance of well-routed and well-maintained airlines cannot be overstated. With the right materials, planning, and regular inspections, equipment owners can ensure that their machinery runs efficiently, keeps downtime to a minimum, and operates safely in the toughest environments.