Troubleshooting Hydraulic Hose Issues in Heavy Equipment

[MikePhua]

Heavy equipment is designed to endure rigorous work conditions and perform under pressure. However, problems such as power loss, particularly in tracks, can occur and often stem from hydraulic issues. One common issue involves hydraulic hoses, which are critical in maintaining proper hydraulic pressure and flow to key components like tracks, arm functions, and lifting mechanisms. When there's a lack of power in the track system, it can significantly affect the performance of the equipment. In this article, we’ll dive into how to troubleshoot such hydraulic issues, specifically focusing on swapping hydraulic hoses to check for power loss, and what steps can be taken to identify and resolve the problem.
Understanding the Role of Hydraulic Hoses
Hydraulic hoses are used to transfer hydraulic fluid between various components of heavy machinery. They are designed to handle high pressure and are a key part of the system that powers the tracks, arms, and other hydraulically operated functions. The fluid within the hoses carries the power necessary for movement. When these hoses experience wear, blockage, or damage, they can cause a reduction in power delivery, particularly to the tracks, which could lead to the lack of power you're experiencing.
Hydraulic Fluid Flow:
The hydraulic fluid, under high pressure, moves through the hoses and is directed to various parts of the machine, such as motors, cylinders, and the track system. In the case of a track system, the hydraulic motor that drives the track relies heavily on the consistency of the fluid pressure to turn the wheels or sprockets. If the hose supplying this motor is clogged or leaking, the system will lose power, and the tracks will lack the force needed for operation.
Common Causes of Hydraulic Power Loss in Tracks

1. Damaged or Leaking Hydraulic Hoses
   • The most obvious reason for power loss is a damaged or leaking hose. A broken hose or cracked fitting can lead to a loss of pressure, causing the track motor to not receive the necessary fluid to operate. This can be visually checked for hydraulic fluid leaks.
     
   • Signs: If there’s visible fluid leakage around the hoses or fittings, it's clear the issue lies in the hose or connections.
     
2. Clogged Hoses
   • Over time, dirt, debris, or the buildup of contaminants in the hydraulic fluid can clog hoses, restricting fluid flow. This can cause a drop in pressure and result in the loss of power to critical systems like the tracks.
     
   • Signs: Inconsistent performance, jerky movements, or reduced power are indicators that there may be a restriction in the hydraulic flow.
     
3. Air in the Hydraulic System
   • Air in the hydraulic system can also lead to power loss. Air bubbles prevent proper pressure buildup, leading to inadequate power delivery. This can often occur after fluid changes, improper maintenance, or if there’s a leak in the system.
     
   • Signs: Erratic operation, loss of track power, and fluctuating hydraulic pressure can point to air being trapped in the system.
     
4. Improper Hydraulic Fluid Levels
   • Low hydraulic fluid levels or using the wrong type of hydraulic fluid can cause a drop in system performance. Without sufficient fluid, the system will struggle to maintain the required pressure.
     
   • Signs: Warning lights or gauges indicating low fluid levels, or visibly low hydraulic oil can indicate a lack of sufficient hydraulic fluid.
     
5. Faulty Hydraulic Pump
   • The hydraulic pump is responsible for generating the pressure needed for hydraulic fluid to power the system. A failing pump will reduce fluid pressure, leading to power loss in the tracks.
     
   • Signs: A sudden drop in performance, combined with noisy operation or difficulty in achieving full speed, could indicate a problem with the pump.
     

Steps to Troubleshoot and Fix Hydraulic Hose Issues

1. Inspect the Hydraulic Hoses
   • Visual Inspection: Start by visually inspecting the hydraulic hoses for any signs of damage or leaks. If the hoses appear worn, cracked, or have visible oil stains, this indicates a need for replacement or repair.
     
   • Hose Flexibility Test: Flexing the hose while monitoring for leaks can help determine if there are any small cracks or weak spots.
     
   • Tighten Fittings: Sometimes, loose fittings are the source of the problem. Tighten any loose hydraulic hose fittings to ensure proper sealing.
     
2. Test Hydraulic Pressure
   • Use a hydraulic pressure gauge to test the hydraulic pressure at various points of the system. This can help determine if there's a significant loss of pressure that may be causing power issues.
     
   • Low Pressure Diagnosis: If the pressure is too low, it could indicate a blockage or leak. If it's normal but still not transferring power efficiently, you might need to consider air in the system or internal component failure.
     
3. Swap the Hydraulic Hoses
   • If you suspect the issue is localized to the hoses, swapping hoses from a known functioning system can help rule out hose-related problems. If swapping hoses resolves the issue, the problem is indeed with the hose or connection. It could also point to the need for cleaning or flushing the hydraulic lines to remove blockages.
     
   • Step-by-Step:
     
     1. Turn off the equipment and release any pressure in the hydraulic system.
        
     2. Disconnect the hose that is suspected to be the issue.
        
     3. Swap it with a known good hose.
        
     4. Reconnect the system, and turn on the equipment to test if the power is restored to the tracks.
        
4. Check for Air in the System
   • If the system is low on hydraulic fluid or there’s a sign of air in the system, you will need to bleed the system to remove the air. This process varies depending on the machine, so refer to the manufacturer’s guide.
     
   • Bleeding Process: Open the bleeder valves to allow air to escape, then top up the hydraulic fluid to ensure the system is fully primed.
     
5. Flush the Hydraulic System
   • If the hydraulic hoses are clogged with debris or contaminants, a complete system flush is necessary. This involves draining the hydraulic fluid and replacing it with clean fluid while running the equipment to flush out the system. Ensure that all filters are cleaned or replaced to prevent further blockages.
     
6. Check Hydraulic Fluid Levels and Quality
   • Make sure that the hydraulic fluid is at the correct level. If it's too low, top it off with the correct type of hydraulic fluid. If the fluid is old, contaminated, or degraded, perform a fluid change and replace it with fresh fluid.
     
   • Filtration: Make sure the hydraulic filters are clean and not clogged, as this can reduce the fluid flow and pressure.
     
7. Consider Professional Help
   • If you’ve tried the above methods and the problem persists, it might be time to consult with a professional mechanic. Issues like a faulty hydraulic pump or damaged internal components require specialized knowledge and equipment to diagnose and repair.
     

Conclusion
Hydraulic power loss in tracks, particularly in heavy equipment like skid steers, can significantly affect its operation and productivity. Hydraulic hoses play a crucial role in maintaining pressure and fluid flow to the various parts of the machine. When there’s a lack of power in the tracks, it’s essential to troubleshoot the system systematically—starting with checking hoses for damage, leaks, and blockages.
Regular maintenance of the hydraulic system, including hose inspection, fluid checks, and ensuring the pump and components are in good working order, will help prevent such issues. However, if swapping hoses or checking for air in the system doesn’t solve the problem, further inspection or professional assistance may be needed to restore the equipment to full functionality.