this blog has moved to https://www.mobilehosefixersgoldcoast.com.au/blog/ How to repair a Hydraulic Hose the Complete Guide that will Save you Time and Money

Introduction

Removing Repairing and or replacing a damaged Hydraulic Hose is not generally very difficult. That being said there are quite a few important steps to ensure the final outcome is a success.

With a little bit of planing, preparation and using the comprehensive guidelines below you and your machine's hydraulic system will be back up and operating in the shortest possible time and or with the least effect to your wallet or bank balance.

For 13 lucky years my team and I have removed manufactured and installed over 50,000 hose assemblies.

If you are looking to join the hydraulic hose replacement industry and earn some good Money in the process this blog is a good first introduction on the basics of what we do, why we do it and how we do it.

It has been put together by the team at Mobile Hose Fixers & Hydraulics as both a guide and a reference to assist you to carry out your hydraulic hose repair work safely and efficiently.

Before you start you must make a through review of the surroundings and situation, identify the hose AS WELL as any other spare or replacement parts necessary to fulfill the requirements of the application.

It is imperative that you observe and obey all safety requirements before, during and after work has been carried out. 

You are required under the Workplace Health and Safety Act to notify the owner or operator of any unsafe conditions or possible premature failure of hoses or associated fittings.

Care must be taken to avoid oil spills. Appropriate caps and plugs must be fitted and drip trays used in order to minimise spills. When spills occur, it is necessary to use rags or oil absorbing materials such as pads and granules to ensure that the oil is removed.

Note: In Australia and most other parts of the world It is an offence against environmental legislation to allow oil to be introduced into the storm water drainage system. Under no circumstances may spilled oil be flushed or dumped into gutters or storm water drains. Take all spilled and waste oil away with you for proper disposal or collection by a registered waste organisation.

Although this is a comprehensive blog that outlines most procedures and gives practical advice on hose making. You may still,  however, come across unusual situations requiring creative solutions.

Use your initiative to resolve these situations, Above all you must always follow  safety procedures, and ensure that all checks are carried out under normal working conditions.

Contents.

1. Safety First ALWAYS ( P.P.E)
2. Pressure Force and Gravity
3. Prepare to get Dirty (oily hands or neoprene gloves)
4. Finding the Damaged Hose (trace the leak to the source 😉)
5. Understand the Mechanics (what does the hose do?)
6. Make the machine safe 
7. Protection from the Elements sun wind rain
8. Tools more Tools Special Tools and Techniques
9. Get to it.  Perseverance and Resilience.
10. It's OK to Swear (it helps release stress and tension) 
11. Colored cable ties Plugs and Caps (keeping it all Organised and Clean)
12. Secret tricks to help remove the old hose and replace the new hose (rope and wire and tape are your friend)
13. Once the Hose is out (now what are your Options?) 
14. Store Bought OEM, After Market, or D.I.Y.
15. Store
16. D.I.Y
17. STAMPED and APPS to help you identify what you require.
18. Reusable fittings advantages and Disadvantages.
19. D.I.Y Video, Hydraulic Hose Assembly with Reusable fittings.
20. Hose types and Basic Identification 

All our new team members get quickly introduced, trained and then relentlessly questioned and tested on the acronym S.T.A.M.P.E.D. why, because we feel we have proved it thousands of times over that questions asked and answers received based on these 7 letters result in a more effective, durable and safer hydraulic hose repair.
We have completed over 50,000 High Pressure Hydraulic Hose Repairs, and we have found that  starting your questions based on this 7 letter acronym will help even the most inexperienced team member pinpoint with much better accuracy just what hose type and construction will be most suited for the application.

From Top Left Fabric Braid up to 500 PSI  (35 Bar)

Single Wire Braid up to 2000 PSI (135 Bar)

Multiple Wire Braid up to 4000 PSI (270 Bar)

Multiple Spiral Wire Wrap up to 6000 PSI (410 Bar) 

Read on to find out how you can get your self out of trouble and back working with the right hose most ideally suited for you and your machine's requirements.

So when you contact us expect to be asked a few important questions using the Acronym  S.T.A.M.P.E.D and then, based on your answers, we will formulate the best, quickest and most economical solution for you. 
Our solutions or options may include.

• Sending one of our Mobile Service Technicians out to do the job for you.
•  Arrange for you bring the hose or even the entire machine to our Gold Coast service center.
• Us packing and sending you the parts or the completed hose assembly you need along with instructions to Do It Yourself (DIY).

S.T.A.M.P.E.D stands for 

• S = Size 
• T = Temperature
• A = Application
• M = Media
• P = Pressure
• E = Ends
• D = Delivery 

S = Size, 
The size or more importantly the Hose Inside Diameter. 
Generally you will need to replace the original hose with one of the same inside diameter. On long runs of pressure wash hose for example we may recommend the next larger size available to maintain original design flow and pressure drop. 

Three (3 ) Hose Samples each with a different inside diameter
From top to bottom 1/4" (6.5 mm) 1/2" 12.7 mm and 1" (25.4 mm) 

 T = Temperature,
For most Australian operating conditions it is sun and heat rather than cold that causes damage and deterioration in hydraulic hoses. 
The operating temperature is important in selecting suitable materials of Construction. Normal hydraulic hose will typically run around 60 to 75 degrees Celsius, transmission and power steering hoses may operate up to and around 120 degrees Celsius. 
Truck air brake compressor hoses may reach 150 degrees Celsius or more 

Four (4) Hose samples with their Maximum Continuous Working Temperature

From Top to Bottom, Synthetic Fiber Reinforced Nylon 70 C°,Steel Reinforced Synthetic Rubber 120 C°,Steel Reinforced High Temp Synthetic Rubber 160 C° Stainless Steel Reinforced (PTFE ) Teflon 260 C°. 

