Hydraulic Hose Replacement: When & How

Web Desk event Nov 16 2021 10:12AM visibility 427
Hydraulic Hose Replacement: When & How

Hydraulic hoses are for transferring pressurized fluid between different components in the hydraulic system. For this, the selected hydraulic hose needs to be strong enough to withstand this high pressure and temperature. The flexible hose design will fit perfectly with all types of systems and help to reduce the overall size and complexity of the design. Lack of maintenance and wrong assembly/selection of hoses are major reasons that lead to hose damage. When the hose is damaged, my suggestion is to replace it by considering how serious it is. Else, this can result in leakage and other safety hazards. In this article, the discussion is on when to replace a hydraulic hose and how it needs to be performed.

Usually, hydraulic hoses will last for a minimum of one to two years and up to a maximum of ten years. The lifetime of the hose will depend on selected hose quality, type of operation, and more. If your hose fails in less than two years, it will not be always an issue with your hose, there may be some other external factors resulting from failure/malfunction of other components. Vibration is also a serious concern that results in surface wear, abrasions, or cuts due to physical contact of the hose surface with other components having high temperatures. Other reasons for hose failure include issues with chemical compatibility, increased operating pressure, wrong selection of hose size, environmental factors related to application, and incorrect hose assemblies.


The question is when a hydraulic hose needs to be replaced. Yes, it is when the hose is damaged and this can be identified simply with a visual inspection. If there are no signs of leakage, abrasions, cracks or twisting, then your hose is safe and you can continue using it. To prevent future issues related to hose failure, it is advised to perform scheduled inspections at least once a month. The factors that need to be inspected include:

  • Twisted hoses will cause structural weakness resulting in hose leakage.
  • Corroded or cracked fittings need to be replaced immediately.
  • Any damage to the outer cover of the hose.
  • Kinked or crushed hoses will result in increased pressure around the kink, which negatively affects hose strength.
  • Abrasion that results in the exposure of wire within the hose
  • Hardened or blistered hose cover
  • Oil leakage around the hose fittings and oil running along the length of the hose.


A hydraulic hose needs to be replaced if it is found to be damaged. Before replacing, it is required to analyze the hose and identify the situation by disconnecting the power supply of that system. The different stages of the hydraulic hose replacement procedure are:

  • Prepare the hydraulic system by disconnecting the power supply and checking the components that need to be removed or adjusted to ensure that they do not hinder the replacement process.
  • Lose the fittings and remove the hose that needs to be replaced.
  • Seal the fittings with a designated fitting plug or rag
  • Install the hose by following proper techniques.
  • Visually check the connections at first and if found error-free test the system


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