Hydraulic hoses are among the most important components of any hydraulic system. They carry pressurized hydraulic fluid between different parts and allow them to perform their tasks. However, like any machinery, these hoses are not meant to last forever. Due to constant high pressure, they wear out over time. Due to hose failure, the entire hydraulic system stops working. That’s why it’s crucial to know about them before everything stops. To help you understand that, in this guide, I will discuss 10 common hydraulic hose failures and their solutions. You will know how a hydraulic hose can fail and how to solve the issue instantly. So let’s get started.
10 Hydraulic Hose Failures and Their Solutions
As you know, hydraulic hoses are responsible for carrying pressurized fluid. They are constantly exposed to heat, dirt, rubbing, bending, and movement. All this leads to different failures of the hoses. But the good news is that a hydraulic hose gives warning signs before it fails permanently. If you ignore them, they can grow into bigger issues. So let’s dive in and explore different hydraulic hose failures and their possible solutions.
1- Hydraulic Hose Leakage
The first major hydraulic hose failure is leakage. In this problem, hydraulic fluid escapes from the hose or its fittings, and you can clearly see it outside. This fluid leakage reduces the system’s pressure and makes the machine work less efficiently. The main reason for the leakage is the old, worn-out hose itself. The outer cover is damaged from rubbing against other machine parts, resulting in leakage. Besides this, old or worn-out fittings can also lead to hydraulic hose leakage.
Solution
The best solution is to find the exact source of the leak as soon as possible. Tighten loose fittings if they are safe to reuse. However, if these fittings are ruptured, replace them rather than repair them. Also, inspect hydraulic hoses regularly and keep them away from sharp edges that can damage them or their fittings.
2- Hose Burst Due to Excess Pressure
The second major issue is a burst in the hydraulic system. A hydraulic hose bursts when the pressure inside it exceeds what the hose can handle. When this happens, the hose suddenly splits open or tears, which immediately causes the hydraulic fluid to spray out with great force. This is the one issue in which the entire hydraulic system quickly stops working.
There are several reasons why too much pressure can build up inside a hydraulic hose. The first one is that the hose is installed incorrectly. It cannot handle the pressure properly, which causes a burst. Secondly, when the machine starts, stops, or changes direction quickly, a burst occurs. A blocked hydraulic line or a faulty pressure relief valve can also cause pressure to rise.
Solution
The best way to prevent this problem is to use a hydraulic hose with the correct pressure rating for your machine. Moreover, ensure the hydraulic system is working properly and the pressure relief valves are in good condition. If not, immediately replace the pressure relief valve. Also, inspect the hoses for any signs of damage or wear.
3- Abrasion Damage
Abrasion damage occurs when a hydraulic hose rubs against another hose, a metal surface, or a machine part while running. This constant rubbing slowly wears away the outer cover of the hose. At first, the damage may look small. But if it continues, the protective cover wears through, exposing the reinforcement inside the hose.
All this weakens the hose and increases the chance of leaks or sudden failure. The main cause behind this issue is the incorrect installation of the hose. It doesn’t have enough support, so it continues rubbing. A hose that moves too much during operation also easily rubs against nearby parts.
Solution
To resolve this issue, you must inspect hydraulic hoses regularly and look for worn or rubbed areas on the outer cover. If you find the hose is rubbing against another surface, change its position or secure it with proper clamps. You can also use hose sleeves or protective covers to reduce wear. If the outer cover is badly damaged or the reinforcement is visible, replace the hose.
4- Cracked or Dry Hose Cover
A cracked or dry hose cover is a common sign that a hydraulic hose is getting old. In this failure type, the outer cover becomes hard and dry, with small cracks. From the outside, these cracks seem very small, but they allow dirt and moisture to reach the inner layers.
These factors weaken the hose, leading to leaks or complete failure. Prolonged exposure to heat, direct sunlight, ozone, and changing weather is the primary cause of cracks. Using the hose for many years or exposing it to unsuitable chemicals also speeds up the hose’s aging.
Solution
To fix a cracked or dry hose cover, you should examine the hose for cracks, dryness, or hard spots. Replace any hose that shows clear signs of aging instead of waiting for it to fail. If possible, keep hydraulic hoses away from excessive heat, direct sunlight, and harmful chemicals. All these things are major causes of cracking in the hose cover.
5- Kinking and Twisting
Kinking and twisting are failures when a hydraulic hose is bent too much or twisted like a rope. No doubt a hydraulic hose is flexible. It is made to bend a little. However, if it is bent too sharply or twisted, the inside of the flexible hydraulic hose is squeezed. This makes it difficult for hydraulic fluid to flow through the hose properly.
As a result, the hose weakens and starts leaking or even rupturing. This problem mainly arises when the hose is put in the wrong position. Sometimes the hose is too short, so when the machine moves, it gets pulled too tight. In other cases, the hose is bent around a sharp corner or twisted during attachment. When this happens, the hose gets damaged faster.
Solution
The best solution to prevent this failure is to install the hose in a straight position. Don’t twist or pull it too much. Make sure the hose is long enough to move freely when the machine is operating. Also, avoid bending the hose too sharply. During regular inspections, check that the hose still has its normal shape. If you notice it is badly bent or twisted, replace it before it causes bigger problems.
6- Hose Blistering
In blistering, small bubbles or raised lumps appear on the surface of a hydraulic hose. These blisters are a clear sign that the hose is damaged from the inside. The hose with the blisters works properly for a short time. However, blisters indicate that the hose is weakening and will burst quickly. This problem can happen for several reasons.
For example, high heat often damages the hose’s interior and causes the outer cover to swell. If you use hydraulic fluid that is not compatible with the hose, it can weaken its inner layers and cause blisters. In some cases, moisture or air trapped inside the hose causes the cover to bulge. No matter the cause, blistering is a warning that the hose is no longer in good condition.
