Common hydraulic risks
Where hydraulic systems are most vulnerable
A hydraulic system is only as reliable as its most exposed connection. Left open, a thread, port or flange lets in the dirt, moisture and damage that jam valves, fail seals and wear pumps. These are the five risks worth designing out.
Dirt in pipes, hoses and components
Dust, sand, metal shavings, paint residue or moisture can enter a system through open connections. Even small particles cause damage: valves jam, seals fail, and pumps and cylinders wear.
Solution: Temporarily sealing these openings the moment they are exposed keeps particles out.
Impact and transport damage
Precision threads, cones, sealing surfaces and flange faces get knocked, dropped or rubbed during production, storage and transport, and a dented seat or flange face leaks. An open connection also lets in moisture and corrosion.
Solution: Shielding threads, cones, O-ring zones and flange faces from impact through handling, storage and transport.
Oil loss during service and maintenance
During maintenance, hoses, cylinders, pumps, valves and manifolds are often disconnected and oil leaks out. The result is extra cleaning, a contaminated workplace, and a higher risk of malfunction after reassembly.
Solution: Sealing open pipes, ports and hoses during service to limit oil loss.
Wear and damage to hydraulic hoses
Hoses move with the machine and are constantly exposed to dirt, heat, UV, oil and chemicals. Those external factors wear the cover down and raise the risk of a rupture.
Solution: Covering exposed hoses to guard against chafing, impact and wear.
Heat from painting and coating
Components pass through blasting, painting, powder coating and curing ovens during finishing. Standard plastic plugs soften or melt at those temperatures, so the mask fails and paint or powder fouls the thread, bore or sealing face.
Solution: Masking with heat-rated silicone, EPDM or cork that holds its shape through the oven and pulls off clean.
