You can identify and replace worn hoses with the right product, while also preventing system contamination.
Most construction equipment is dependent on hydraulic hoses for its life. A ruptured hydraulic hose can bring down productivity faster than any other thing. It is worth taking the time to inspect the hydraulic hoses before you go. This will help reduce costly failures down the road.
It is worth considering the potential costs of hose failure, including lost production, environmental impact, and injury to operators and other personnel. It is possible to replace hoses while equipment is still in service as part of a hydraulic hose repair London Essex and Kent maintenance program. This will prevent costly downtime.
In critical applications, hoses should be replaced as part a preventative maintenance program (PM). Hose life expectancy is comparable to that of automobile tires. The rubber will begin to wear after four to six years. You can expect to see cracking and weeping around couplings.
Start by inspecting the hose assembly thoroughly. You don’t need to replace the hose assembly if there is no sign of leakage, abrasion wear or cracks. Some customers may choose to have hose assemblies replaced at a scheduled overhaul because of other factors, such as the distance from the jobsite or cost.
Technology predicts the end of life
There are many signs that a failure is imminent in many cases. A potential problem is indicated by wetness, leaks, cracks in rubber, loss or flexibility, or wear rubber. Once these signs are present, there is no way to predict how long a particular hose assembly will last.
It is important to inspect hydraulic equipment every day. Never touch the hydraulic system while it is under pressure. If hot hydraulic fluid is injected into the skin, it can cause severe bodily injury or even death.
However, until recently, there was no way to identify failure indicators and replace hydraulic hoses. There is technology that can monitor these indicators and warn of impeding failure. This capability is provided by Eaton LifeSense Hose. This reduces the need to dispose of hydraulic hoses that are not in use.
Gates Sentry IQ is a hose monitoring system that monitors the performance of hydraulic hoses. It monitors hydraulic hoses in use. It detects pressure spikes and correlates them with the temperature of the hose at the time the spike occurs. The end-of-life of hydraulic hose assemblies is estimated by the correlation between temperature and pressure.
It is not uncommon for hydraulic hose failures to be caused by external damage. Abrasion can be caused by hose assemblies rubbing against each other or on surrounding surfaces.
The environment is exposed to the reinforcement of the wire by covering abrasion. Sometimes, the abrasion can also cause damage to the wire. It may also corrode due to exposure of water or other environmental contaminants. This could lead to the hose becoming weaker.
External guarding may be necessary in some cases to reduce abrasion. Hydraulic sleeving and guarding are used to provide additional protection against abrasion and erosion due to environmental conditions, temperature, and machine application. If the machine application or original assembly requires it, replacement hose assemblies must include sleeving and guarding.
You might also consider using an abrasion-resistant hose such as Caterpillar ToughGuard, which is specifically designed for extreme abrasion applications.
There are many types of sleeves or hose guards that can protect hydraulic hoses against external wear and damage. There are three types: metal spring guards, nylon sleeving and plastic spring guards.
Protect exposed hose by using metal spring guards. They protect it from twisting, twisting and kinking. This guard must be attached to the hose during assembly.
Coil sleeves or plastic spring guards protect the hose from water, air and gasoline. These can be attached after the hose has been installed. Nylon or textile sleeves protect hoses against abrasion. They can be used inside equipment or where hoses may rub against each other.
However, abrasion sleeves have a drawback. The sleeve makes it difficult to inspect the hose visually, which can lead to damage and a catastrphic problem. Abrasion sleeves are becoming more popular because of this.
Learn the specifications
Although many hoses may appear similar, and have the same dimensions, there are important differences you need to understand. The most important thing is to ensure that the replacement hose meets or exceeds the specifications of the original hose assembly.
By paying attention to the selection and installation of hose assemblies, equipment operators and technicians can help reduce premature hydraulic hose failure. It can be hard to choose the right hose among the many available. Gates recommends using the “STAMPED” method to ensure that you get the right hose assembly. STAMPED stands for Size and Temperature, Application, Material to Be Conveyed, Pressure, Ends or Couplings, Delivery.
