Key Steps on how to Replace a Hydraulic Hose

How to Replace a Hydraulic Hose & Disconnect a Hose For Changing

Wondering how to replace a hydraulic hose? Bulldozers, loaders, excavators, and most other heavy machinery use hydraulic hoses to operate. Hydraulic systems deliver immense power and are easy to maintain, but even the finest hydraulic machinery will occasionally require a hose change.

Replacing hydraulic hoses requires training and experience in order to do it safely, but if you need a quick refresher, this article will remind you how to change a hydraulic hose.

How to Replace a Hydraulic Hose Safely

You’ll notice that “safety first” is a theme that runs through all of the following steps. This is because hydraulic fluids are toxic and can cause injury to you & your equipment and harm the environment. This is why it’s crucial to follow safety procedures while changing hydraulic hoses.

1. Gather Your Tools

Ready to learn how to  replace a hydraulic hose? The first step is to gather all of the necessary tools. Here’s a checklist to get you started:

• Goggles
• Gloves
• Long-sleeved shirt
• Pants (all your skin needs to be covered)
• Mask (because hydraulic fluid can vaporize and is toxic if breathed in)
• Spill sheet or bucket for catching hydraulic fluid
• A cleaning solution for cleaning hose couplings
• 2 wrenches that can fit around your hose fittings/adaptors
• Lubricant (just in case your couplings are stuck)
• Camera or phone (to take a photo of the hose configuration before you detach things so that you know how to put things back together)
• Rag
• Replacement hose assembly

Again, make sure you’re wearing your safety equipment before you begin disconnecting the hose. And ensure that the replacement hose assembly is an exact match (length, width, PSI rating, etc.) for the hose you’re removing.

Note: If you happen to get hydraulic fluid on your skin, eyes, or mouth, call your local Poison Control Center immediately and ask for medical direction.

2. Locate the Leak

With your equipment gathered, it’s time to start learning how to disconnect hydraulic hoses!

Conduct a visual inspection of the hydraulic pump, fittings, and hoses so that you can determine which hose is leaking or compromised.

If you’re having trouble finding the leaking hose, rub a piece of cardboard on your hoses. The leaking hydraulic fluid will stain the cardboard, helping you find the failing hose.

3. Make Note When Dissembling

Next, take a couple of photos of the hose assembly so that you can remember how it was configured. The last thing you want is to detach your hose and then forget how it’s supposed to bend or which fitting goes where.

4. Relieve Pressure

Disable the hydraulic source and relieve all the pressure from the hydraulic cylinders. This process varies depending on the machinery you’re using, so check your equipment’s owner’s manual to be sure you correctly remove all the pressure from your hoses.

5. Ensure Hydraulic Equipment is Secure

Now shut off the power to your machine and ensure that your heavy equipment is secure. This step is crucial to your safety, as hydraulic lines often provide structural support to machinery. You don’t want to disconnect a hose and then suddenly have a tractor arm drop on your head.

6. Remove Accessories and Clean the Couplings

In order to access the hose, it may be necessary to remove a hose guard or sleeve, clamps, or housing components. Take a new photo after removing each piece, and make sure to label each component as your remove it to ensure you’re able to put the puzzle back together.

Finally, as dirt and grime can quickly bury a hose’s couplings, you may need to spray down the hose couplings with a cleaning solution and wipe them clean.

7. Remove the Hose

With the hose sleeve removed, the couplings cleaned, and your safety equipment on, it’s time to detach your hydraulic hose. Before starting, put down your spill sheet or bucket to catch any hydraulic fluid that may leak out of the hose.

Now, clamp a wrench to each of the hose’s couplings — one to keep them in place and the other to unscrew the hose. If necessary, apply lubricant to loosen the couplings’ grip.

Next, loosen the hose’s fittings, and voila! You can pull out the hose.

8. Clean Fittings

With the hose out of the way, take your rag and clean the fittings. You don’t want any grime or debris slipping inside your hydraulic system and damaging your machinery.

9. Install the New Hose

Attach your new hose, ensuring that it’s an exact match of the old hose. Verify that the PSI, thickness, length, and fittings are all compatible with your system and each other.

To ensure that you put everything back correctly, consult the photos you took while disconnecting your hose.

And there you go! You’ve successfully learned how to disconnect  hydraulic hoses.

Professional Hose Replacement Near You

For high-quality  hose replacement and professional hose assembly, visit Greenshields Industrial Supply today. For nearly 70 years, we’ve been Northwest’s go-to hydraulic hose fittings service, and our experienced technicians are happy to help answer your questions and get you outfitted with new hydraulic hoses.