Hydraulic systems are the true "muscles" of many machines – from agricultural and construction equipment to advanced production lines and industrial presses. Their reliability directly translates to productivity, and any failure unfortunately results in costly downtime. Although modern hydraulic components are designed to operate in extreme conditions, they require proper care and regular servicing.
In today's post on the BRhydraulic blog, we'll take a look at the 5 most common causes of faults in hydraulic systems and suggest how to effectively prevent them.
1. Contaminated hydraulic oil – the silent killer of the system
It's estimated that dirty oil is responsible for up to 70-80% of all hydraulic failures. Dust, metal shavings, water, or sand that enter the system act like an abrasive paste on precision components. These contaminants can clog delicate sliders in solenoid valves , damage cylinder surfaces, and drastically shorten pump life.
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How to prevent this? Regularly check the oil level and replace hydraulic filters according to the machine manufacturer's recommendations. Maintain absolute cleanliness when topping up the fluid and check the tightness of filler caps and vents.
2. Worn seals and leaks from cylinders
Hydraulic cylinders are designed to convert oil pressure energy into precise linear motion. Operation under heavy loads, extreme temperature fluctuations, and the aforementioned contamination cause gradual deterioration of seals. This manifests itself through external oil leaks, internal leaks resulting in reduced pressure force, or uneven operation (also known as rod jerking).
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How to prevent it? Respond to the first signs of "sweat" on the piston rod and protect it from mechanical damage. If your cylinder is worn out, it's worth investing in reliable solutions. BRhydraulic offers robust cylinders in various diameters and strokes, made from precisely machined materials, minimizing the risk of premature failure.
3. Overheating and burning of electromagnetic coils
Coils are key control elements in solenoid valves. Their failure most often results in the valve not responding to the control panel signal and the machine being immobilized. Coil burnout can be caused by a voltage surge in the system, moisture, excessive ambient temperature, or – very often – the coil being powered up when it is not properly seated on the valve stem.
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How to prevent this? Check the condition of the wires and plugs (e.g., DIN type). Fortunately, if the coil fails, replacement is quick and inexpensive. Our store offers a wide selection of coils for valve sizes NG6 , NG10 , NG16, NG25, and NG32 – powered by 12V DC, 24V DC, 110V AC, or 230V AC.
4. Incorrectly selected distributors and pressure surges
An improperly matched distributor ( solenoid valve ) to the pump's capacity can cause flow throttling, excessive oil heating, and significant pressure surges. Failure to implement appropriate safeguards is also dangerous. When pressure backs up into the control system under load, seals can rupture and housings can crack.
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How to prevent this? Always match the solenoid valve's capacity to the system's parameters. It's also worth using check valves , which allow the medium to flow in only one direction, stabilizing pressure and protecting the pump and the rest of the system from overloading. At BRhydraulic, we offer precise slide solenoid valves (e.g., the reliable 4WE6 and 4WE10 models) that guarantee smooth and safe control.
5. Operating temperature too high
Hydraulic oil at excessively high temperatures drastically loses its lubricating properties, becomes thinner, and accelerates the hardening of seals—both in cylinders and inside solenoid valves . Overheating can result from a damaged cooler, too little oil in the reservoir, or continuous fluid flow through the overflow valve.
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How to prevent this? Monitor the machine's operating temperature gauges. Optimal hydraulic oil temperature is typically between 40°C and 60°C. Any operation at temperatures significantly above 80°C should be a warning sign requiring immediate diagnosis.
Summary
Most of the above problems can be easily avoided with regular maintenance, ensuring the working fluid is clean, and responding quickly to even the slightest irregularities. However, when it's time to replace or upgrade the system, selecting the highest quality parts is key.
We invite you to explore what BRhydraulic has to offer! We offer reliable actuators , precision distributors (CETOP) , durable solenoids , and check valves that will ensure long, trouble-free operation of your machinery.
If you have any questions or concerns about selecting the right solenoid valve, coil, or actuator for your machine, please contact us – our specialists will be happy to advise you!