If you are in an industry that relies on hydraulic systems to transfer power or fluids, you know how important hydraulic hose assemblies are. From construction and agriculture to oil and gas, manufacturing, and transportation, hydraulic hose assemblies are an integral part of many industries.

For example, in the construction industry, hydraulic hose assemblies power the hydraulic cylinders that control the movement of heavy machinery like excavators and bulldozers. Similarly, in agriculture, they are used to power the hydraulic cylinders that control the movement of equipment like tractors and combines. In the oil and gas industry, hydraulic hose assemblies are crucial for drilling, fracking, and pipeline maintenance. In manufacturing facilities, they power hydraulic presses, molding machines, and other machinery. And, they even power hydraulic brakes and steering systems in automobiles and aircraft.

In order to keep your business running smoothly, it’s important to choose the right hydraulic repair center for hose assembly selection and replacement. That’s why we’ve gathered three expert tips to help you make an informed decision. With these tips, you can ensure that you’re getting the right hydraulic hose assembly for your needs and that it will be replaced properly when the time comes.

Here are our 3 Expert Tips for Hydraulic Hose Assembly Selection and Replacement:

Choose the Right Hose for the Job

Choose the Right Hose for the Job

It's essential to select the right hose for the specific application. Factors to consider include the type of fluid being conveyed, the temperature and pressure requirements, and the environment in which the hose will be used. Choosing the wrong hose can result in damage, leaks, and potential safety hazards.

Inspect and Replace Regularly

Inspect and Replace Regularly

Hydraulic hoses and hydraulic cylinder rebuild should be inspected regularly for signs of wear, damage, or leaks. A damaged or worn hose or cylinder can lead to a failure, resulting in system downtime and potential safety hazards. Experts recommend replacing hydraulic hoses every 2-3 years or sooner, depending on usage and environmental factors. Similarly, a hydraulic cylinder rebuild should be performed when there is excessive wear or damage to the cylinder. Regular maintenance and inspection of both hydraulic hoses and cylinders can help ensure the safe and efficient operation of hydraulic systems.

Proper Installation and Maintenance

Proper Installation and Maintenance

Proper installation and maintenance of hydraulic hoses are critical for optimal performance and safety. It's important to follow manufacturer guidelines for installation and tightening torque specifications. Additionally, it's important to keep hoses clean and free of debris that could damage them or cause clogs.

When it comes to hydraulic needs, it’s essential to work with a company that has the expertise and knowledge to handle the job. We’re a trusted leader in the hydraulic industry, with decades of experience in basic hydraulic troubleshooting and repair. From selecting the right hose for the job to regular maintenance and replacement, we can handle all of your hydraulic needs with professionalism and expertise. With our attention to detail, commitment to safety, and focus on customer satisfaction, you can trust us to provide the highest quality hydraulic solutions for your business. 

Need help finding the right hydraulic parts?

At Yarbrough Industries, we have a large selection of hydraulic products and offer diagnostic, testing, repair, and replacement services to help get your operations back up and running in no time.

If you use and maintain hydraulic equipment on a regular basis, you’ve more than likely found yourself running into a repair job that could have been easily fixed if you or your technicians had the right parts on hand. 

Instead, you’ve probably found yourself scrambling to find a vendor with the right part(s) in stock, rush ordering, and holding onto hope they’re able to get it to you sooner than later. Sound familiar?

While storing an excess of hydraulic spare parts does not make a whole lot of sense, having the right ones to keep your equipment up and running plays a big role in having an effective maintenance plan. But where do you start?

Here is a closer look at how to effectively manage your part inventory and what hydraulic parts you may want to keep around in case a machine goes down. 

Analyze & Identify Hydraulic Parts

One of the toughest challenges of managing an effective part inventory is having the right type of parts available when you’re troubleshooting your system and have to stop production.

Knowing your machinery and which parts are critical to its operations is the first step in creating an effective spare part inventory. This can include having everything from extra cylinders, pumps, and motors to extra valves, hoses, seals, and even o-rings. 

So how do you figure out which parts you should keep handy? 

To get a good idea, you should begin by analyzing past equipment and part data. Everything from past maintenance records, inventory adjustments, purchase orders, and downtime logs will provide invaluable insight into what spare parts will be the most beneficial and economical to have available at a moment’s notice. In addition, it doesn’t hurt to talk to your maintenance technicians and purchasing agents to see if they have any further insight or recommendations based on their experience with the equipment. 

