When hydraulic hoses fail, it will cause a lot of hassle regardless of the industry or equipment that is used. These failures will inevitably cause operations to stop because machines and entire systems must be shut down for checks and repairs to begin. So, it will be a massive headache because of the downtime, costly maintenance, and potential losses that you may incur.

Also, if you’re dealing with high pressures, it will be dangerous as your employees may be harmed when the hydraulic hose fail. So, we have listed five of the most common issues that can cause hydraulic hoses to fail and some things that you can do to prevent them.


Since hydraulic hoses are not fixed, they will either stretch or contract as the interior pressure changes. So, when it rubs against other objects, like other hydraulic hoses and metal edges, it can cause abrasion. It is problematic because the protective covering of the tube is chipped away to the point that the steel reinforcement wires are fully exposed. As a result, it can cause them to leak.

Some manufacturers include plasticisers which are mixed with the material that constitutes the protective covering to protect hydraulic hoses from abrasion. A plastic guard or nylon sleeve can also be used in specific problem areas to protect it further.

Poor Design or Installation

Three things belong in this category: poor routing, improper assembly, and incorrect fitting. Poor routing can potentially cause abrasion or a pivot point. So, you should avoid placing or routing hydraulic hoses near areas with high temperature except when there is no other choice. Also, you need to pay attention to the minimum bend radius so that it stays within the recommended levels and to avoid kinks, buckling, and failure.

If the hydraulic hose is designed to be mobile and supports a substantial amount of movement, you should use a swivel on its ends. So, you’ll need to find alternate routes, longer hoses, and other types of fittings when needed.

Improper assembly is another thing that should be avoided. When you are cutting hydraulic hoses, they must be cleaned carefully and flushed with water to prevent contamination by debris that can cause abrasion. Also, the inner tube must be cleaned as thoroughly as possible, and both ends of the hoses should be clamped after crimping the fittings in place.

The hydraulic hose’s fitting (the area where the hose and crimp seal meet) should also be checked because it can cause the hose to be bent too close to the joint. It may be caused by poor routing and the weight of the hydraulic hose itself.

To solve the problem, you should use a bend restrictor (a plastic or rubber sleeve that measures around 15 cm long) which prevents the hose from bending further. Also, it adds further support to the tube in its problematic areas.

Extremely High or Low Temperatures

When hydraulic hoses are subjected to extreme temperatures, they start to reduce flexibility and harden. High temperatures, in particular, can cause the plasticisers found in the inner tube to harden or break down and eventually begin to crack. After several uses, the cracks in the inner tube can spread to the outer parts of the hose. To see if you have this problem, try removing a hose and listen for a cracking sound when you attempt to bend it or if it stays bent after a few minutes. These are the most visible signs of heat aging.

To lessen the effects of heat aging to the hydraulic hoses, avoid routing them through areas with extreme temperatures, and check if it is rated to continue operating under the temperatures in your system. On the other hand, if the exposure of the hoses to heat cannot be avoided, you should install heat guards over them for added protection.

Tube Erosion

Tube erosion occurs inside the hose, and it is usually caused by a concentration of liquids that are flowing in very high velocities (sometimes particles are also present). With the continued use of the hydraulic hose, the erosion continues to occur, and it can cause an external leak to develop.

So, one of the best ways to combat this is to see if the hose is appropriately sized for the expected maximum fluid velocities that it will be exposed. You should also ensure that you use a hydraulic hose that is designed to handle abrasiveness of the liquid.

Fluid Compatibility

You should know that hydraulic hoses are designed only for specific fluids. So, if a tube is exposed to an incompatible fluid, even though it is made of quality materials, the hose’s inner tube will be damaged. It can also swell and delaminate eventually. If this happens and causes leaks, the hydraulic system can be contaminated with particles.

Now that you know about the most common causes of hydraulic hose failure, you’ll likely go for do-it-yourself repairs to save money. It’s good because you’ll learn, save time, and you’ll know what to do if problems occur in the future. However, if you don’t want to be bothered by learning how to do it or you don’t have enough time to do repairs, you should consult the experts from Ryco 24.7. With Ryco 24.7, you will be assured that your problem will be solved in no time. If repairs can’t fix the hose, they also offer replacement parts so that you can get back to work in no time! Visit our website now or call (02) 9605-5433 for more information.

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