Hydraulic Hose Repair

Hydraulic hoses operate under pressure while being exposed to movement, vibration, heat, abrasion, weather, and demanding working conditions. Over time, these factors can damage the hose cover, reinforcement, fittings, or internal tube.

A replacement may be needed when a hose shows:

• Hydraulic fluid leakage
• Cracks, cuts, or splits
• Exposed wire reinforcement
• Abrasion or worn outer covering
• Bulges, bubbles, or soft areas
• Corroded or damaged fittings
• Loose or separated hose ends
• Crushed, kinked, or twisted sections
• Fluid leaking around a crimped fitting
• Heat damage
• Repeated hose failure
• Signs of age or deterioration

A hose that appears acceptable externally may still have internal damage. Changes in flow, unusual movement, excessive heat, or contamination may indicate a problem that is not immediately visible.

Hydraulic hose repair does not normally mean patching a ruptured hose and placing it back into service.

The proper process typically involves:

• Identifying the failed hose assembly
• Determining the hose size and pressure requirements
• Identifying the fittings on both ends
• Measuring the correct overall length
• Selecting a compatible replacement hose
• Installing the appropriate fittings
• Routing and securing the hose correctly
• Inspecting the system for related problems

Reusing a damaged hose or installing an incorrectly specified replacement can lead to another failure, reduced equipment performance, or a serious safety hazard.

Hydraulic equipment uses hose assemblies in numerous lengths, diameters, pressure ratings, and fitting configurations.

A replacement assembly may require:

• A specific hose inside diameter
• A required working-pressure rating
• Straight or angled fittings
• Different fittings on each end
• Metric or imperial thread types
• A particular sealing method
• Abrasion-resistant covering
• Compatibility with the hydraulic fluid
• Resistance to heat or environmental exposure
• Precise assembly length

Whenever possible, bring the complete original hose assembly with both fittings still attached. The old assembly often provides valuable information about the hose type, fitting configuration, routing, and length.

Hydraulic systems use many different connection types. Two fittings that appear similar may use different threads, sealing surfaces, angles, or pressure ratings.

Common hydraulic connections may include:

• JIC fittings
• ORB fittings
• ORFS fittings
• NPT fittings
• BSPP fittings
• BSPT fittings
• Metric fittings
• Flange connections
• Quick couplers
• Banjo fittings
• Straight-thread connections
• Pipe-thread connections

The fitting must be identified accurately before a replacement hose is assembled. Forcing together incompatible fittings can damage threads, prevent proper sealing, and cause a failure under pressure.

Horizon can also help identify related hydraulic adapters, couplers, and connection components.

Replacing a hose without identifying why it failed can result in another breakdown.

Common causes of hydraulic hose failure include:

A hose that rubs against a frame, bracket, another hose, or moving component can gradually wear through its protective covering and reinforcement.

High fluid temperatures, engine heat, exhaust systems, or inadequate airflow can damage the hose tube and outer cover.

A hose that is too short may be stretched as equipment moves. A hose that is too long may sag, rub, kink, or interfere with other components.

Sharp bends, twisting, inadequate support, and incorrect clamp placement can place unnecessary stress on a hose assembly.

Sudden increases in system pressure can exceed the hose or fitting rating even when normal operating pressure appears acceptable.

The hose must be compatible with the fluid, pressure, temperature, movement, and environmental conditions of the application.

Dirt, metal particles, moisture, and deteriorated hydraulic fluid can damage the inside of the hose and other system components.

Improperly matched, corroded, cracked, or poorly installed fittings can leak or separate from the hose.

Hydraulic hose materials deteriorate over time. Age, storage conditions, exposure, and operating cycles can all affect service life.

Hydraulic systems can operate at pressures high enough to inject fluid through the skin.

Never use your hand or fingers to search for a hydraulic leak. A small pinhole leak may be difficult to see but can still cause a serious injection injury.

If hydraulic fluid penetrates the skin, seek emergency medical treatment immediately. The injury may initially appear minor but can cause severe tissue damage.

Before inspecting or removing a hose:

• Shut down the equipment
• Lower or mechanically support raised components
• Relieve stored hydraulic pressure
• Allow hot components and fluid to cool
• Follow the equipment manufacturer’s safety procedures
• Wear appropriate protective equipment
• Keep ignition sources away from leaking fluid
• Clean spilled fluid promptly and responsibly

Do not work beneath equipment supported only by hydraulic pressure.

Providing accurate information helps identify the correct hose and fittings.

Bring or provide:

• The complete original hose assembly
• Overall hose length
• Hose inside diameter
• Hose markings
• Working-pressure rating
• Fitting type on each end
• Fitting thread size
• Straight or angled fitting configuration
• Equipment manufacturer
• Equipment model number
• Hydraulic fluid type
• Operating temperature
• Photographs of the hose routing
• Photographs of both connection points
• A description of how the hose failed

Do not discard the old hose, fittings, adapters, or protective sleeves until the replacement has been properly identified.

Horizon provides hydraulic hose support for equipment used in a wide range of industries and applications, including:

• Construction equipment
• Agricultural machinery
• Tractors and attachments
• Skid steers and compact equipment
• Excavators and loaders
• Dump trailers
• Utility equipment
• Material-handling equipment
• Industrial machinery
• Hydraulic presses
• Hydraulic power units
• Pressure-washing equipment
• Landscaping and land-clearing equipment
• Truck-mounted hydraulic systems
• Shop and maintenance equipment

Hose availability and replacement requirements depend on the application, hose size, pressure rating, fittings, and operating conditions.

A hose that repeatedly fails in the same area may indicate a larger equipment or system problem.

Potential causes include:

• Incorrect hose routing
• Excessive system pressure
• Pressure spikes
• Component movement
• Damaged mounting points
• Excessive vibration
• High operating temperatures
• Incorrect hose specifications
• Contaminated hydraulic fluid
• Restricted fluid flow
• Improperly installed clamps or supports

Repeatedly replacing the hose without correcting the underlying cause can increase downtime and repair costs.

Contact Horizon Hydraulic Sales & Service when you need help identifying or replacing a leaking, damaged, worn, or failed hydraulic hose assembly.

For the fastest evaluation, provide the complete hose assembly, equipment information, photographs, and a description of the failure.