The Comprehensive Guide to Identifying and Preventing Hydraulic Failure

Hydraulic systems are the backbone of many industrial applications, and their failure can lead to significant downtime, costly repairs, and lost productivity. The consequences of hydraulic system failure can ripple through an entire operation, affecting schedules and bottom lines. 

Therefore, understanding the signs of failure, its causes, and preventive measures is crucial to maintaining optimal performance and ensuring the longevity of your hydraulic equipment. You can minimize disruptions and keep your operations running smoothly by staying vigilant and proactive.

Key Indicators of Hydraulic System Failure

Early detection is crucial to prevent hydraulic system failure, which means preventing extensive damage and costly repairs. Recognizing the symptoms can help in taking prompt action to address underlying issues.

Here are three primary indicators that your hydraulic system may be failing:

1. Abnormal Noise

Abnormal noise is one of the earliest and most noticeable signs of when a hydraulic system fails. These sounds often indicate underlying issues that, if left unaddressed, can lead to more severe damage and system inefficiencies. 

Understanding the types of noises and their causes can help diagnose and rectify problems promptly. Two common sources of abnormal noise in hydraulic systems are aeration and cavitation.

2. Aeration

Air contamination in hydraulic fluid causes a banging or knocking noise as it compresses and decompresses. This alarming noise indicates that air has entered the system, compromising the fluid’s performance.

3. Cavitation

When the volume of fluid demanded by the system exceeds the supply, vapor cavities form within the fluid. These cavities implode when compressed, producing a characteristic knocking sound. This situation often results from poor system design or insufficient fluid levels.

4. High Fluid Temperature

Fluid temperatures above 180°F (82°C) can degrade hydraulic fluid, damage seals, and reduce lubrication, leading to system component damage. High temperatures accelerate fluid oxidation and varnish formation, which can clog filters and orifices, further exacerbating system inefficiency and wear.

5. Slow Operation

Reduced machine performance, such as longer cycle times or slow operation, often signals hydraulic system issues. This symptom can be due to various factors, including internal leakage, fluid contamination, or component wear. Promptly addressing slow operations can prevent further damage and maintain productivity.

What Are The Common Causes of Hydraulic System Failure?

Hydraulic system failures can stem from multiple sources, each contributing to the overall degradation of system performance. Identifying and understanding these causes can aid in effective preventive maintenance. Here are four key reasons for hydraulic system failure:

1. Hydraulic Fluid Contamination

Contamination by abrasive and non-abrasive materials can cause premature wear of hydraulic pumps and valves. Ensuring the cleanliness of both components and the types of fluids before use is essential. Contaminants like dirt, metal particles, and water can enter the system through poor maintenance practices or faulty seals, leading to significant damage over time. 

Even with newly installed fittings, contamination can occur, highlighting the manufacturer’s responsibility to maintain high cleanliness and quality standards.

2. Heat-Aging

Overheating causes thermal expansion, leading to the brittleness and premature aging of hose materials. Excessive heat can break down the elastomers and plastics within hoses, reducing their flexibility and strength. This often results in cracks, leaks, and eventual hose failure.

3. General Abrasion

Improper installation can cause hose assemblies to rub against other components, causing wear. Ensuring proper clamping and minimizing contact can reduce abrasion. Abrasion-resistant hose covers can also help, but the primary focus should be correct installation and routing to avoid excessive wear.

4. Hose Fitting Incorrect Insertion Depth

Improper assembly of hose fittings during crimping, particularly incorrect fitting insertion, compromises the connection and can lead to hose blow-off, posing safety hazards. Ensuring fittings are inserted to the proper depth is critical for maintaining a secure and reliable connection. Regular training and adherence to assembly guidelines can mitigate this risk.

Proactive Measures for Hydraulic System Maintenance

Monitoring hydraulic systems proactively and addressing issues early can prevent significant failures. Regular maintenance, including fluid analysis, system inspections, and component replacements, can extend the life of hydraulic systems. 

Air-Way Manufacturing offers extensive hydraulic fitting and adapter inventory, ensuring rapid response and minimal downtime during emergencies.

Ensuring Hydraulic System Reliability with Air-Way

Recognizing signs of hydraulic system failure, understanding common causes, and implementing preventive measures are vital for maintaining system integrity and performance. 

With Air-Way Manufacturing’s commitment to quality and fast response, you can ensure your hydraulic systems operate smoothly and efficiently. For more information on our hydraulic offerings, view our catalog online or contact us today.