Causes of Common Hydraulic Problems

From improper hose use to air contamination and system over operation, there are many hydraulic problems that can result in failed hydraulic hoses. And because hose failure can cause damage to equipment and severe injury to crew members, it’s crucial that you avoid these issues and properly train employees on how to install and use hydraulic hoses.

To help you mitigate the risk of hose failure on your job site, this article introduces you to 9 of the most common problems that result in hydraulic hose failures.

Signs of Hydraulic Problems

Before listing the problems that result in hose failure, let’s start by exploring the symptoms caused by these issues. That way you can know whether or not your equipment is already suffering from damaged or failing hydraulic hoses.

• Poor Machinery Operation. Is your machinery running slower than usual? Are cycle times taking longer? These are both indicators that something is wrong with your hydraulic system. A damaged hose may be the cause.
• Leaking Fluids. If there is hydraulic fluid leaking from your machinery, then a hose is to blame. The damage may be to the hose itself, its seals, or its fittings.
• Unusual Levels of Machinery Noise. If hydraulic fluid becomes contaminated with air then it can generate a loud banging noise. This is called “aeration” and is a symptom of a hydraulic problem. Another kind of abnormal noise is “cavitation,” a knocking noise also caused by house misuse.

Now that you understand what the symptoms of hydraulic issues look like, let’s explore the hydraulic problems themselves. Here are 9 situations that can quickly result in hose failure:

1. Human Error

Here at Greenshields Industrial Supply, our hose repair technicians replace hundreds of hoses each week, and unfortunately, human error is the #1 most common problem that we see causing hose failure. This includes actions like accidentally cutting a hose, installing the wrong hose, getting debris inside the hydraulic system, and other easily avoidable mistakes.

2. Heat Degradation

Operating the hydraulic system above maximum temperature can cause a hose to stiffen, harden, and then crack. To mitigate the risk of your hose drying out, ensure you are only using hoses rated for the temperature of your application.

3. Aeration (Air Contamination)

Aeration occurs when improperly installed hoses weaken and become porous over time. As degradation occurs, air can leak into the hydraulic fluid via holes in the hose or the shaft seal. If left unrepaired, aeration can damage system components, resulting in costly repairs.

4. Improper Installation

Using a hose that is too long or too short for the application can result in forced twisting, pulling, kinking, crushing, or abrading of the hose.

5. Improper Assembly

Intermixing hose, fittings, or assembly equipment that is not recommended as compatible by the manufacturer can quickly cause a hose to degrade and fail. This is why it’s crucial to follow the manufacturer's instructions for fabricating hose assemblies.

6. System Over-Operation

Exposing the hose to rapid or transient rises (surges) in pressure above the maximum operating pressure or below the minimum recommended pressure can degrade a hose over time.

7. Exceeding or Failing to Meet the Bend Radius

Hoses must meet the minimum bend radius when they’re installed. Failure to do so can result in torn and buckled hoses, leaking fluid, and damage to machinery. If you’re operating a suction or vacuum hydraulic system, then check hoses for flattening or kinking in bends. To mitigate the risk of a hose tearing, buckling, or kinking, in a bend, make sure you check the manufacturer’s specified bend radius.

8. Fluid Incompatibility

Each hose is engineered to transport a specific type of fluid. Using an incompatible fluid in your hose can cause the inner tube material to break down, swell, and even wash out. When purchasing a replacement hose, remember that it must be compatible with the inner tube and the fittings, O-rings, and even the hose’s outer cover.

9. Unprofessional Hose Assembly

Hoses can also fail if they’re assembled by an inexperienced or unprofessional person. A lot of debris is created when cutting a hose, which requires careful flushing. If left inside the hose, these abrasive particles can be pressed against the hose by the fittings, creating tiny fractures that eventually lead to failure. This is why it’s important to purchase your hoses from an experienced and reputable supplier.

Hydraulic Hose Repair & Replacement Near You

Has one of your hoses failed due to poor operation, heat degradation, or another common hydraulic problem? Bring your hose assembly into Greenshields Industrial Supply and one of our experienced hydraulic technicians will quickly cut and assemble a new hose for you.

To learn more about our services and to take advantage of one of the largest hydraulic hose inventories in the Northwest, please contact our store today.