Stop Blaming the Hose: What Really Causes Hydraulic Hose Failure
Updated: Sep 15
When a hydraulic hose fails, the hose gets blamed immediately.
It cracked. It leaked. It burst. Case closed, right?
Not always.
Sometimes the broken hose is the problem. Other times, it is simply the part that finally gave up after dealing with another problem somewhere in the system.
That is why replacing a hydraulic hose should involve more than removing the damaged one, making a replacement and getting back to work. Before the new hose goes on, it is worth asking one important question:
Why did this hose fail in the first place?
Look at Where It Failed
The location of the damage can tell you quite a bit.
Did the hose fail near the fitting?
Is there a worn spot where it has been rubbing against equipment?
Is the outer cover damaged? Does the hose appear twisted?
Is there a sharp bend immediately after the fitting?
These details matter.
Hydraulic hose manufacturers identify abrasion, improper routing, excessive bending, twisting, pressure issues and repeated flexing among the conditions that can contribute to premature hose failure.
In other words, the hose may be broken, but it may not be the original troublemaker.
It May Be Getting Rubbed the Wrong Way
Hydraulic equipment moves, vibrates and works in some pretty unforgiving environments.
If a hose repeatedly rubs against a piece of equipment, another hose or another surface, that contact can wear away the protective outer cover. Eventually, the reinforcement underneath may become exposed and damaged.
A replacement hose installed along the exact same path can end up with the exact same problem.
Sometimes the real repair involves looking at the routing, protecting the hose from the contact point or finding a better way for the hose to travel.
A Hose Needs Room to Move
A hose that is too short can be under constant tension as equipment moves.
A hose that is too long can create unnecessary movement, rubbing or awkward bends.
Then there is bend radius. Hydraulic hose is designed to flex, but that does not mean it can make every turn we ask of it. Bending a hose too sharply, especially close to a fitting, can put unnecessary stress on the assembly and shorten its service life.
The goal is not simply to make a hose that reaches from Point A to Point B.
It needs to fit the way the equipment actually operates.
Twisting Is Different From Bending
A hydraulic hose can bend during normal operation. Twisting is another story.
If the hose is twisted during installation or the movement of the equipment continually torques the hose, the reinforcement inside can also be affected. That can reduce hose life and contribute to failure.
Sometimes this is easy to miss because the hose technically fits. The better question is whether it fits correctly through the full range of the machine's movement.
Sometimes the Application Has Changed
Equipment does not always spend its entire life doing exactly what it did on Day One.
Attachments change. Operating conditions change. Components are replaced. Machines are modified. Workloads increase.
A hose that was appropriate for one application may not be the right choice for another.
Pressure requirements, temperature, fluid compatibility, hose size and operating environment all play a role in selecting the proper hose.
That is another reason replacing a hose based only on what came off the machine may not always tell the whole story.
Fix the Cause, Not Just the Evidence
A damaged hose is pretty obvious. The conditions that caused it to fail may not be.
That is where a little investigation can make a big difference!
Before Hose Guys installs a replacement, we take a look beyond the damaged section to determine
Was the hose rubbing?
Was it twisted?
Was it bending too sharply?
Was it under tension?
Does the equipment repeatedly move or vibrate at that connection?
Is the hose appropriate for the application?
Finding the answer may help keep the replacement hose from coming back with the same problem.
Hose Guys Looks Beyond the Break
At Hose Guys, the job is not simply about making another hose. It is about helping get equipment back to work with a hose assembly that is right for the application.
That means looking at the failure, considering how the hose is routed and paying attention to what the equipment is doing around it. Because sometimes the best thing you can do for a broken hydraulic hose is stop blaming the hose.
Need a hydraulic hose replacement or onsite hose service? Contact Hose Guys and let us help get you connected and back to work.
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