You should be wary of adapters that allow you to use a different size of hose. Field operators can use adapters to replace OEM hoses with a different type or size that is not appropriate for their equipment. An operator might replace a -12 (3/4-in.) hose to save money or because the parts store does not have the right replacement hose. ID) with a 1/2-inch -8 hose. ID) with a -8 hose (1/2-in).
The smaller size can increase the volumetric pressure within the hose. This could generate heat, crimp the hose or put excessive pressure on the coupling. All of these could lead to premature failure.
Many users are attracted to adapters because of the availability of hoses. -10 hose (5/8 in.) is the worst. ID is rare in North America. Operators would prefer to go down to a 8 (1.2-in. To save money, hose ID is often used. This could lead to equipment acting unpredictably on a drive or control system.
Keep track of any problems on the machine. It may be a good idea to upgrade to a more durable or stringer hose if a particular hose is failing or needs to be replaced more frequently than the average number of hoses on your equipment.
You must follow all installation guidelines, including minimum bend radius, twist, orientation, storage, and securement. Most hose will have a generic SAE/ISO specification on the Layline’ or a manufacturer’s product designation. A SAE EN856 Type R12, for example, is a four-spiral high-pressure hose specification that specifies performance based on the manufacturer.
Cross references are provided by all manufacturers between generic product numbers and their own product numbers. “However, some manufacturers will go beyond the specifications to provide higher service levels and longer lives.
Maintain a clean system
Keep in mind, however, that hydraulic systems of high performance can be easily damaged by contamination.
To remove any oil, grease, or debris from the hose, you should spray it with brake cleaner before you take it off. When you take the hose off, this will reduce the chances of dirt, dust or grime getting into the ports. To prevent debris or dust from getting into the ports, use a plug or cap to cover the ports while you service the hose. You can skip the need to cap the ports if you have a spare hose and just install it. To prevent contaminants from entering the hydraulic system, use brake cleaner to clean threads and surfaces where the replacement hose will attach.
Clean plastic or metal caps are recommended to cover any open hose ends, tube ends, and other ports after a broken hose assembly has been removed. Clean plastic can also be used to wrap exposed hose ends, tube end or related ports.
Do not leave any item exposed for longer than is necessary. Exposure to the atmosphere of any system port is a potential entry point to contaminants. Therefore, it is important that the exposure duration be kept as brief as possible.
Clean doesn’t necessarily mean new. Sometimes, the hose may have some residue from its manufacturing process. Before installing hose assemblies, it is important to clean them thoroughly. Unclean hose assemblies can easily introduce contamination to the hydraulic system.
Caterpillar suggests that you use forced air to remove any contaminants from a new hose. This should be repeated twice: once in each direction through the hose assembly. To protect the assembly from contaminants during storage and transport, you should seal and plug the ends of the hose assemblies.
There are many other methods to clean your hose. The shop’s capabilities, cleanliness requirements and the importance of the application will all influence the cleaning methods. Cleanliness is essential for hose that goes to a pumping part. However, it is not necessary for hose that goes to a tank filter or tank.
There are three methods to clean hydraulic hose assemblies. They can be cleaned with different levels of cleanliness: shop air blow (projectile), fluid flush, or pellet gun (cleaning pig). After the hose is cut to the required length, blow shop air through it. This is the easiest and most common cleaning method. A shop air blow is the most effective and efficient method of cleaning but it does not offer much.
You can also use a pellet, or ‘cleaningpig’, to clean the hose. This is done by using compressed air. The pellet can be used to remove up to 6 inches of debris and cuttings. After the hose is cut, the pellet will be pushed back towards the openings of the hose and flush them out.
The best cleaning method is a fluid flushing device. This technique flushes cleaning fluid at high speed through the hose until it meets the highest cleanliness standards. To prevent debris from getting in, cover the assembly at both ends.
Hydraulic hose failures can be avoided by regular inspections, proactive preventive maintenance, selection of the right products, and concerted effort to clean up.