22 Jul Hydraulic Hoses and the Danger of Leaks

Hydraulic Hoses and the Danger of Leaks

Hydraulic systems operate under extremely high pressure. A leaking hydraulic hose is more than a maintenance problem—it can create serious injection, burn, fire, slip, and environmental hazards. Even a small pinhole leak can release hydraulic fluid with enough force to penetrate the skin.

Prevent Hose Damage

Many hydraulic hose failures result from abrasion, deterioration, improper routing, or incorrect assembly. Help prevent failures by:

• Using hoses of the correct type, size, length, and pressure rating.
• Routing hoses according to the equipment manufacturer’s instructions.
• Keeping hoses away from sharp edges, hot surfaces, moving components, and other sources of damage.
• Using all required clamps, brackets, supports, sleeves, and abrasion guards.
• Inspecting hoses for cuts, cracks, bulges, kinks, abrasion, exposed reinforcement, corrosion, and leaks.
• Replacing damaged hoses rather than continuing to operate equipment until complete failure occurs.

Never ignore damage to a hose’s outer covering. Once reinforcement is exposed, moisture and corrosion can weaken the hose and lead to sudden failure.

Never Use Your Hands to Find a Leak

A high-pressure hydraulic leak may be so small that it is difficult to see. Never use your hand, fingers, or any other part of your body to locate a hydraulic leak.

Instead:

• Stay clear of the suspected leak.
• Shut down the equipment when required for inspection or repair.
• Relieve stored hydraulic pressure before servicing the system.
• Follow applicable lockout/tagout procedures.
• Use an appropriate piece of cardboard, wood, or other recommended method to help locate a suspected leak from a safe distance.

Never tighten, loosen, adjust, or repair a pressurized hydraulic connection.

High-Pressure Injection Injuries

Hydraulic fluid under pressure can penetrate clothing and skin. The injury may initially appear to be only a small puncture, but fluid injected beneath the skin can cause severe tissue damage and may result in permanent disability or amputation.

A suspected hydraulic injection injury is a medical emergency. Seek immediate professional medical treatment. Tell medical personnel that the injury involves high-pressure fluid injection and, when known, identify the hydraulic fluid involved.

Do not delay treatment simply because the wound appears minor.

Safe Hose and Fitting Repairs

Before repairing hydraulic hoses or fittings:

1. Shut down the equipment and isolate hazardous energy.
2. Relieve stored hydraulic pressure according to the manufacturer’s procedures.
3. Verify that the system is no longer pressurized before beginning work.
4. Clean fittings and connection points before assembly.
5. Inspect fittings for cracks, damaged threads, distortion, or other defects.
6. Use compatible fittings, hoses, seals, and components specified for the system.
7. Install new seals when required and follow the manufacturer’s assembly instructions.
8. Tighten fittings to the manufacturer’s specified torque—do not overtighten.

Never force together fittings that do not properly match. Similar-looking fittings may have different threads, sealing surfaces, or pressure ratings.

Proper Hose Assembly

Improper hose assembly can result in a hose separating from its fitting under pressure. A failed hose can release hot hydraulic fluid and whip violently, striking nearby workers.

When fabricating or replacing hydraulic hose assemblies:

• Use components designed and rated for the hydraulic system.
• Follow the hose and fitting manufacturer’s assembly and crimping specifications.
• Make sure fittings are fully and correctly inserted.
• Inspect crimping equipment and dies for damage or wear.
• Verify completed assemblies meet the manufacturer’s specifications.
• Never use ordinary screw-type hose clamps as substitutes for properly designed hydraulic hose fittings.

Only employees who are trained and authorized should perform hydraulic hose repairs or fabricate hose assemblies.

Remember

Never ignore a hydraulic leak and never search for one with your hands. Shut down and depressurize the system before repairs, use compatible components, and replace damaged hoses promptly.