Hydraulic Hose Bursts: What Causes Them and How to Prevent It

Hydraulic hose failures are one of the most common — and dangerous — issues in heavy equipment. A sudden burst can spray high-pressure fluid, create safety hazards, and bring operations to a halt.

Main Causes of Hose Failure

  • Excessive pressure spikes: Operating near or above rated pressure damages hose walls
  • Improper routing: Kinks, twists, or abrasion points weaken hose structure
  • Heat exposure: Prolonged heat causes hose material to degrade from the inside out
  • Old age: Hoses lose elasticity and bonding over time, even if they appear intact
  • Poor assembly: Incorrect crimping or fitting selection results in weak spots

Early Warning Signs

  • Bulging or blistered outer jacket
  • Fluid seepage around fittings
  • Visible wear from rubbing or UV exposure
  • Intermittent pressure loss or hose vibration

Prevention and Best Practices

  • Replace hoses on schedule — don’t wait for visible damage
  • Use abrasion sleeves and clamps to protect routing paths
  • Always match hose and fitting ratings to your machine’s specs
  • Inspect hose assemblies during every service cycle

Conclusion

Most hose bursts are preventable. With routine inspection, proper routing, and pressure-matched components, you can avoid failure before it happens. Don’t let a $60 hose take down a $60,000 machine.

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