The images are far too graphic to print within this article. But if you do an Internet search on hydraulic injection injuries, you will find plenty of photos and stories that are vivid enough to make a lasting impression and, maybe more importantly, encourage you to give hydraulic systems the respect they deserve.

"Everyone needs to be aware of hydraulic system safety," says Gary Kleiner, training and development manager, Fluid Connectors Group, Parker Hannifin Corp. "It's not only the maintenance technician's responsibility, but everyone who works on and around hydraulic systems under pressure."

Of course, a lot of working with hydraulics is common sense, says Rod Erickson, senior technical instructor, Eaton Training Center. Yet, mistakes happen.

"Mistakes can happen when someone forgets to secure a load or when they forget to bleed the pressure," he says. "People can get lax when they've worked around equipment for a long time. Plus, when you're working on a repair, especially in the field, you're always under the gun. You want the machine fixed right, but you want it fixed now. Time is money and labor is expensive. As a result, you may be in a hurry and that's generally when accidents happen."

A loaded gun
When properly maintained, a hydraulic system isn't necessarily dangerous. But hydraulic hoses and assemblies do have a shelf life; when improperly stored, installed and/or serviced, they can burst and spew hot, highly pressurized fluid that can injure workers or equipment operators standing nearby.