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Why is my hydraulic hose leaking?
Hose leaks are a common issue when working with hydraulic systems. But chances are, your hydraulic hose isn’t leaking because it’s defective. Often, hydraulic hose leaks are caused by improper assembly, including the use of a wrong type of fitting or the right one being installed incorrectly.
Any hose is only as good as the way it was assembled
Hydraulic hoses are designed to withstand high pressures, temperatures and rough conditions. But if the installation isn’t done correctly — whether it’s an improperly installed fitting, not enough hose slack, or no hose support — they can easily fail and cause dangerous leaks. Hose leakage doesn’t only generate direct costs through oil loss but also indirect costs in the form of safety risks such as slip hazards. Leaks can also affect machine efficiency. If, for instance, the cycle time of a hydraulic circuit is three seconds, and there’s leakage that delays it to around six seconds, the efficiency of the machine is reduced by 50 percent.
Additionally, if an O-ring is missing or damaged or if over-under-torquing the connections have occurred, leaks won’t only be the likely result. The seal may also no longer be aligned correctly, and the threads might be damaged.
Hose fittings are not created equal
Some types of fittings leak more than others, as well, especially after they’ve been removed and reinstalled. For example, removing and retightening an NPT or JIC fitting can strip its threads, essentially causing a pathway for hydraulic oil to drip through. These designs are usually leak-tight upon the first installation, but really should not be removed and installed again. If there is a need to remove an NPT or JIC fitting, a completely new fitting assembly should be installed.
A simple solution is to use an O-ring fitting. These soft seals create positive seals that do not leak. However, these are not fail-safe if not selected correctly. Make sure the O-ring is compatible with the media being sealed and the operating temperature range to keep it from breaking down and causing leaks.
New fitting installation must be done flawlessly
Installation and routing of a new hose can also cause leaks if the hose is not long enough. If a hose is too short, it cannot expand and contract with the constant changes in pressure and temperature. This will cause strain on the fittings, hose covers, and reinforcement, again, causing them to leak.
Contamination, the bane of all hydraulic systems, can damage the inner tube of a hydraulic hose and result in leakage. To avoid particles in your hydraulic hose, all hose assemblies should be cleaned before fittings are installed, either by flushing or using high-pressure projectiles. Once a hose assembly is cleaned, use caps and plugs to keep them clean until they are installed in the system.