how to repair broken hydraulic hose


How to Repair a Broken Hydraulic Hose


Hydraulic hoses are essential components in any hydraulic system, as they transmit fluid power from one component to another. However, these hoses can sometimes sustain damage or develop leaks, leading to decreased performance and potential system failure. Repairing a broken hydraulic hose is crucial to ensuring optimal functionality. In this article, we will discuss the steps involved in repairing a broken hydraulic hose, along with important safety precautions to consider.


1. Identifying the Problem: Assessing the Damage

2. Gathering the Required Tools and Equipment

3. Cutting and Preparing the Hose

4. Attaching a New Fitting

5. Testing and Reinstalling the Repaired Hose

Identifying the Problem: Assessing the Damage

The first step in repairing a broken hydraulic hose is to identify the problem. Look for visible signs of damage, such as leaks, cuts, abrasions, or bulges in the hose. Additionally, check for any loss of hydraulic fluid or changes in system pressure. If you suspect a broken hose, it is essential to isolate and depressurize the system before proceeding with the repair.

Gathering the Required Tools and Equipment

To repair a broken hydraulic hose, you will need a few essential tools and equipment. These include safety gloves, safety glasses, a utility knife, a hose cutter, a measuring tape, hydraulic hose fittings, hose clamps, a wrench, and replacement hydraulic hose. Ensure you gather all these tools before starting the repair process.

Cutting and Preparing the Hose

After gathering the necessary tools, it is time to cut and prepare the damaged hose. Begin by measuring the length of the damaged section and mark it using a measuring tape. Next, carefully cut the damaged area using a hose cutter. Make sure to cut precisely and avoid any jagged edges. Once cut, remove any debris or loose material from the inside of the hose.

Attaching a New Fitting

The next step in repairing a broken hydraulic hose is attaching a new fitting. Take the replacement fitting and ensure it matches the specifications of the hose you are using. Apply a thin layer of lubricant or hydraulic oil to the fitting threads to ensure smooth installation. Using a wrench, tighten the fitting securely onto the hose. Double-check for proper tightening to prevent any potential leaks.

Testing and Reinstalling the Repaired Hose

With the new fitting attached, it is crucial to test the repaired hose before reinstalling it. Re-pressurize the hydraulic system and visually inspect the repaired section for any signs of leakage. If there are no leaks and the system operates properly, you can reinstall the hose. Ensure all connections are secure and tightened as required. Take note of any special instructions or torque specifications provided by the equipment manufacturer.


Repairing a broken hydraulic hose is essential to maintain the integrity and functionality of hydraulic systems. By identifying the problem, gathering the necessary tools, cutting and preparing the hose correctly, attaching a new fitting securely, and testing the repaired section, you can successfully restore a broken hydraulic hose. However, it is crucial to follow safety precautions and consult a professional if you are unsure about any step in the repair process. Regular maintenance and inspection can help prevent future damage and ensure long-lasting performance of hydraulic systems.


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