Hydraulic hoses are an essential component of your heavy machinery’s hydraulic system. Essentially, they consist of an inner tube, a reinforced layer or multiple spirals and an outer protective layer and are made of flexible rubber. Hydraulic hoses need to be strong and durable to withstand the high pressures and temperatures of the hydraulic fluid flowing within from one component to another, however even the highest quality hoses are susceptible to failure.

But what are the top causes of hydraulic hose failure and how can you prevent them?

Top causes of hydraulic hose failure

1. Abrasion.

Abrasion is a leading cause of your hydraulic hose’s failure and this can be caused by general wear and tear as well as a lack of inspection. Abrasion usually takes place when the hose rubs against either another hose, or another surface. The friction inevitably causes damage to the hose through friction, leading to weakening, wearing and tears.

Another thing to keep in mind is that, when pressurised, hoses will move and pulse so even if your hose does not appear to be touching any other components, the reality can be very different when actually under operating conditions.

2. High temperatures

Hydraulics most often operate between -40’c to 100’c, and the higher the temperature, the greater the risk of your hydraulic hose breaking. This is because heat causes the rubber inner lining to form cracks (sometimes audibly!) and can also harden the hose exterior, reducing flexibility. Prevent your hydraulics from overheating and consider using heat guards to protect your hydraulic hose against extremes of temperature.

3. Tube erosion

Hydraulic hose erosion can occur when particles of debris are present in your hydraulic fluid and/or if the fluid itself is moving at very high speeds. Your tube needs to be strong and durable enough to withstand the pressure of moving hydraulic fluid, and the right size needs to be chosen, depending on the speed of the hydraulic fluid flow. Constant debris contact with the inside of the hose will quickly damage the structure and lead to hose failure.

4. Fluid incompatibility

There are a variety of hydraulic fluid types, consisting of water-based, petroleum-based and synthetic, each of which has its own characteristics. The viscosity and optimum operating temperature will vary for each of these, so it’s important to select the right SAE fluid for your components. Adhere to the manufacturers recommendations as failure to do so can lead to clogged hydraulic hoses and a faster than normal rate of tube deterioration. Hoses, fittings, O-rings and outer covers all need to be compatible with the fluid used.

5. Improper assembly

Linking to cause number three of hydraulic hose failure (tube erosion), improper assembly and installation can cause hydraulic hose failure through contaminants and debris being present in the tube. Moreover, a poor depth of insertion or swage diameter can lead to the hose fitting coming off and damaging the entire system, and professional installation is key here. Always remember to check that hoses are clean and contaminant-free during assembly, especially if cutting the hose to size, and fully insert hydraulic hoses into the recommended depth found in its installation notes.

Dangers of hydraulic hose failure

So, why is it essential to be able to spot and prevent hydraulic hose failure in your heavy machinery? Hose failure can lead to:

• Machinery shutdown
• User downtime
• Pricey repairs
• Risk of injury or fatalities if high pressure leaks or explosions occur

If you’re in need of high quality replacement hydraulic parts for your heavy-duty equipment, we are here to help. At Jaytrac, we stock and supply replacement parts for Caterpillar, Komatsu, and Volvo machinery. For more information, please contact us via telephone at 01604 491 133 or email us at sales@jaytrac.co.uk.