Why Troubleshooting Your Hydraulic System Is Critical for Business Continuity

Your hydraulic system is essential to your business. When it fails, your entire business stops, and it’s critical to get it back up and running as soon as possible. If you have a newer hydraulic system, you know how complicated it can be to identify the issue. While troubleshooting can be challenging, you can do it.

Why is it essential to troubleshoot your hydraulic system?

Knowing how to troubleshoot your hydraulic system can save you a lot of time and money. Most companies troubleshoot their machines by changing many parts, which causes a lot of downtime and wasted money on unneeded parts. Another negative aspect is no one knows what was wrong with it, and the next time there’s an issue, you’ll waste time and money again.

The good news is no matter how complicated the system appears, it only has a few primary components, such as the sump motor, pump, valves, actuators, and hydraulic fluid. However, any of these areas could be the reason for the failure. To fix it quickly and get things up and running, you’ll need to know why it failed in the first place. Below you’ll find a few common reasons for the failure and tips on troubleshooting your hydraulic system.

Signs of Hydraulic Issues

Signs of hydraulic problems are easy to tell. They may lose power or speed in the cylinders, causing stalling. The machine will become louder than usual. Any pump components can be at fault, and in newer systems, there may be minor parts that could be the actual cause of failure.

Hydraulic Basics

Don’t forget the basic rules of hydraulic systems

• • Hydraulic fluid will take the path of least resistance
  • Pressure drops in the hydraulic fluid will cause heat to be generated
  • Hydraulic pumps generate flow, not pressure
  • Resistance to flow is what causes pressure
  • The flow determines the speed of the actuator, while the pressure determines the force.

Inoperative system

• • No oil in the system or not enough oil is the first thing you should check. If it is low, fill it and then watch for leaks.
  • If the wrong oil is in the system, it can cause it to stop operating. Make sure you put the correct oil in. If you didn’t, then you’ll need to drain the oil and then put the right oil in.
  • Dirty or clogged filters will shut down the machines. You’ll need to drain the oil and then replace the filter or filter element to fix this.
  • If there is an oil link restriction or collapse, you’ll need to drain the oil and clean or replace the lines.
  • Air leaks in the pump suction line will cause the machine to stop working. You’ll need to repair or replace the cable if you notice this.
  • Worn or dirty pumps cause shutdowns. If this happens, you’ll need to clean the pump or replace it.

Erratic system operation

• • Air in the system is usually the cause of this. You’ll need to check the suction side of the system and repair it if needed.
  • Restrictions in the filters or lines if this is the case, you’ll want to replace or clean the lines.

The system operates slowly

• • The oil viscosity is too high or cold. You’ll need to allow the oil to warm up before using the machine.
  • Low pump drive speed. You’ll need to check the manual and operate it at the correct rate.
  • Air in the system. Check the suctions for leaks and then repair them.
  • The primary system components are worn. You’ll want to check them out and then replace them, if necessary.
  • If there are improper adjustments, it will mess up the system’s operations. You’ll need to check them and then make the proper adjustments.
  • If the oil is low or not flowing through the system, there may be a leak. Thoroughly look for leaks and tighten fittings to replace seals or broken lines.

The system operates too fast

• • Typically this is related to the speed of the engine. Simply reduce the rate.

Noisy Pump

• • Air leaks or incorrect oil is usually the cause of this. Replace or clean the oil.

The Most Common Issues

The most common hydraulic systems issue is the buildup of dirt on the inlet filter. This can happen on a new system after just a few hours of use and one that has been in use for years. The stringer is generally located by the pump inlet, or it can also be found immersed below the oil level in the reservoir.

If cleaning the pump and relief valves didn’t work, disconnect the plumbing and cap the lines. Then start the pump and see if there’s a pressure build-up while tightening the relief valve. If the flow decreases as the setting are raised and can’t achieve full pressure, the issue is most likely with the pump.

If the inlet filter has been cleaned and the plumbing checked for leaks, the oil is probably slipping internally. This can be due to the thin oil in the pump itself being worn out. Check the temperature of the oil, and if it’s more than 30 degrees F, it is probably pump slippage.

Time to call the professionals?

If your hydraulic system is having issues, don’t panic. If you remember a few basics, you can quickly fix the problem and get your employees back to work. If troubleshooting isn’t getting you the results you need, it might be time to call a hydraulic repair service for some expert advice.

Servo Kinetics in Ann Arbor are the industrial hydraulic experts to call if your industrial hydraulic equipment has failed or is showing signs of needing repair. With more than 45 years of experience in industrial hydraulic repair services, we promise you the highest quality hydraulic repairs at the lowest possible cost and fast turn-around.

Our hydraulic repair services include Vickers classic factory rebuilds, Servo valve repair, reverse engineering services and more! Contact one of our experts today.