We all know that hydraulic systems work on pressurised hydraulic fluid movement. This is only possible through the use of hydraulic hoses. These hydraulic hoses carry pressurised fluid to or from pumps, motors, valves, actuators and other system components to drive the system. But, over time and usage, they tend to wear and tear and lose their flexibility and durability. This flexibility is a critical factor to withstand the high pressure of the system fluid. This is why it is a very critical aspect to learn when, why and how to change hydraulic hoses to enhance your hydraulic machine’s life.
How a Hydraulic Hose Fails?
Hydraulic hoses are built to last, but over time, pressure cycles and wear can lead to their failure. So, if your hydraulic hose fails unexpectedly, it can cause injuries, property damage, costly cleanups, downtime, and higher labour and material costs. Hydraulic Engineers suggest a proactive replacement approach for hoses. While some signs of failure are obvious, others aren’t, and you need to learn them over time or in this article to make sure your system keeps running smoothly and efficiently.
Factors Affecting Your Hydraulic Hose’s Service Life
Understanding when a hydraulic hose requires a change is based on certain factors that you need to learn. This will make sure that your hydraulic hose lasts longer.
- First, match your hose size to the system’s flow rate to prevent overheating or damage. You can consult the hydraulic hose manufacturer’s guidance for proper sizing.
- Then, you need to ensure your hose operates within the recommended temperature range to avoid brittleness or cracking. It reduced the life span of the hydraulic hose drastically.
- After that, you need to choose hoses rated for higher pressure than your system’s maximum to avoid failure. It is called the factor of safety, and it should be 1.25 or 1.5 times higher than the required pressure. You can also use pressure-relief valves to manage spikes.
- Sometimes, environmental factors like heat, friction, or movement can damage your hose. So, you can use proper installation and protection (e.g., hose guards) to extend its life.
- Finally, check compatibility between the hose and hydraulic fluid to prevent damage and maintain performance.
When You Need to Replace Your Hydraulic Hose
To determine that it is the right time to replace your hydraulic hoses, you need to look out for these signs that your hydraulic hose needs replacement:
- Crushed or distorted hoses, from the outer side.
- Fluid leakage (inside or at the fittings), which happens due to cracks in the hose.
- Exposed wire reinforcement of the hoses.
- Significant surface damage to the hoses.
- Kinks or twisted hoses (wrong routing).
- Hardened, blistered, or softening covers
- Corroded fittings (red rust indicates replacement needed).
How to Change a Hydraulic Hose: An Efficient Approach
An efficient approach means that it should be in time before failure, take less time to change the hydraulic hose, use fewer tools, appropriate selection of hose size and follow a step-by-step approach for quick work.
1. Pinpoint the Problem
You can start by thoroughly inspecting the system to determine which hydraulic hose is malfunctioning based on above mentioned points. It’s crucial to identify the exact issue before moving forward with the replacement. Once you’ve located the damaged hose, make sure to purchase a replacement that matches or exceeds the original’s performance specifications.
2. Evaluate the Setup
Then you need to look at the surrounding components, such as hydraulic valves, AC motors, DC motors, pumps, power packs, etc., to figure out what needs to be removed or adjusted in order to access the faulty hose.
3. Prepare the System
Now, clear the workspace. This includes releasing pressure to prevent fluid leakage, lowering any high-hanging parts to avoid accidents, and disassembling parts that might block your view or access.
4. Loosen the Fittings
With the system clear, proceed to loosen the fittings that connect the hose to the rest of the hydraulic assembly.
5. Remove the Old Hose
After loosening the fittings, carefully remove the old hose. Be sure to catch any leftover fluid in a designated waste container, preventing contamination or mess.
6. Seal the Fittings
Before you begin installing the new hose, use fitting plugs or a rag to seal off the connections. This prevents any fluid leakage from the open fittings while you work.
How to identify the hydraulic hose fitting?
Hydraulic Hose Fitting Thread Identification Quick Reference Guide Download
7. Install the New Hose
Install the new hose by following proper techniques and adhering to the manufacturer’s instructions. Ensure that you’re using the correct torque settings when tightening the fittings. If needed, tag the hose for future reference.
8. Double-Check the Installation
Take a moment to visually inspect the new hose installation.
Test the System
After assembling everything, it’s time to test the system. Run it to check for leaks or performance issues. A successful test means the replacement was carried out properly, and the system should be back in working order.
Determine Replacement Intervals
Once all the processes are complete, you will need to track hose inspections to assess durability and establish replacement intervals before failure occurs. Tagging hoses, along with noting inspection and replacement dates, will help you save time while making replacements. The aim is to replace hoses proactively, before they fail, as mentioned at the start.
Conclusion
It is a fact that all hydraulic hoses will eventually fail. So, the best way is to make a proactive plan on when and how to change a hydraulic hose before it fails. Preventing their failure from affecting equipment or facility operations necessitates proactive measures, as outlined above.
About Hydraflu
Hydraflu is the leading Hydraulic Equipment provider across the globe. We provide all the solutions to your hydraulic systems from dock levellers, liftgates, motors, hydraulic power packs, hydraulic pumps, hydraulic valves and all auxiliary equipment and components. So, either you want advice on your hydraulic hose or are looking for a replacement? Contact us now, and we’ll be sure to help.
