Troubleshooting Tips for Hydraulic Equipment
Hydraulic equipment can be notoriously difficult to troubleshoot, especially if the problem occurs intermittently. However, even intermittent problems can be a major drain on productivity and uptime, and eventually those intermittent issues can become catastrophic, system-ruining failures.
This is why it is critical for organizations to diagnose any hydraulic equipment issues as soon as possible, in order to minimize downtime costs. If your business is currently dealing with hydraulic equipment failures, here are some troubleshooting tips worth considering.
What is the Nature of the Hydraulic Equipment Failure?
When a hydraulic system does experience a failure, it often manifests as either a pressure or a volume problem. In other words, either the system doesn’t come up to sufficient pressure, or the system can’t deliver sufficient hydraulic fluid to the actuating component.
Before your personnel or a hydraulic technician gets their hands dirty working with the system, you should know what kind of problem you’re dealing with and where it’s located. A lot of time and money can be wasted on breaking down hydraulic equipment if there isn’t a plan in place. Before escalating an issue, do your best to understand whether it’s due to pressure, volume or fluid quality deficiencies.
What Needs to be Checked When Evaluating the Hydraulic System?
During the troubleshooting process, you’ll need the full picture on your hydraulic equipment. That includes checking the following:
- Whether or not the hydraulic system has been adjusted or recalibrated
- The maintenance logs to verify whether any components have been replaced
- The hydraulic fluid level and fluid quality
- The condition of all hydraulic filters
- The condition of the pump’s couplers
- Whether visible fluid leaks are present
- The temperature of important hydraulic system components
Follow this troubleshooting check list and you’ll have a better idea of where the problem is located and how it’s presenting within the system.
How Can Schematics Help the Troubleshooting Process?
Schematics are helpful but often overlooked resources when troubleshooting hydraulic equipment. If your schematic drawings are available, they’re worth reviewing before taking apart the system.
Schematics are especially important if you suspect there’s a defective component that’s located in a difficult to access spot (like inside a manifold). By studying the schematic, you can determine how each part of the system connects with each other, which can reveal where issues are likely to emerge before you have to crack a single piece of equipment open.
Schematics also provide information about any parts used inside the system, including model numbers. A single number or letter difference in the model specification is enough to affect hydraulic system performance, which can lead to various problems.
If you’re troubleshooting a hydraulic equipment failure, ensure your system’s schematics are available for reference.
What Are Some Signs That There is a Problem with Your Hydraulic Equipment?
Not sure if it’s time to troubleshoot a hydraulic equipment problem? If any of the following signs are present, it’s definitely time for a deeper inspection:
- Loss of power or inconsistent power delivery – If your hydraulic system can’t consistently deliver sufficient power to actuating components, there could be many culprits. It could be a bad valve that isn’t actuating fully. It could be the result of degraded hydraulic fluid (and reduced flow efficiencies). It could be due to bad system calibration. And in many cases, reduced flow or pressures are caused by internal hydraulic fluid leaks, which may produce bypass through the system.
- The presence of hydraulic fluid leaks – If you notice hydraulic fluid building up on system components or pooling around parts of the system, that’s always worth following up on. Hydraulic leaks are major contamination risks and will affect system performance, so don’t ignore them. However, hydraulic fluid can escape from the system and flow some distance down hydraulic lines, so don’t assume that the leak is near the hydraulic fluid itself.
- Visible sediment in the hydraulic fluid – Every month or two, it’s recommended that hydraulic system operators take a fluid sample from a test port in the system. If there is noticeable sediment floating in the fluid, that’s a major sign that your system needs to be shut down and thoroughly cleaned out. Even if sediment isn’t visible, it’s still a good idea to send a sample to an engineering lab regularly to check for minute amounts of sediment that may not be detected with the naked eye.
- Overheating hydraulic fluid or system components – Overheating hydraulic fluid or system components is often caused by contamination, but it can also be the result of malfunctioning hydraulic valves obstructing flow or a damaged heat exchanger. You can check for overheating with a thermal gun or an infrared camera, and it’s important to address overheating right away, as it can affect hydraulic fluid dynamics.
- Unusual sounds or odors during operation – Your hydraulic equipment operators should be familiar with how your system sounds and smells during operation. If the equipment starts whining, banging or “gurgling,” it could be due to trapped air in the system or excessive wear. Foul odors are often caused by hydraulic fluid contamination. In both cases, you’ll need a full inspection to determine the extent of the problem.
Need to Troubleshoot a Hydraulic Equipment Issue? Consult the Experts
Hydraulic equipment troubleshooting can be a time sink for those without experience. In many cases, it makes sense to bring in a hydraulic equipment expert as soon as you’re noticing issues, as this will speed up the troubleshooting process and ensure an accurate diagnosis.
Further, by partnering with a proven hydraulic expert for troubleshooting purposes, you’ll have faster access to any needed hydraulic equipment repairs. That can greatly offset downtime costs and timelines.