Many vehicles, equipments and industrial machines use hydraulic hoses. These hoses generally are quite durable and reliable. When any hose break, it is best to contact a certified professional who specializes in testing and repairing hydraulic hoses.
However, if necessary, you may need to perform on-site repairs until you can find a professional. Temporary fixing of hydraulic hoses is not a difficult task as people think. Once this process is broken down into six steps, the repair work becomes quite easy.
1. Identify the correct hose
Most heavy equipment can perform multiple functions (for example, lifting, pushing, pulling, or cutting), and each function may require a different minimum pressure capability. Therefore, there may be different types of hydraulic hoses with different minimum pressure ratings on a single device. Therefore, it is best to determine which specification the hose that needs to be repaired must meet. In most cases, the hose assembly is made to a specific length, and you will need to splice in a shorter assembly to make up for the parts that were cut off during repairs. Remember, even temporary replacement of incorrect hoses is very dangerous. All hydraulic hoses must specify the minimum operating pressure and maximum burst pressure of the hose.
2. Remove the damaged area
Once you have completed the first step, you will need to cut the hose in the damaged area. Even if the only problem is that the coupling at one end of the hose is leaking, you must cut off the defective end. Thoroughly clean the area around the cut end of the hose. Remove dust, dirt, or other contaminants from the area, as they may contaminate hydraulic oil.
Even tiny dust can damage internal components and cause expensive failures. Therefore, it is very important to ensure that the pipe fittings and cut hose ends are clean before proceeding with the remaining maintenance work.
3. Use an adapter to complete the installation
In some cases, a hydraulic adapter is required to complete the installation of the repaired hose. Since it is not always possible to carry every type of hydraulic coupling, an acceptable solution is to have a kit with various adapters. If necessary, install the adapter on the appropriate port to ensure a strong connection is established.
4. Confirm the correct length
Next, place the hose assembly in its place and confirm that the length is sufficient. Overstretched or poorly laid hoses will experience additional stress and fatigue. Although too many hoses are better than too few hoses, it is ideal to choose the right length according to NAHAD and the manufacturer's guidelines. Hydraulic systems are often under pressure, and hoses that are too short are more prone to dangerous (and costly) failures. Once the length of the hose is appropriate, make sure it is routed correctly. This will enable the rest of the hydraulic system to work properly. Many equipment use angled fittings to lay hoses to allow hydraulic oil to flow more freely. If an angled adapter or coupling is required, install the angled joint first to ensure correct positioning. Once the angle adapter is in place, the end of the hose assembly can be threaded onto the adapter or port.
5. Ensure a proper seal
Thread the remaining end of the hose assembly to the opposite port and verify that a proper seal is formed. Even a small gap or defect in the seal can cause problems for the hydraulic system, so check the tightness of the seal carefully before proceeding. Remember, the seal must be firm, but not too tight. When installing the hose, do not twist or twist. Use a wrench to tighten the pipe fittings, being careful not to overtighten the seal.
6. Circulate fluid at low pressure to check for leaks
Finally, open the hydraulic system to circulate the oil or hydraulic oil at low pressure. This will make it easier to spot potential leaks and any damaged connections. Circulating hydraulic oil at low pressure will also purge any remaining air. The air in the system may reduce performance or damage the pump and other fragile components.
Continue to run the hydraulic system for a few minutes, and then check again for leaks. Never check for leaks by hand, as this may cause fluid injection damage. Instead, use cardboard or a piece of paper. Leaks may take several minutes to show up, so be sure to check the system repeatedly before driving a vehicle or using machinery.
