7 Signs Your Hydraulic Hose Is About to Fail

Sep 11

3 min read

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Hydraulic hoses are the driving force behind industrial machinery. They work quietly under intense pressure, extreme heat, abrasive conditions, and constant movement to keep your equipment running.

But when a hose fails? Everything stops.

The Result of a Hose Failure

Significant downtime expenses
Frustrated operators
Lost contracts or costly penalties
Serious safety risks from high-pressure oil leaks

And the numbers back it up: 37% of unplanned hydraulic downtime is caused by hose failure. In UK manufacturing, the average cost of downtime is £5,121 per hour.

Sources: https://www.rs-industria.com/maintenance-engineering-report-2023

The Good News

Most hose failures are preventable. At Lister Fluid Power, our engineers attend breakdowns every day, and we see the same warning signs again and again. If operators and administrators know what to look for, they can stop problems before they become disasters.

Here are the 7 key warning signs your hydraulic hose is about to fail and why acting early saves money, time, and headaches.

1. Cracks or Abrasions on the Outer Cover

Surface damage like cracking, scuffing, or wear is often caused by UV exposure, friction, or chemical contact. Even minor abrasions can compromise the hose’s integrity under pressure.

Close-up of a yellow hydraulic machine with black hoses. One hose is cracked, set against an industrial background. — Cracked hydraulic hoses and fittings on heavy machinery showing signs of wear and potential maintenance needs.

2. Leaks, Oil Mist, or Drips

Visible fluid around the hose or fittings is a clear red flag. Look for wet spots, puddles, or a fine mist of hydraulic fluid. Leaks reduce system pressure and pose safety risks.

Hands in green gloves hold a hydraulic hose against a red, industrial machine, with visible dirt and oil leak. Beige background. — The technician is engaged in repairing a leaking hose, a crucial task for maintaining the efficiency of machinery on a construction site.

3. Bulges or Blisters

A bulge in the hose body usually signals internal damage or layer separation. This is a serious warning — and often a precursor to rupture.

Rusty hydraulic hoses and metal pipes against a worn orange background, showing industrial wear, bulge and grime, with visible bolts and connectors. — Close-up of hydraulic hoses against a red industrial backdrop, with one hose showing a noticeable bulge, indicating potential wear or damage.

4. Kinks, Twists, or Flattened Areas

Improper routing or bending can cause kinks, restricting fluid flow and stressing the hose structure. Over time, this leads to internal damage and failure.

Close-up of a rusted metal fitting on a black kinked hose against a blurred, earthy background. The mood appears worn and aged. — Close-up of a worn hydraulic hose showing a significant kink and rust on the metal fitting, indicating the need for maintenance or replacement.

5. Exposed Reinforcement Wires or Textile

If you can see the braid or fabric, the hose has lost its protective shield, leaving it vulnerable to bursting, leaking, or structural failure.

Close-up of a damaged black rubber hose with cracked surface revealing woven wire beneath, set in an industrial background. — A close-up view of a deteriorating rubber hose reveals significant wear and tear, exposing its underlying braided structure, indicating the need for urgent replacement to prevent potential failures.

6. Stiffness or Loss of Flexibility

Hoses harden with age as rubber compounds degrade due to heat, ozone, oxidation, and the loss of plasticisers. This stiffening reduces flexibility, making the hose unable to safely withstand pressure cycles. If a hose feels rigid, it's a sign that it may burst under pressure and should be replaced.

Red hydraulic machinery with black hoses on a yellow base. The background is a green corrugated surface, conveying an industrial setting. — A close-up of industrial machinery showing two hoses, with one appearing less flexible than the other, connected to a red and yellow mechanical component.

7. Loose or Corroded Fittings

Rust or discoloration around connectors can weaken seals and lead to hose detachment or leakage. Corrosion also suggests exposure to moisture or chemicals.

Rusty pipes with connectors lie on a dirt-covered metal panel. Gray and orange hues dominate. Some text faintly visible. — Rusty hydraulic fittings and hoses on industrial machinery, showing signs of corrosion and wear amidst a muddy environment.

The Importance of Timely Hose Replacement

Cost Efficiency: Addressing hose issues before they escalate helps reduce repair expenses, avoid emergency overtime, and prevent costly clean-ups, thereby saving substantial amounts in downtime.
Safety Priority: Proactively replacing hoses mitigates the risk of hazardous high-pressure leaks, potential injuries, and environmental contamination.
Contract Retention: Timely intervention ensures equipment functionality and project timelines, safeguarding revenue and maintaining reputation.
Machinery Protection: Swift replacements prevent fluid leaks from causing damage to pumps, cylinders, and other critical components.

When the signs are visible, you don’t need to be an expert to know that a failure is imminent. If you spot even one of these signs, act now. Replacing a hose early is always cheaper — and safer — than waiting for it to fail.

Lister Fluid Power’s mobile engineers are on call 24/7 to keep your machines running. West Midlands - 0800 056 0307

South Wales - 01873 857225