Having this information will help you better forecast and identify exactly what type of parts to have on hand in case a machine’s hydraulic system fails

Here are a few spare hydraulic parts and components we recommend keeping in stock: 

  • Pumps
  • Hoses
  • Valves
  • Filters
  • Cylinders
  • Belts
  • Gaskets
  • Actuators
  • Fan Motors
  • Seals and O-rings

Remember, it is often more cost-effective to repair old hydraulic parts and keep them as spares than it is buying new ones. If you have old broken parts lying around, working with an experienced hydraulic repair technician can help you salvage them so they’re good as new and ready to use. 

Not sure whether to repair, rebuild or buy new hydraulic equipment? Check out this article we wrote. 

Maintain Your Hydraulic Part Inventory

If you have a solid maintenance plan in place and are taking care of your hydraulic equipment on a regular basis, ideally spare parts should not have to be used too often. However, as the saying goes – it’s better to be over-prepared than under. 

That said, you don’t want a cluttered inventory full of unnecessary spares taking up space. 

To manage your part inventory and help determine the most economical quantity of parts to order there is a formula known as the Economic Order Quantity Formula (EOQ).

The EOQ Formula can help you prevent both loss and waste in your inventory by calculating an annual order quantity that minimizes costs and maximizes your order efficiency. You can find out more about the EOQ Formula here

EOQ Formula

Here is a simplified example:

Annual Demand: 200 units
Order cost: $5.00
Holding Cost: $1.25
Calculated Order Amount = 40 units

While having a formula is helpful, there is no equation that will help you maintain a perfect inventory at all times. There are too many variables and unforeseen circumstances that come with maintenance and repairs. That’s where having a reliable hydraulics vendor comes into play. 

A reliable vendor will effectively help you manage your part inventory by understanding your equipment needs, help you save time and money, and be able to get you out of a pinch when circumstances call for it. 

When it comes to hydraulics, a reliable vendor should have hydraulic repair experience and a diverse inventory of products available. They should be able to supply you with a wide variety of high-pressure hydraulic products, including pumps, cylinders, valves, clamping components, and also any related hydraulic products, including pneumatic and lubrication products.

Overall, maintaining the proper inventory of spare hydraulic parts can be the difference between extensive unscheduled downtime or same-day repairs. Analyzing and identifying these parts, keeping up on routine maintenance, managing your inventory, and having a reliable go-to hydraulic shop will all help you speed up repair times, minimize downtime, and eliminate excessive costs when equipment goes down. 

Need help finding the right hydraulic parts?

At Yarbrough Industries, we have a large selection of hydraulic products and offer diagnostic, testing, repair, and replacement services to help get your operations back up and running in no time.

The industrial world is continuing to evolve. This means adding more sophisticated ways of reducing unscheduled downtime. However, even with all the automated processes, you still need discipline to ensure the fundamentals of troubleshooting and failure analysis/analytics aren’t lost. Adding devices to monitor operating conditions does little if you can’t put that feedback into context.

The importance of the information gleaned from the repair and refurbishment of equipment can’t be understated. This should be a critical component of any downtime reduction strategy, as it can deliver more than just the face-value savings that result from repair versus replace.

Properly analyzing the mode of failure can provide valuable information about what caused that failure, and thus can be used in an effort to resolve underlying issues. Resolving these underlying issues is the true key to avoiding future unscheduled downtime.

Common Modes of Failure

There are several common modes of failure for variable displacement piston pumps. Understanding these modes of failure, the causes, warning signs, and the prophylactic means of monitoring will help you to reduce unscheduled downtime.

The four most common modes of failure in piston pumps result from the following:

  • Oil contamination
  • Fatigue from transient pressure spikes
  • Blocked or restricted pump inlet
  • Pump case over-pressurization.

These four modes account for the vast majority of all failures seen in the thousands of units inspected and repaired each year by the service technicians.

Oil Contamination 

Contamination can be the result of many things, including egress of water, environmental contaminants, or component ware elements.

Telltale signs of contamination include:

  • Valve plate scoring
  • Vertical scratches on piston barrels
  • Scratches on the face of pistons
  • Excessive wear of saddle bearings (or embedded particulate)
  • Plugged orifices
  • Stuck compensator spools
  • Pistons being seized within the cylinder bore of the barrel.

