Anytime there is a failure with a hydraulic system hose, it’s important to understand what went wrong so that it can be avoided in the future.
There are a number of reasons that a hydraulic hose can fail. Often it can be something like an ill-fitting component, incorrect assembly or installation or a combination of all three. However, whatever the cause, quite often all failures can be avoided by implementing proper procedures.
Let’s explore the most common causes of hydraulic hose failure:
Issue #1. The component has been blown off
Reason: This is due to the hose not being put deep enough into the fitting. The purpose of the grips in the shell is to hold the fitting tightly onto the hydraulic hose. It’s quite often that last grip that makes all the difference for a strong hold.
Solution: Check the manual to determine if there is a recommended insertion value for the hose, if so, mark the hose appropriately. Insert the hose – you might want to use an insertion-depth gage.
Issue #2: The hose is brittle and the cover of it cracks when it’s flexed. The cover may also look to be dried out and charred in addition to the assembly retaining its installed shape once removed.
Reason: the hose has had heat over the recommended temperature for it. This has resulted in the elastics and plastics lsoing their flexibility. Cavitation can also create this situation.
Solution: Decrease the temperature of the fluid. Replace the hydraulic hose with a model that is built for hotter temperatures. You may also need to review the heat of the fluid to understand whether it can be run more efficiently with a heat exchanger.
Issue #3: Leakage may have blown off the fitting from the hose.
Reason: The shell was not fitted well enough; there may have been either too much or too little crimping during assembly.
Solution: Replace the hose assembly. Check for proper fitting usage and review instructions of the crimping machine being used — including the proper tool.
Issue #4: Burst hose and the wire reinforcement has failed.
Reason: The end of the service life has been reached by the hydraulic hose. It could be that it’s worked through a number of high pressure cycles which caused the hose to flex too much in one spot.
Solution: review how it’s used and replace as appropriate.
Issue #5: The hose either leaks or has bubbles appearing on the cover, close to the fitting.
Reason: It’s possible that the hose was either cut or damaged on its inner tube during the fitting. This may have been caused by not using enough lubrication and moisture has entered around the fitting’s socket.
Solution: determine what needs to be replaced and replace it.
Issue #6: On the external cover there is damage with either twist of broken wires.
Reason: There was not enough lubrication during fitting and the hose was twisted.
Solution: Review how the hose and fitting should have been assembled. Replace the hose and add clamps if necessary. Ensure that the hose will only flex in one spot.
Issue #7: The hose has completely burst, the cover is either torn or deteriorated and the damaged reinforcemeent wires are being displayed .
Reason: The hose has been rubbing either against sharp corners, other hoses or brackets. Alternatively the clamp size is wrong.
Solution: Replace the hose, and use a protective hose guard or shield. Use clamps to prevent the hose rubbing against other objects.