Solution
The only solution for a blistering hose is to remove and replace it as soon as possible, as it cannot be repaired safely. Also, make sure you are using the correct hydraulic fluid and keep the hydraulic system from overheating. Look for bubbles or swollen areas so you can replace the hose in time.
7- Loose or Damaged Hose Fittings
Sometimes the hydraulic hose is not the issue. It is the metal fittings at the ends of the hose that cause the hydraulic system to fail. These fittings connect the hose to other hydraulic components. If they become loose, cracked, bent, or worn out, hydraulic fluid escapes from the connection.
As more fluid leaks out, the machine loses pressure and eventually stops working. Loose or damaged fittings usually result from constant machine vibration. Also, dirt and dust accumulate, damage the fittings, and prevent them from creating a strong seal. If you use the wrong-size fittings or overtighten them during installation, they get damaged.
Solution
To solve this problem, check all hose fittings during regular maintenance, not just the hose itself. If you notice that any fitting is worn out, quickly replace it with a new one. Also, make sure you choose the right fitting size that matches your hose requirements.
8- Internal Hose Blockage
Often, you look at the hose, and it seems perfect, but it still isn’t working properly. In such cases, the real issue is hidden inside it. Over time, dirt, small pieces of rubber, metal particles, and other unwanted materials build up inside the hose. All these contaminants block the path through which the hydraulic fluid flows.
As a result, the fluid cannot move freely, which disrupts the hydraulic machine’s overall function. An internal blockage happens if the hydraulic fluid is dirty, right? This is because you don’t replace the filter on time. In some cases, a damaged hose also releases small rubber particles. Those particles travel through the system, creating a blockage.
Solution
The effective way to prevent this problem is to keep the hydraulic system clean. Always use clean, good-quality hydraulic fluid. After that, replace filters according to the maintenance schedule. If you think the hose is still blocked, inspect the system carefully and replace it if it is damaged.
9- Heat Damage
Heat is one of the biggest enemies of a hydraulic hose. When a hose is exposed to high temperatures for a long time, its material slowly weakens. Due to this, hoses become hard, brittle, or less flexible than before. As this happens, cracks appear, the hose loses strength, and it might lead to leaks or improper operation.
This problem often occurs when the hydraulic system runs hotter than normal. Also, if you install the hose too close to engines, exhaust components, or other heat sources, it can overheat. Using hydraulic fluid that becomes excessively hot can also affect the hose from the inside.
Solution
To reduce heat damage, keep the hydraulic hose operating within its recommended temperature range. Check the cooling system regularly and make sure it is working properly. If hoses are located near hot machine parts, use heat shields or protective covers.
10- Chemical or Fluid Compatibility Damage
Not every hydraulic hose is made to work with every type of hydraulic fluid or chemical. Instead, each hose can handle different fluids depending on its material. If the wrong fluid is used, it will definitely damage the inside or outside of the hose.
The hose becomes soft, swollen, hard, or weak over time. As the damage gets worse, the hose starts leaking. Sometimes, different types of hydraulic fluids are mixed, which causes this issue. Moreover, sometimes the wrong fluid is added during maintenance.
Solution
The easiest and most effective way to prevent this issue is always to use the hydraulic fluid recommended by the hose manufacturer. Before using any cleaning chemical, make sure it is safe for the hose material. If you notice that the hose has become swollen, unusually soft, or hard after coming into contact with a fluid or chemical, replace it as soon as possible.
How to Prevent Hydraulic Hose Failures from the Start
Generally, replacing the hose is a very difficult and costly process. That’s why it is best to protect your hose from all these failures from the start. The good thing about hydraulic hoses is that they don’t fail suddenly. Instead, they show some signs that you can cope with earlier. So let’s dive in and discuss how you can protect your hose from the above-mentioned failures.
- Install the Hose Correctly: First, many problems arise from incorrect installation. Even a high-quality hose can fail early if it is installed incorrectly. So choose the correct hose length, connect it properly, and place it in a position where it can move naturally
- Avoid Sharp Bends: A hydraulic hose can be bent, but only within a certain limit. If it is bent too sharply, its inside becomes squeezed. So always route the hose with smooth, natural bends.
- Protect Against Abrasion: Continuous rubbing slowly wears away the outer cover. To protect it, keep it away from other surfaces that could cause it to rub. Make sure the hose is properly supported with clamps or holders.
- Check Operating Pressure: Every hydraulic hose is designed to work within a specific pressure range. Too much pressure can cause rust, and too low pressure reduces efficiency. So always use a hose with the correct hose pressure rating for your hydraulic system.
- Inspect Hoses Regularly: Small problems are much easier and less expensive to fix. So regularly inspect the hose, and if you find any minor issues, don’t ignore them but fix them quickly.
- Use Quality Hydraulic Fluid: The condition of the hydraulic fluid directly affects the hose’s lifespan. Dirty or poor-quality fluid can carry small particles and block the system. So use clean, high-quality hydraulic fluid recommended for your hose.
Conclusion
Hydraulic hoses are a major part of any hydraulic system. They carry pressurized fluid to different machinery components. However, these hoses often wear out and show failure over time due to continued use. If you ignore those failures, the entire hydraulic system can fail. That’s why, in this guide, I have discussed some common hydraulic hose failures.
But the good thing is that these failures can be fixed. When you know the solution, you can quickly resolve the problem at an earlier stage before it grows into a bigger one. Remember, preventing hydraulic hose failures is much easier than repairing the damage after a hose breaks. That’s why, from the start, inspect, maintain, and keep checking your hydraulic hose for any signs of failure.