How To Replace A Hydraulic Hose?

When to Replace a Hydraulic Hose: Signs, Safety & Step-by-Step Fitting

Hydraulic hoses keep your system running by carrying pressurised fluid between pumps, valves and actuators. Over time, hoses can deteriorate, crack, leak or fail. Planning a hydraulic hose replacement before failure is one of the best ways to reduce downtime and prevent damage.

Safety first

Hydraulic fluid under pressure can be dangerous. Always depressurise the system and wear suitable PPE before checking or replacing any hydraulic hose.

How to determine whether your hydraulic hose needs replacing

As a general rule, it’s best practice to replace a hydraulic hose around 5 years after the printed manufacture date. Even if the system hasn’t been used, rubber degrades over time due to age, heat, sunlight and environmental exposure.

That said, time-based replacement is only one part of good maintenance. Regular visual checks help you spot signs of hydraulic hose failure early.

Common signs your hydraulic hose needs replacing

Cracks in the outer cover
Tears or splits
Abrasion marks or scuffing
Outer rubber worn through with visible reinforcement wires
Crushed or pinched sections (kinks/flat spots)

If you see any of the above, replace the hose before using the system again.

How to check if a hydraulic hose is leaking

If there are no obvious signs of damage, the next step is checking for leaks:

Wipe away any existing fluid from the hose.
Wait briefly and then run a piece of cardboard along the hose (never use your hands).
If a wet spot appears, your hydraulic hose is leaking and requires replacement.

How to remove a damaged hydraulic hose

Before working on any hydraulic system, protect yourself from contact with hydraulic fluid and ensure all pressure is released.

PPE to wear before starting

Safety goggles and gloves
Long sleeves and long trousers
A mask if you’re not working in a well-ventilated area

Depressurise and prepare the work area

Release pressure using the system’s lever/relief method (follow your manual for the exact procedure).
Shut off all power to the system.
Cycle the control lever back and forth a few times to remove residual pressure.
Place a cloth or bucket beneath the hose area to catch any escaping fluid.

Removing the hose (clean + two-wrench method)

Remove any coverings/hoods so you can access the hose and fittings.
Clean both hose ends and connectors to prevent dirt entering the hydraulic system.
Use two spanners: hold the fixed fitting steady while loosening the rotating nut counterclockwise.
Detach one end, then repeat on the other end.

What to do to install a new hydraulic hose

The replacement hose must match the original hose specifications (length, bore, pressure rating, fitting type and thread). If you’re unsure what you need, contact Flowfit for help selecting the correct hydraulic hose.

Install the new hose safely

If the hose may rub on components, fit an abrasion sleeve for protection.
Clean the hose fittings and mating connectors before installation.
Thread the first end in by hand, then tighten with spanners until secure (avoid overtightening).
Fit the second end: hold the fitting with one spanner and tighten the swivel nut with the second.
Refit any covers/hoods removed during access.
Test at low pressure first and inspect carefully for leaks before returning to normal use.