Fatigue from Transient Pressure Spikes

The fatigue that results from transient pressure spikes will present in the form of broken pistons (at the neck), shafts (where the cylinder barrel rides or at the tail), sheered control pins, damaged yokes, or the appearance of cracks between the kidneys of the cylinder barrel. Of the four common modes of failure, this is by far the most difficult problem to identify through electronic monitoring. It takes a device with an exceptionally quick scan rate as spikes can form and dissipate within the window of a few milliseconds.

If you suspect that your system is experiencing transient pressure spikes, hand-held monitoring devices are offered by many OEMs and are an excellent addition to any reliability team’s troubleshooting toolbox.

Blocked or Restricted Pump Inlets

Blocked or restricted pump inlets will typically present in the form of cavitation on the valve plate or what some service technicians refer to as a “marble sound.” Vacuum at the inlet leads to the formation and collapse of small vapor-filled voids. The shockwave generated by the collapse of these voids leads to surface damage on the valve plate as well as the telltale sound.

Ways to monitor for this condition include the following:

  • A limit switch mounted on a suction ball valve feeding the pump (a common system interlock)
  • A pressure transducer installed into the suction line
  • Vibration monitoring through the use of accelerometers mounted to the pump

Pump Case Over-Pressurization

Pump case over-pressurization can present in the half-moon gouging or full-moon scoring of the swashplate, damaged shoe retainer, bent seal retainer, or protruding shaft seals as well as shoe damage—rounded edges, loose fit on the ball, and excessive wear on the backs of the shoes. This kind of damage will be the result of shoe lift or rolling caused by the increased case pressure.

This condition can be monitored through the use of a pressure transducer in the case line. In practice, however, this is rarely done. The most common type of monitoring for case drains is flow observation. Monitoring for flow can give you a good indication of pump life—allowing you to see how efficient the pump is running (that is if 10% is leaving the case only 90% is going into the system). As a guide: Flow greater than 10% of total flow capacity of the pump indicates excessive wear. It is also worth noting that this method of monitoring pump life is not valid for pumps that have an internal check between the case and suction.

Understanding these modes of failure, the signs, root cause, and methods for identification will help to reduce unscheduled downtime and improve overall system reliability when it matters most.

Yarbrough Industries has years of experience with hydraulic pumps and motors and is always happy to answer your questions or help with things such as troubleshooting, on-site installations and technical training/support. For more information, please contact us.

Need additional assistance? Contact us today!

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When your hydraulic system stops working, no matter the cause, it can bring productivity to a grinding halt (both literally and figuratively). Troubleshooting and tracking down the problem will take skill, experience and common sense. There are a few basics that anyone can handle, however. The basics of hydraulic troubleshooting serve as a reminder to keep it simple and take time to do each step. This will save money and time in the long run.  

Preparing for Troubleshooting

Before you even begin the troubleshooting process, it’s important to know what the problem is. This means you have to ask questions before you start. Some basic questions might be:

  • How long has this been happening/When did it start?
  • When did you first notice the problem and what was happening? (startup/shut down/heavy load/temperature change/etc.)
  • Have there been any recent changes to the system, such as maintenance, modifications to the settings, or repairs?
  • When was maintenance last performed?

Once you have as much information as you can gather, pull the hydraulic schematics for reference. It’s important to know that you should not attempt troubleshooting without this! The schematics provide valuable information about flow and pressure in the system.

Common Problems

There are a number of issues that commonly prevent hydraulic systems from working properly, such as an inoperative system or overheating hydraulic fluid. In any basic troubleshooting, it’s key to look at the most typical issues that arise in hydraulic systems first.

System Inoperative

When your hydraulic system is inoperative, there are several things that can be checked. First, you must verify the hydraulic fluid levels and check for leaks, as they can lead to significant loss of hydraulic fluid. Filters are also a common problem because if they are dirty or clogged, they can seriously impact performance. Check your hydraulic lines for restrictions such as collapse or clogging. Be sure you do not have any air leaks affecting the suction line. Also, inspect the pump itself; if it is worn, dirty, or out of alignment, it will affect system performance. The drive can be a source of issues if belts or couplings are slipping or broken. 

Slow Operation

If your hydraulic system is working more slowly than normal, it could be as simple as the hydraulic fluid is too thick, which may be due to cold temperatures or the use of an inappropriate hydraulic fluid. Air trapped in the system can be a problem, as well as restrictions in the line, due to dirty hydraulic filters. Another potential issue is badly worn hydraulic components such as pumps, motors, cylinders, and valves.

