Very few organizations pay attention to hydraulic leaks and how they can impact production capacity, asset reliability, and reactivity when a mitigation strategy is in place. This Tool Box Talk may help you take that next step.

1. Tool Box Talk – How to Stop Hydraulic
Leaks and Why
"When fluid is under pressure and leaks it can pull a vacuum thus
allowing contamination to be introduced into system components
causing partial and total functional failure"
General Rules That Should Be Followed
These tips are not an option if you want to stop Hydraulic failures
"Remember 10 microns is smaller than the size of a white blood cell"
1. Always add hydraulic fluid that has been filtered to the
micron rating allowed for any component in the system.
2. When installing a new hose to replace a leaking one,
change all fittings and hose at the same time and torque
fittings.
3. When a hydraulic hose has wear it is a maintenance issue
and needs to be solved with one of the following:
a. Rerouting of hoses
b. Protecting hoses using hose covers for reduce
abrasive caused by hoses rubbing against other
hoses or other items.
4. Ensure maintenance techs are trained in and use
effective procedures.
5. Only a small portion of maintenance techs should
possess the knowledge of troubleshooting hydraulics
systems, unless a troubleshooting guide is developed and
taught to everyone; however, anyone who touches a
hydraulic system, from adding oil to changing hose, must
be trained to a specification and standard. Here are some
of the areas they must be trained on:
a. Hydraulic Fluid Contamination Methods
b. Proper Installation of Hydraulic Fluid
c. Storage of Hydraulic Fluid
d. Micron Level Required for Equipment
e. Proper Installation of Hydraulic Hose – this is based
on the hose and fitting manufacturers
f. If required: Proper Manufacture of a Hydraulic Hose
NOTE: One Micron is so small one cannot see it. Most
hydraulic systems today must maintain their fluid at less
than 10 micron absolute. 25 microns is the size of a white
blood cell .
Warning: Intermix/Interchange with Other
Manufacturers’ Components practices could create
system failure, partial and total functional failure.
This practice can be dangerous. Leak‐tight seals that will
withstand high pressure, vibration, vacuum, and
temperature changes depend on close tolerances and
consistent, exacting quality control in conjunction with
good design principles. The critical interaction of precision
parts is essential for reliability and safety.
– The Swagelok Company
Hydraulic Hose Most Common Failure Modes
Wear – Pump Failure due to Contamination
Leakage – Caused by no one using the torque wrench
causing contamination to be pulled in to the systems
because of vacuum. "Oil Leaking out, Contamination
coming in"
• Leakage of hydraulic fluid from hydraulic fittings
o Not following hose fitting or hose manufacturer’s
recommended installation best practices
o Fittings may even need to be torqued or the use
of a gage may be required
• Leakage of hydraulic fluid hoses based on wear,
o Hoses are not routed most effectively or
protected using a protective sleeve
Safety is an issue with oil on the floor could cause
someone to fall. Do not just clean up the Spill,
"Eliminate the Root Cause if the Spill"
Questions? send your questions to rsmith@worldclassmaintenance.org
For a more detail article on "Maintenance of Hydraulic Systems"
go to: https://bit.ly/3kUbQsZ