Hydraulic equipment is designed to be pushed to its limits, but continuous operation under such demanding conditions causes significant wear and tear. The key to troubleshooting hydraulic system issues and preventing equipment downtime in the field is to pay close attention to your equipment’s performance.
Conducting regular visual inspections as part of your hydraulic system maintenance and understanding the common warning signs of component failure will help you catch issues before it’s too late.
1. Poor Performance
Sluggish operation or jerky movements can have several causes, including fluid contamination, leaking cylinders, trapped air in the system, or a failing hydraulic pump. If you are noticing consistent performance issues, it’s time to conduct a thorough system inspection.
2. High Temperatures
Fluid temperatures exceeding specifications often result from excessive system pressure, dirty filters, clogged coolers, or overworked equipment. Continuing to operate the equipment under these conditions will further accelerate component wear and damage the system.
3. Odd Noises
Grinding, knocking, and other strange pump noises might indicate low hydraulic fluid, worn bearings, air contamination, or restricted suction lines. Start by checking the fluid reservoir level, then inspect your filters, suction lines, and bearings.
4. Leaks
Hydraulic fluid leaks occur when a hose or line is cracked, fittings and connections are loose, or cylinder seals are worn or weakened. You can conduct a visual inspection; however, depressurizing the system is the safest and most effective way to thoroughly check each component.
5. Contamination
Fluid contamination, the #1 cause of system failure, stems from numerous issues, such as dirty filters, faulty fittings, or the introduction of contaminants during routine repairs. A hydraulic oil analysis can help you pinpoint whether contamination is causing the problem.
6. Control Issues
Erratic control lever function often indicates an issue with a sensor, valve, solenoid, or electrical component. Look for loose electrical connections, blown fuses, or stuck valves. Voltage testing might also be required if issues with valves and sensors are ruled out.
7. Component Wear
Visible wear, including cracks, abrasions, corrosion, discoloration, or bulging hoses, results from normal wear and tear and exposure to environmental elements. Issues like minor hose abrasions or a slightly loose fitting might seem minor; however, left unaddressed, they can result in a burst hose or other catastrophic failure under normal operating conditions.
8. Pressure Issues
Pressure drops or decreased lifting power are typically caused by internal cylinder leaks, failing valves and components, or a clogged fluid line. Check fluid levels and look for signs of contamination. Pumps and valves should also be inspected for function and signs of wear. After your hydraulic system troubleshooting and repairs are complete, make sure the pressure gauge is sized correctly for consistent, accurate readings.
Prioritize Hydraulic System Maintenance
If you experience any of the issues above, immediately stop operation, let the system cool, and conduct a visual inspection. Attempting to continue operating equipment under any of these conditions can cause permanent system damage and place operators at risk. For part replacements in the field, we recommend always using authorized replacement parts to keep systems running to OEM specifications and prevent voiding the manufacturer’s warranty.
At Oil-Air Products, we help operators troubleshoot system issues in the field and offer hydraulic system maintenance and repair services to get equipment back on the job. Our technical team is here to answer your product questions and find solutions for your equipment challenges.