What to Do If My Hydraulic Hose Bursts
A burst hydraulic hose can bring your entire operation to a stop — fast. Whether you’re running a digger, press, or production line, a hydraulic breakdown means lost time, safety risks, and potential environmental damage from hydraulic fluid leaks.
The good news? If you act quickly and safely, you can limit the damage, identify the cause, and get your machinery back up and running — fast.
Step-by-Step: What to Do When a Hydraulic Hose Bursts
When a hydraulic hose bursts, pressure inside your system can reach thousands of PSI. Acting calmly and correctly is key to preventing injury and further damage.
1. Stop the Machine Immediately
Shut down all hydraulic power. Don’t try to move or reposition anything. Keeping the system pressurised will force more fluid out and increase the risk of fitting or seal failure.
⚠️ Never touch or inspect the leak while the system is running. High-pressure fluid can penetrate skin and cause serious injury.
2. Isolate and Depressurise the System
Once power is off, relieve hydraulic pressure according to your manufacturer’s safety procedures. This prevents any residual hydraulic fluid from escaping when inspecting the damaged hose.
3. Contain the Leak
Use absorbent pads, spill kits, or sand to contain hydraulic fluid leaks. Hydraulic oil is hazardous to both people and the environment, so containment is a legal and safety responsibility.
4. Identify the Damaged Hose
Look for visible cracks, bulges, kinks, or signs of wear. Check fittings, connections, and any nearby areas for hydraulic fluid spray or damage.
If multiple hoses run close together, inspect them all — one burst often signals others are near failure.
5. Call a Professional Hydraulic Hose Repair Service
Hydraulic hose replacement isn’t a job to rush or guess. The wrong fitting, length, or hose type can cause repeat failures or unsafe pressure levels.
Hydra-Line’s 24/7 emergency hydraulic service covers the Midlands and surrounding regions, offering on-site mobile hose repair and replacement. Our vans are fully equipped to manufacture new hoses on-site — no waiting, no towing, no downtime.
What Causes a Hydraulic Hose to Burst?
Understanding the cause helps prevent the next breakdown.
Common reasons include:
Excessive pressure surges from rapid valve closure or system overload
Abrasion from hoses rubbing against machinery
Incorrect hose routing or bending radius
Age and fatigue from long service life or UV exposure
Contamination within the hydraulic fluid
Improper fitting installation or torque levels
Regular hydraulic maintenance and system inspections drastically reduce these risks.
How to Prevent Future Hose Failures
Schedule Regular Hydraulic System Inspections – Catch wear and fatigue early.
Use Quality Components – Inferior hoses and fittings fail faster.
Replace Old Hoses Proactively – Don’t wait for visible cracks.
Protect Against Abrasion – Use sleeves, clips, or guards.
Check Pressures and Temperatures – Ensure hoses match system ratings.
Hydra-Line offers preventative hydraulic maintenance and hose replacement programs to keep your machines
operating safely and efficiently.
When to Call Hydra-Line
If you’re facing a hydraulic system failure, burst hose, or hydraulic fluid leak, our engineers are ready — 24/7.
On-site hose manufacturing & fitting
Fast response across the Midlands
Experienced industrial hydraulics engineers
Fully stocked mobile workshops
Trusted by construction, transport, and manufacturing firms
Whether it’s emergency hose repair, hydraulic fitting repair, or ongoing hydraulic maintenance, Hydra-Line gets your equipment back in action quickly and safely.
Don’t Wait for the Next Breakdown
A burst hydraulic hose can halt your business — but it doesn’t have to.
Hydra-Line’s rapid-response mobile hose repair service keeps you moving.
👉 Call now for 24/7 Emergency Hydraulic Hose Replacement:
📞 01782 658535
🌐 www.hydra-line.uk/contact