Views: 8 Author: Brent Harrison Publish Time: 2023-01-31 Origin: Max Industrial Solutions
Many vehicles, equipment and industrial machines use hydraulic hoses. These hoses are usually fairly durable and reliable, but if you work or drive long enough, they can eventually leak or break, resulting in reduced productivity, increased costs, and even environmental or site hazards. When this happens, it is a good idea to contact a certified professional who specializes in testing and repairing hydraulic hoses.
However, in the event of an emergency, you may need to carry out on-site repairs until you can reach a professional. Temporary fixing of hydraulic hoses is not as daunting as one might think. Once the process is broken down into six steps, the fix is easy.
Most heavy equipment can perform multiple functions (i.e., lifting, pushing, pulling, or cutting), each of which may require a different minimum pressure tolerance. Because of this, there may also be different types of hydraulic hoses with different minimum pressure ratings on a single piece of equipment.
Therefore, it is a good idea to determine which specifications the hose to be serviced must meet. In most cases, the hose assembly is of a specific length and you will need to splice in the shorter assembly to make up for the part that was cut off during servicing.
Keep in mind that even temporarily replacing an incorrect hose can be very dangerous. All hydraulic hoses must indicate the minimum working pressure and maximum burst pressure on the hose. If you have any doubts, consult a professional.
Once you have completed the first step, you will need to cut off the damaged area of the hose. Even if the only problem is a leaking joint at one end of the hose, you must cut off the defective end. Thoroughly clean the area around the cut end of the hose. Remove any dust, dirt or other contaminants from the area as they may contaminate the hydraulic fluid.
Even tiny bits of dirt can damage internal components, leading to costly failures. Therefore, it is vital to ensure that both the fittings and the cut hose ends are clean before performing the rest of the repairs.
In some cases, a hydraulic adapter is required to complete the installation of the repair hose. Since it is not always possible to carry all types of hydraulic couplings, an acceptable solution is to have a kit with various adapters. If necessary, install the adapter on the appropriate port to ensure that a strong connection has been established.
Proper tightening (or tightening) of adapters and couplings is an important part of the repair process. Excessive or insufficient torque can adversely affect the hydraulic system. If you are unsure how much torque to apply, consult the system manufacturer or a trained professional before operating.
Next, place the hose assembly in its place and verify that the length is sufficient. Overstretched or poorly wired hoses will be subject to additional stress and fatigue. Although too much hose is better than too little, according to NAHAD(National Association of Hose and Fittings Distribution) and manufacturer guidelines, having the right length that allows for the correct wiring is ideal. The hydraulic system is under constant pressure, and too short a hose makes dangerous (and costly) failures more likely.
Once the hose is the proper length, make sure it is properly wired. This will allow the rest of the hydraulic system to work properly. Many devices use angled fittings to guide the hose and allow hydraulic fluid to flow more freely. If an angled adapter or coupling is required, install the angled adapter first to ensure proper positioning. Once the angled adapter is in place, the end of the hose assembly can be threaded to the adapter or port.
Insert the remaining end of the hose assembly into or into the opposite port to verify that a proper seal has been created. Even small gaps or defects in the seal can cause problems for the hydraulic system, so carefully check the tightness of the seal before operating. Remember, the seal should be firm but not too tight. Do not twist or twist the hose when installing it. Use a wrench to tighten the fitting, taking care not to overtighten the seal.
Finally, the hydraulic system is turned on so that the oil or hydraulic fluid circulates at low pressure. This will make it easier to spot potential leaks and any broken connections. Circulating hydraulic fluid at low pressure will also remove any remaining air. Air in the system may degrade pump performance or damage pumps and other precision components.
Continue running the hydraulic system for a few minutes and then check again for leaks. Never check for leaks by hand, as this can lead to fluid injection injury. Instead, use cardboard or a piece of paper. Leaks can take several minutes to become apparent, so be sure to check the system carefully before driving the vehicle or using the machine.
Stained hydraulic fluid such as CITGO's Mystik®JT-9™LeakShield®AW hydraulic fluid is pre-stained in a unique color to help workers detect any possible leaks. Eye-catching lubricants can speed up field repairs because crews can easily identify areas of concern.
Simple repairs to hydraulic hoses are not as difficult as you might think. However, it is still advisable to have your work examined by a professional. This helps ensure that no mistakes are made and limits future problems.
If you suspect a hydraulic hose leak or damage, act quickly and make the necessary repairs or replacements immediately. Leaving a leak unattended and unrepaired can cause significant damage to the entire system and leave a gaping hole in your wallet. Whether you are using a farm tractor, transport truck, or industrial machine, the integrity of the hydraulic system depends on the quality of the hose.