Erratic Operation

When a system is operating in an erratic, unpredictable manner, it can be very frustrating. One of the most common causes for this is air trapped in the system or hydraulic fluid that is too cold. Damaged internal components, such as bearings and gears can also be a reason, although it is a bit less common.

Excessive Noise or Vibration

Something that almost anyone who works with hydraulic equipment has experienced is excessive/abnormal noise or vibration. The pump being noisy calls for a check that the oil level is sufficient, the correct type of fluid is being used, and that the oil is not foamy. If the oil is foamy, that informs you that there is air in the fluid. This can lead to cavitation and expensive damage. It is also wise to verify that the inlet screen and suction line are not plugged. For both pumps and hydraulic motors, there can also be internal issues, namely worn or misaligned bearings. Noise and/or vibration can also mean you need to make sure the couplings are secure and tight. Keep in mind that pipes and pipe clamps can vibrate if they are not secured properly, so take a moment to check them over if none of the other checks show an issue.

Overheating Hydraulic Fluid

Excessive heat is never a good sign in a hydraulic system and often leads to a system working at sub-optimal levels. One of the primary purposes of hydraulic fluid is to dissipate generated heat, but the system should not be generating enough heat to cause the fluid to reach high temperatures.

There can be many causes behind hot hydraulic fluid, starting with contaminated hydraulic fluid or fluid levels that are too low. There may be oil passing through the relief valve for too long at a time; in this case, the control valve should be set to neutral when it is not in use. Worn-out components within the system can also lead to excessive temperatures due to internal leakage. Restrictions in the line or dirty filters can result in hot hydraulic fluid or if hydraulic fluid viscosity is too low, it can lead to overheating as well. Finally, there may be a need to make sure that the oil cooler is functioning correctly and that the key components are clean enough for the heat to radiate away from them.

No Fluid Flow

Having no flow within the hydraulic system is a serious issue that can have several different sources. The first step is to determine exactly where the fluid flow stops, such as failure of the pump to receive fluid at the inlet (usually the result of a clogged line or dirty strainers) or a failure for fluid to exit the outlet, which could be due to a pump motor that needs replacing, a sheared coupling between the pump and drive, or a pump/drive failure. It would also be a good idea to make sure the pump rotation is set correctly and the directional valves are in the correct position.

The most expensive problem would be a damaged pump that needs to be replaced or repaired. Getting your hydraulic system back in working order can be a time-consuming process. At Yarbrough Industries, we understand the importance of having a functional, efficient hydraulic system. We know that downtime is a price that you can’t pay in both money and time. That is why we offer comprehensive hydraulic services on-site troubleshooting and repair. Our team of experienced technicians can work on motors, pumps, valves, cylinders, and systems. When complex repairs are called for, we have a full machining center and certified welders. We also offer customized maintenance plans tailored to your needs and your equipment.

 

Contact us today to find out how Yarbrough Industries can help keep your hydraulic systems operating efficiently.

Get direct access to industry-leading content

This industry moves fast, but you can move even faster if you’re up to date on trends, technical developments, and best practices. The Yarbrough Industries blog is a go-to source for valuable, timely and detailed information. Sign up to ensure that you don’t miss a single post.

Maintaining equipment, no matter the size or parts, is the best way to get a great return on your investment. When you are thinking about your pump or motor, the bearings, seals and gaskets are no exception. Preventative measures can save you money, time and effort by minimizing wear and tear on your equipment over time. Let’s take a look at some ways you can ensure process reliability by protecting your gaskets, seals and bearings with preventative pump maintenance.


Pump Bearings


It is essential to routinely examine changes in lubrication, vibration, temperature and noise of your pump/motor to determine that your pump bearings are operating properly. There could be several factors affecting the performance of pump/motor bearings. Your environment, speed, loading and lubrication can all determine how much stress it handles and how long the bearings last. By taking notice of changes, you can prevent damage that could extend well beyond the pump/motor bearings.

To start, consider the noises coming from a pump/motor. Take the time to evaluate any unusual sounds, as many times, you will hear uncharacteristic noises from pump/motor bearings if there is damage, poor lubrication, contamination or excessive clearance.

Vibration with your pump/motor bearings is likely caused by an imbalance, misalignment or play. Use standard practices to evaluate the vibrations, such as recording the vibration data and vibration acceleration. It’s common for pump/motor bearings to have an increased magnitude of vibration when the bearings are damaged or worn.

