Removing and Replacing a Hydraulic Hose
Hydraulic systems store large amounts of pressure, even after shutdown.
Improper hose removal is one of the most common causes of high-pressure injection injuries, oil spray hazards, and unexpected equipment movement.
This scenario teaches safe step-by-step hose replacement using proper hand tools.
1. Task Overview
Hoses may require replacement due to:
- Leakage
- Cracked or worn outer layers
- Burst risk
- Abrasion damage
- Fitting corrosion
- Routine scheduled maintenance
Hydraulic systems operate under extreme pressure — safety is critical.
2. Required Tools & PPE
Tools:
- Correct-size open-end or combination wrenches
- Adjustable wrench (only if necessary)
- Clean rags
- Flashlight or inspection lamp
PPE:
- Safety glasses or face shield
- Oil-resistant gloves
- Protective clothing
- Anti-slip footwear
3. Step-by-Step Safe Procedure
Step 1: Isolation and Pressure Release
- Shut off hydraulic power
- Lockout/tagout the system
- Slowly activate controls to relieve pressure
- Check gauges for zero pressure
- Loosen test points to verify zero energy
Hazard controls:
- Prevent high-pressure injection
- Avoid sudden hose movement
- Reduce oil spray risk
Step 2: Inspect Work Area
- Place drip trays
- Clean the area
- Improve lighting
- Identify pinch points
- Confirm stable footing
Step 3: Inspect Tools Before Use
- Confirm correct wrench sizes
- Check for cracks, wear, slop
- Ensure no rounding risk
Step 4: Loosen Hose Fittings
- Use two-wrench technique (one holds, one loosens)
- Apply controlled torque
- Keep hands clear of line-of-fire
- Never place face near fittings
Hazards:
- Sudden release of trapped fluid
- Hose whip
- Slippage
Step 5: Remove the Hose
- Gently remove hose once fittings are loose
- Cap open lines immediately
- Drain residual oil
- Inspect threads and sealing surfaces
Step 6: Install New Hose
- Confirm correct hose rating and length
- Ensure fittings match male/female orientation
- Avoid twisting the hose
- Tighten using controlled force
- Do not overtighten fittings
Step 7: Pressure Test
- Remove tools from area
- Restore power slowly
- Watch for leaks
- Tighten gently if required, never overtorque
4. Common Mistakes to Avoid
- Removing hose without confirming zero pressure
- Using incorrect wrench size → rounding fittings
- Placing hands in line-of-fire
- Over-tightening fittings
- Twisting the hose during installation
- Standing directly in front of hose ends during testing
5. Learning Objectives
Trainees should be able to:
- Identify hydraulic hazards
- Release stored pressure safely
- Use correct tools for hose removal
- Control line-of-fire and pinch point risks
- Install new hose correctly
- Conduct safe pressure testing