Hydraulic System Issues and Solutions

[MikePhua]

The hydraulic system is a crucial component in many heavy-duty machines, responsible for providing power to perform various operations. However, the hydraulic system may encounter some common issues, which can lead to a decrease in equipment performance or even complete failure. Below are the causes, diagnostic steps, and solutions for common hydraulic system issues.
Common Causes of Hydraulic System Issues

1. Low or Poor Quality Hydraulic Oil
   If the hydraulic oil level is too low or the oil quality is poor, the system's lubrication performance is affected. This can lead to oil leaks, stalling, or insufficient power from the hydraulic system.
   
2. Hydraulic Pump Failure
   The hydraulic pump is responsible for delivering hydraulic oil to various hydraulic components. If the pump is malfunctioning, it may cause the system pressure to drop, affecting the equipment's operation.
   
3. Stuck or Leaking Hydraulic Valves
   Hydraulic valves regulate the direction and pressure of the oil flow. If the valves are stuck or leaking, it can prevent proper oil flow, affecting the functionality of the machine.
   
4. Leaks in Pipes and Connectors
   Leaks in pipes, fittings, and seals are common issues in hydraulic systems. Oil leaks can cause a drop in hydraulic system pressure, making the equipment unstable or inoperable.
   
5. Clogged Filters
   The filters in the hydraulic system clean the oil. If the filters are clogged or not replaced in time, impurities in the oil can cause system wear or blockages, impairing the machine's performance.
   

Diagnostic Steps

1. Check Hydraulic Oil Level and Quality
   First, check the hydraulic oil level to ensure it's adequate. Also, inspect the oil quality to see if it's degraded. If the oil level is too low or the oil quality is poor, replenish or replace the oil as necessary.
   
2. Check Pump Performance
   Use a pressure gauge to check the hydraulic pump’s output pressure. Ensure it’s functioning correctly. If the pump’s output pressure is unstable or too low, the pump may need to be repaired or replaced.
   
3. Check Hydraulic Valves
   Inspect hydraulic valves for signs of sticking or leakage. You can manually operate the valves to ensure smooth movement and check for leaks.
   
4. Inspect Pipes and Connectors for Leaks
   Examine all pipes, fittings, and seals for oil leaks. If a leak is found, repair or replace the affected components.
   
5. Check the Filters
   Inspect the hydraulic system’s filters to ensure they aren’t clogged or excessively dirty. If the filters are clogged, clean or replace them to maintain proper oil flow.
   

Solutions

• Replenish or Replace Hydraulic Oil: Based on the inspection, add hydraulic oil to the correct level and ensure it is clean and free of contaminants.
  
• Repair or Replace the Hydraulic Pump: If the pump is faulty, it may need to be repaired or replaced along with any related components.
  
• Clean or Replace Hydraulic Valves: Clean or replace faulty hydraulic valves to ensure proper oil flow regulation.
  
• Fix Pipe Leaks: Repair or replace any leaking pipes, fittings, or seals to prevent oil loss and maintain system pressure.
  
• Replace Filters: Regularly check and replace filters to keep the oil clean and prevent damage to the system.
  

Conclusion
Hydraulic system issues can be caused by various factors, but many problems can be effectively prevented with regular checks and maintenance. Timely oil replacement, cleaning of the pump, checking valves and pipes, and maintaining the filters can help keep the hydraulic system in good working order. If problems persist, it’s advisable to consult a professional repair technician for further diagnosis and maintenance.