Three Early Warnings of Hydraulic System Troubles and How to Prevent Them

Hydraulic systems are essential for powering industrial operations with precision and reliability. However, like any system, they can develop issues over time, leading to costly downtime and repairs. Identifying early warning signs and utilizing the right diagnostic tools is key to maintaining performance and extending the lifespan of your equipment.

This blog outlines three common warning signs of hydraulic trouble and provides a comprehensive guide to the tools you need to diagnose and resolve them.

1. Slow or Inconsistent Operation

A noticeable decline in the speed or performance of hydraulic actuators is often a sign of reduced flow or pressure. Common causes include:

• External Leaks:
  • Visible fluid leaks around fittings or beneath components, often caused by damaged hoses, worn seals, or loose connections.
• Internal Leaks:
  • Harder to detect, these occur within pumps, valves, or cylinders and result in inefficiencies and localized heat buildup.

Recommended Tools:

• Pressure Gauge: Identify drops in pressure across the system.
• Flow Meter: Measure flow to pinpoint inefficiencies or internal leaks.
• Infrared Thermometer: Detects overheating caused by leaks or wear.

Prevention Tips:

• Regularly inspect hoses, fittings, and seals for visible damage.
• Use flow meters and pressure gauges to monitor system performance.
• Replace worn components before they cause significant issues.

See the related blogs on preventive maintenance of hydraulic hoses and knowing when to replace a hydraulic hose. Another related blog, “What is Causing Your Hydraulic System to Leak” has a free download of our Port End Assembly Guide, which can educate your maintenance personnel on preventing connector leaks in the first place.

2. Unusual Noises During Operation

Hydraulic systems should run quietly. Unusual sounds such as knocking, whining, or screeching may indicate:

• Aeration:
  • Air entering the hydraulic fluid causes foaming and erratic movement.
  • Common causes include low fluid levels, damaged suction hoses, or loose fittings.
  • See related blogs on knowing when to replace a hydraulic hose, scheduled hydraulic hose replacement, and preventive maintenance of hydraulic hoses for more information on the subject.
• Cavitation:
  • Caused by vaporized hydraulic fluid, often due to the pump being unable to meet system demands.
  • Results in loud whining or screeching noises and erodes metal components.

Recommended Tools:

• Suction Gauge: Detects cavitation in the pump inlet.
• Fluid Analysis Kit: Test for air or vapor contamination in the fluid.

Prevention Tips:

• Check and tighten all fittings to prevent air ingress.
• Maintain correct fluid levels and replace damaged suction hoses.
• Monitor pump performance to avoid cavitation.

3. Elevated Hydraulic System Temperatures

Overheating, typically above 180°F, reduces hydraulic fluid viscosity and accelerates wear on components. It is often caused by:

• Internal Leaks: Generate heat due to pressure loss.
• Aeration and Cavitation: Both increase system inefficiencies and lead to overheating.
• Inadequate Heat Dissipation: Caused by low reservoir levels or blocked airflow.

Recommended Tools:

• Temperature Sensors: Monitor fluid and component temperatures.
• Flow Meters: Detect blockages or other inefficiencies causing overheating.

Prevention Tips:

• Use hydraulic fluids with proper viscosity for your system.
• Regularly clean and replace filters to maintain cooling efficiency.
• Install and monitor temperature alarms to address overheating early.

Hydraulic System Diagnostic Tools

Properly analyzing and troubleshooting hydraulic systems requires diagnostic tools that measure pressure, temperature, and flow at different points in the circuit. For more complex systems, advanced diagnostic solutions are essential.

Parker SensoControl Diagnostic Tools Overview

The Parker SensoControl family offers four diagnostic solutions tailored to maintenance needs based on system complexity.

*Note: Additional accessories may be required to perform certain functions.

Investing in the appropriate diagnostic tools ensures accurate problem detection, efficient repairs, and minimal downtime.

Proactive Maintenance: The Key to Hydraulic System Health

Preventing hydraulic system issues requires vigilance and proactive care. Here are some best practices:

• Conduct regular inspections to identify leaks, unusual noises, and temperature changes.
• Use diagnostic tools like pressure gauges, flow meters, and temperature sensors to monitor performance.
• Train operators to recognize and respond to early warning signs.
• Replace worn-out components such as seals, hoses, and filters on a set schedule.

Recognizing the early warning signs of hydraulic trouble is essential to maintaining system performance and avoiding costly failures. With the right tools and a proactive approach, you can ensure your hydraulic systems operate efficiently and reliably.

For expert advice, high-quality diagnostic tools, or maintenance support, contact MFCP today. We’re here to help you keep your systems running smoothly.

Posted by Marek Bobik