Never had this problem, and i am surprised if it is the hose reel thats doing it and the diameter of the drum belly would have been correctly designed for this purpose.
I think it could be an inferior hose or a batch of them. I worked for Twelve years for Pirelli cables and worked on plastic extrusion the whole time i was there, which included armoured cable to hollow tubes, and optical fibre cable to pipes etc, so i know a bit about how they are made. They are probably made in long lengths then cut into the required lengths.
If a machine is badly set up,it will turn out crap for a whole shift or even longer if the operator does not spot the fault. Myself and many operators, would turn a blind eye and often let cables out of the door knowing there was a fault. If the wall thickness or radial thickness is not the same all the way around, when the cable or pipe is would onto a drum, it is both in a state of expansion and compression depending on how it is wound, and this will cause a split.
Obviously the more pipe on the drum, the circumference gets bigger and the bending of the hoses is less so you don't get the problem.
There is a formula that is used to work out reel sizes or drum sizes for cables and pipes, and i was wondering if yours was custom made for your van, the belly is not big enough. I made my own from wood to hold 200 feet of pipe for now as my van was not big enough.
I bought my truck mount new from Prochem is August 200 and am pleased with it. How are you getting on with yours?
Dave