how to change a hydraulic hose


How to Change a Hydraulic Hose: A Step-by-Step Guide


Hydraulic hoses are an essential component of any hydraulic system. Over time, these hoses can wear out, develop leaks, or become damaged. When this happens, it is crucial to replace them promptly to ensure the smooth functioning of the hydraulic system and prevent further damage. In this article, we will provide you with a comprehensive step-by-step guide on how to change a hydraulic hose effectively.

I. Assessing the Hydraulic Hose:

Before starting the replacement process, you must determine the condition of the hydraulic hose. Inspect the hose thoroughly and look for signs of wear, such as leaks, cracks, or bulges. If you notice any of these issues, it is time to replace the hose.

II. Gathering the Tools and Materials:

To change a hydraulic hose, you will need the following tools and materials:

1. Wrenches: Collect a set of open-end or adjustable wrenches in various sizes to loosen and tighten fittings.

2. Replacement Hose: Purchase a hose suitable for your hydraulic system's specifications. Ensure that the hose length and diameter match the original hose.

3. Hydraulic Fluid: Have an adequate amount of the appropriate hydraulic fluid on hand to refill the system after hose replacement.

4. Safety Gear: Wear protective gloves and safety glasses to protect yourself from any potential hazards during the procedure.

III. Draining the Hydraulic System:

Before changing the hose, it is essential to drain the hydraulic system completely to avoid spillage and contamination. Follow these steps:

1. Switch Off: Shut down the hydraulic system by turning off the pump or engine.

2. Relieve Pressure: Release the pressure in the system by moving any control levers or switches a few times.

3. Drain Fluid: Place a suitable container underneath the hose connection point and disconnect the hose from the fitting. Drain the hydraulic fluid completely into the container.

IV. Removing the Old Hose:

To remove the old hose, follow these steps:

1. Loosen Fittings: Using the appropriate wrenches, loosen the fittings securing the hose to the system. Turn them counterclockwise until they are loose enough to be removed by hand.

2. Remove Hose: Gently pull the hose end straight out of the fitting, taking care not to damage the fittings or surrounding components.

3. Inspect Fittings: Examine the fittings for any signs of damage or wear. If necessary, clean or replace them before installing the new hose.

V. Installing the New Hose:

Now it's time to install the new hydraulic hose. Follow the steps below:

1. Lubricate Fittings: Apply a small amount of hydraulic fluid on the inside of the fitting and on the hose end to assist with installation.

2. Insert Hose: Carefully insert the new hose into the fitting, ensuring it is properly aligned and seated. Push the hose in until it reaches the bottom of the fitting.

3. Tighten Fittings: Using the wrenches, securely tighten the fittings onto the new hose. Turn them clockwise until they are snug and leak-free.

VI. Refilling the Hydraulic System:

After replacing the hose, it's crucial to refill the hydraulic system with fresh fluid. Follow these steps:

1. Replace Hydraulic Fluid: Fill the system's reservoir with the appropriate hydraulic fluid recommended by the manufacturer.

2. Bleed Air: Slowly operate the system's controls or pump to purge any air bubbles from the hydraulic system.

3. Monitor: Check for any leaks or abnormalities in the system while it is running. If any issues arise, promptly address them.


By following the step-by-step guide outlined above, you can successfully replace a hydraulic hose. Remember, it is crucial to take your time, ensure proper alignment and tightness, and follow all safety precautions during the process. Regularly inspecting and replacing hydraulic hoses when needed will help maintain the integrity and efficiency of your hydraulic system in the long run.


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