Measuring the temperature of a pump/motor bearing is also an effective strategy to determine its condition. In addition, nowadays most pump/motor bearings are sealed and do not require lubrication. Before pumping grease into your bearings please consult with the staff at Yarbrough Industries as this could cause failures due to excessive grease buildup in the motor windings.


Maintaining Seals

When choosing seals for your equipment, consult with the staff at Yarbrough Industries to ensure that you’re using the proper seals. In most cases, seals are inexpensive, but are crucial to maximizing the efficiency and life cycle of your pump/motor.


Gaskets


When a gasket fails, it’s most likely due to improper installation, lack of maintenance, improper hardware or improper gasket selection. When choosing a gasket, for maximum efficiency, you’ll want to select one that contracts and expands at the same rate as the metal in your pump, especially during low or high-temperature thermal cycling. Doing so, helps prevent sealing loss. You’ll also want to minimize damage to your gaskets by using gaskets with higher-sealability that are designed to prevent leaking. When a liquid is present on the sealing surface, chances of the liquid causing erosion to the pump are increased, leading to a corrosive environment for your equipment.


Evaluating, assessing and troubleshooting problems with gaskets, bearings and seals can significantly impact how well your system operates. While these parts may not be large components, they play a vital part in your system’s overall efficiency. Preventative maintenance and routine assessments are crucial to extend the life of your equipment and the staff at Yarbrough Industries is here to assist with your service needs.

Contact us today to learn more about how we can help you update your equipment and understand more about the importance of maintaining your pump/motor bearings, seals and gaskets.

Get direct access to industry-leading content

This industry moves fast, but you can move even faster if you’re up to date on trends, technical developments, and best practices. The Yarbrough Industries blog is a go-to source for valuable, timely and detailed information. Sign up to ensure that you don’t miss a single post.

Any hydraulic system relies on having quality hoses to continue working effectively. That means selecting the right one could make the difference between operating an effective system or dealing with defects and potential damage.

When looking at hydraulic hoses, they appear relatively simple and possibly even interchangeable. However, hoses are actually multi-layered, sophisticated tools designed and manufactured for specific applications. Figuring out which hose is right for your system depends on several key factors, including size, temperature, compatibility and choosing the right hose fitting connection.

Choosing a Size

If a hose is to function optimally, the inside diameter must accommodate the correct amount of hydraulic fluid, minimize pressure loss and avert heat generation or excessive turbulence, both of which can damage the hose. The “Dash Numbers” measuring system is the hydraulics industry standard used to indicate hose size and the proper accompanying couplings.

Determining Your Temperatures

When looking for a hose, it will need to be able to accommodate two temperature areas — that of the hydraulic fluid and that of the environment in which the hose exists (ambient temperature). Hoses that cannot withstand both the minimum and maximum temperatures of the fluid, as well as those not designed to work near hot manifolds, are likely to fail.

Ensuring Compatibility

Typically, replacement hoses should be duplicates of the original hoses. In some circumstances, however, using a different type of replacement hose might actually be desirable. This is especially true if the hose failed prematurely due to excessive abrasion, unusual mechanical loads, routing challenges, temperature fluctuation or some other environmental factor. With advancements in hose engineering, there may be a better hose available.

As you read in the first paragraph, typical hydraulic hoses consist of numerous tubes, including one inner, one outer and several reinforcement layers. Hose tubing must come in direct contact with the fluid it carries, so it is important to ensure that the inner tube is compatible with the system’s fluids in order to perform reliably. Furthermore, the threads and mechanical interfaces of ends and couplings need to be compatible with the hoses and other system components. If they’re not, leaks and other hose failures can occur.

Choosing the Right Hose-Fitting Connection

The most important factor in choosing a replacement hydraulic hose is the system pressure. It is vital that you know your system’s precise working pressure — including pressure spikes — when choosing a hose to ensure it will function properly. Finding the correct hose tube and the right fittings will help you avoid future hydraulic hose failures, which may include leakage, cracking or whipping.

Delivery of hydraulic fluid is all about volume and velocity. Any replacement hose needs to be properly sized to efficiently and effectively transport hydraulic fluid. If for any reason the system has been altered, you need to determine the hose I.D. by consulting with an expert.

For more information about hydraulic hoses, or if you need assistance choosing the right hose fitting connection for your system, contact us today!

Get direct access to industry-leading content

This industry moves fast, but you can move even faster if you’re up to date on trends, technical developments, and best practices. The Yarbrough Industries blog is a go-to source for valuable, timely and detailed information. Sign up to ensure that you don’t miss a single post.