🔧 This article is part of the FluidForce NZ Hydraulic Hose How-To & Troubleshooting Guides.
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Safe Pressure Testing Practices for Hydraulic Hoses
Hydraulic pressure testing verifies assembly integrity and ensures system safety. Follow these best practices to avoid accidents.
Understand the Test Standard
Use recognised standards:
ISO 1402 or SAE J517 for hose assemblies
Test to 1.5× working pressure for proof testing (not burst)
Use the Right Test Fluid
Use clean, compatible oil or water-glycol — never compressed air or gas.
Bleed air from the system before pressurising.
Prepare a Controlled Environment
Test inside a dedicated pressure bay or safety cage.
Keep personnel at a safe distance.
Use remote or shielded gauges.
Apply Pressure Gradually
Increase pressure slowly to test level.
Hold for 30–60 seconds and inspect for leaks or movement.
Inspect Before Testing
Check for:
Correct crimp diameter
Tight fittings
No visual damage or contamination
Record and Tag
Document test results and tag each hose with test date, operator ID, and working pressure
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