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Inspection template in the LeanSuite app

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Hydraulic hose inspection checklist

A hydraulic hose inspection is a monthly check of the hoses and fittings on one machine. It starts with a question that has to be Yes before anything else: the system is depressurised and locked out. The other 12 questions look for cover damage, exposed wire, kinks, bend radius, the date code, leaks at fittings, routing and restraints, and end with tagging a damaged hose and raising a work order.

A maintenance technician usually runs it on a route, machine by machine. A failure on the floor looks like a hose rubbed through where it crosses a frame, an abrasion sleeve that slid away long ago, oil mist on a guard, or a replacement hose with no date code that nobody can age. A pinhole leak under pressure can inject oil into skin, so never run a hand along a hose to find a leak; look, and use a piece of card.

What it is for, as built: Monthly inspection of hydraulic hoses and fittings on a machine.

Use this template in LeanSuite

The full question list

The 13 questions in the inspection

Every question is answered Yes, No or N/A. Each No is flagged and asks for a photo and a comment, so the finding arrives with its evidence.

Before you start

  1. 1The system is depressurised and locked out before hoses are touched

Hose condition

  1. 2There are no cracks, abrasion or blisters on the cover
  2. 3No reinforcing wire is showing
  3. 4There are no kinks or twists
  4. 5Bend radius is acceptable
  5. 6The date code shows the hose is within its service life

Fittings and routing

  1. 7There are no leaks or weeping at fittings
  2. 8Fittings are free of corrosion
  3. 9Hoses are clamped and supported
  4. 10Hoses are routed away from heat and sharp edges
  5. 11Sleeves and whip restraints are in place where needed

Follow-up

  1. 12Damaged hoses are tagged and a work order is raised
  2. 13Replacement hoses are on the spares list

Worked example, illustrative

A filled-in example

One section as it might be filled in on the floor, with every other section of the inspection answered Yes. The place and finding are made up to show how the inspection reads and scores.

Result: fail, 84.6% against a pass mark of 90

  • 13 questions, all of them count.
  • 2 answered No, so 11 of 13 are Yes: 11 ÷ 13 = 84.6%.
  • 84.6% is under 90, so the inspection fails.

What happened next: Maintenance retorqued the fitting and fitted a heat sleeve and clamp the same day, recheck set for next week.

Scored here as one point per question with N/A left out. In the app each answer carries the points set on the template, so change them after you clone it if your plant weighs some checks more.

Hydraulic Hose Inspection

Inspection, monthly

Machine ID
Press 3, hydraulic unit

Fittings and routing

  1. There are no leaks or weeping at fittingsNo
  2. Fittings are free of corrosionYes
  3. Hoses are clamped and supportedYes
  4. Hoses are routed away from heat and sharp edgesNo

    Comment: Slight weep at the elbow fitting on the return line, oil film on the guard below. Return hose rests against the motor housing with no sleeve.

    Photo attached to each No

  5. Sleeves and whip restraints are in place where neededYes
Drawn from this template's own questions, not a screenshot of the app. Illustrative answers.

When to use it

  • Once a month.
  • The person responsible for the area or equipment answers each question on the spot.
  • Each record starts with: Machine ID.

How it is scored

The template is built with points per answer and a pass mark of 90. In this library every audit is set to pass at 80 and every inspection at 90. Each submitted inspection shows its score and pass or fail, and every No is flagged with its photo and comment.

Change the points or the pass mark after you clone it. How rules and scoring work.

Read and print

More in maintenance and equipment

All maintenance and equipment templates

FAQ

Hydraulic hose inspection checklist: common questions

  1. Monthly, machine by machine on the maintenance route. Add an extra check after any hose is replaced, after a leak repair, and whenever a machine is moved or re-guarded, because routing and clamps change with it. Hoses on presses, shears and anything with a high duty cycle wear faster, so look at them each time you pass if they cross a frame edge.

  2. A maintenance technician who knows the machine's hydraulic circuit and can isolate and depressurise it. They need to read a date code, judge bend radius and spot wire showing through a cover. A failed inspection goes to the maintenance lead, who decides whether the machine runs until the hose arrives or stays locked out until it is fitted.

  3. A fail means a hose that could burst or inject oil: wire showing, a blister, a kink, or weeping at a fitting. Tag the hose, keep the machine depressurised and locked out, and raise a work order for a replacement of the same specification. Never run the machine to see how bad the leak is. In this template every No is flagged and asks for a photo and a comment, and an inspection that scores under its pass mark of 90 is a fail.

  4. Keep the machine ID, date, which hose failed and why, a photo of the damage, the date code of the old and new hose, and the work order that closed it. Over a year this shows which hoses fail early and whether routing or heat is the cause, so you fix the installation rather than keep replacing the hose. In LeanSuite each submitted inspection is stored with its score, its pass or fail, and the photo and comment on every No.

  5. 13 questions in 4 sections: before you start, hose condition, fittings and routing, and follow-up. Every question is answered Yes, No or N/A.

Use this template in LeanSuite

It is ready in the Template Marketplace inside Lean Creator as “Hydraulic Hose Inspection”. Clone it into your plant, change any question, then schedule it to a person, role or asset with reminders. Auditors complete it on a phone or tablet, with photo evidence where required.

Not on LeanSuite yet? On a 90-day pilot our team sets up your account and digitizes the forms and checklists you use today, this one included.

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