A guide to identifying the cause of your hose failure

There are many factors that may have contributed to your hydraulic hose failure – from incorrect routing to extreme temperatures. Identifying the root cause of the hydraulic failure is an important task of hose maintenance and preventing potentially catastrophic events in the future.

Use this guide as a hydraulic hose failure analysis to determine the cause of your failure. Step through each potential reason for failure and assess it against your situation – determining which factor contributed to the hydraulic hose failure and how it can be prevented with HoseMateTM.

A summary of the top 5 causes of hydraulic hoses failure can be found here.

Reasons for hose failure

1. External abrasion

Look for: wearing of the outer hose layer

Hydraulic hose external abrasion occurs when two or more hydraulic hoses rub against each other causing the outer layer of the hose to wear away. This can lead to hose spills, bursts, and catastrophic hose failure.


HoseMateTM is the purpose designed solution to eliminating hydraulic hose abrasion by securing, positioning and separating hydraulic hoses. Find out how to protect hydraulic hoses from abrasion here.


2. Extreme temperatures

Look for:

Extreme heat: hose is hard and brittle – cracks at room temperature

Extreme cold: inner tube or outer layer has cracks – remains flexible at room temperature

Hydraulic hoses have recommended temperature limits. It is important that the hydraulic assembly is kept within these ranges.


Consult hydraulic hose temperature limits and raise or lower temperature appropriately to within the required boundaries.


3. Incorrect hose assembly

Look for:

  • Leaks, spills or bursts between hose and fitting
  • Bubbles on hose outer layer near hose fittings
  • Hose burst occurred on a section of hose that was obviously twisted

Hydraulic hose installation is a tricky task with many factors to be considered – including the design of your hose assembly, hose fittings, and desired fluid flow.


The entire assembly will need replacing – review hose installation instructions for fittings, crimping and routing requirements. If a twisted hose was the cause of the hydraulic hose failure, when replacing the assembly, it is important to ensure the hydraulic hose lay line is straight. A lay line that spirals indicates that the hose is twisted.


4. Incorrect hose routing

Look for: burst occurred at the outside of a bend in the hose

When the burst occurred on the outside of a bend, this is likely attributed to a failure to follow the minimum bend radius. A hydraulic hose minimum bend radius is the lowest radius at which a hose can be bent.


Replace the hydraulic hose assembly. During the house routing process, ensure the minimum bend radius is considered and achieved. The minimum bend radius different for every hose and will be specified by the hydraulic hose manufacturer. If you are struggling to achieve your desired flow, while maintaining the minimum bend radius, HoseMateTM is the solution. HoseMateTM allows you to secure two hydraulic hoses and position them accordingly – while still maintaining a gap between them to eliminate any risk of external abrasion.

Follow our top three tips to ensure correct hydraulic hose routing.


5. Incompatible hose fluid

Look for: deterioration of the inner tube and/or blisters on hose outer layer


Replace the hose assembly with one constructed from materials that are compatible with the fluid, or replace the fluid with one that is compatible with the hose.


6. Hose past its service life

Look for: outer layer wire reinforcement has failed in area of hose burst


Replace hose assembly with new hoses. Use HoseMateTM  to increase the service life your hydraulic hoses across site.