A = Application. 
How, Where and How often is the hose being used. 
Will it be exposed to the elements, sun, Heat, Wind, Rain, Snow and Ice. 
Abrasive environments such as those found Earth moving equipment, 
Aggressive chemicals, not just those found in paint or industrial chemical factories,
Believe it or not the salt in sea / ocean water can be classified as an aggressive chemical environment because salt when mixed with water and the oxygen in air can deteriorate most materials quite quickly.     

Sea Lift, This Machine Drives down a boat ramp and into the sea and positions itself under large twin hulled boats, it then raises up levels out and brings the boat up onto the shore for repairs and maintenance, it may do this task multiple times a day. 

M = Media,
What type of fluid is going to be flowing through your high pressure Hydraulic Hose? Water, Oil, Gas, Chemicals with what PH Acid or Basic?

P = Pressure, 
The normal Operating Pressure is very important in ensuring the correct hose is selected for strength and durability. 
Generally we work with an industry recommended Burst to Working Pressure safety factor of 4 to 1. For example a 1/4 inch inside diameter 2 wire braided hose will have a working pressure of 5600 PSI (380 Bar) and have a Minimum Burst Pressure of 22,400 PSI (1520 Bar)

4 Hose Samples with different materials of construction & Working Pressure Ratings. From Right to Left (small to large).
3/8" bore hose Synthetic Fiber reinforced hose SAE 100R6 pressure 34 BAR (500 PSI)
1/2" bore hose with 1 layer of braided steel wire SAE 100R1, working pressure 136 BAR (2000 PSI)
1/2" bore hose with 2 layers braided steel wire SAE 100R2, working pressure 275 BAR (4040 PSI)
3/4" bore hose 4 layers spiral wound steel wire SAE 100R15 ,working pressure 400 BAR (6000 PSI)

E = Ends,

What connections are on each end of the hose. This is Very Important and can vary quite a lot depending on intended application, working environment, how it is positioned and sometimes more importantly on the machine's country of manufacturer or intended country of origin.

Six 1/4" Hose Fittings from Left to Right

14 mm Metric Male,

 9/16" JIC Male,

 1/4" BSPT Male,

1/4" BSPP Female Straight,

1/4" BSPP Female 45° Elbow,

 1/4" BSPP Female 90° Elbow.      

D = Delivery,
How are you or we going to get your hydraulic hose repaired and leak sorted, and what tests and or special safety procedures will we or you carry out before, during and after final installation and commissioning for example ?

•  Do we come to you?
•  will you take the hose off and bring to us? 
• Will you or can you bring the whole machine to us? or 
• Will we assemble and pack and send the parts to you ready to assemble and install?   

Follow us on Facebook to see all our Daily Adventures & Challenges

The Story is nearly always the same.
 The phone call from the stressed customer is nearly always the same,

I had just one

• more load to take to the land fill site or
• more meter of trench to back fill or
• more driveway to blast clean or 
• car or boat to rinse off... and I was done!

"But then I noticed Oil or Water leaking and pooling on the ground, or worst yet hot Oil was spraying and making a mess of my engine bay or even worse yet pouring on to my customer's newly cured concrete driveway and freshly painted house wall !?

Sometimes the hydraulic hose leak is small and the oil seeps into the ground unnoticed until your machine starts to shudder and loose power or just stops, moving, digging or grinding altogether.
What The ! you think to yourself !?!

Repairs to Excavator with a Pulverizer,
(a concrete crushing attachment) on a demolition site.

With 50,000 High Pressure Hydraulic Hose Repairs completed over the last 12 years There are a couple of ways to get you back to work.  
The best and safest way is to call us at Mobile Hose Fixers & Hydraulics 
(07) 5571 6155 

Need Hydraulic Hose Repairs click here

However, having a mobile High Pressure Hydraulic Hose Repairs technician visit you is not always possible, practical or economical.  

The quickest and most cost effective way to repair or replace a hydraulic hose will require you to have some mechanical knowledge and aptitude and to be capable of safely finding and removing the damaged or leaking Hydraulic Hose. 





You will also have invested in some minor insurance such as a handful of D.I.Y Reusable Hose Fittings , Hydraulic Hose and some tools such as spanners or wrenches and preferably (but not essential) a  vise or vice mounted to a solid bench or other heavy object. 

If you want some Guidance and insight on how you can manufacture new high pressure hydraulic hose assemblies with basic tools and without expensive equipment? 
Then watch this informative 12 minute video to get an idea what is required to complete a Do It Yourself D.I.Y Hydraulic Hose Repair Assembly using Reusable Field Fit Hydraulic Hose Fittings.


Click here to watch our 12 minute D.I.Y hose assembly Video.

Typical Field Fit Reusable, a Hydraulic Hose Repair fitting used for Hydraulic Hose Repairs and Do It Yourself  DIY hose Assemblies. These two (2) piece fittings screw onto the hose in a certain sequence and once assembled are rated to work safely up to the full pressure rating of the hose. 

If this type of repair seems interesting and challenging and within your technical and physical capabilities, you can visit our web store and select and purchase the parts required.

Click here to Buy Field Fit Reusable Hydraulic Hose Fittings 

For Crimp / Swage on Hydraulic Hose Fittings click here

For 1/4" 2 Wire 5800 PSI rated hydraulic hose

For 3/8" 2 Wire 4800 PSI rated hydraulic hose

For 1/2" 2 wire 4000 PSI rated hydraulic hose


For a complete store overview and everything hydraulic, including, hose, fittings, valves, motors and cylinders. But first please read below to fully familiarize your self and or refresh your memory on the process and parts required. 
If you get stuck or need assistance use the contact us page to phone us or send a message.  

 Click here to contact us