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 into work efficiency, and every failure, unfortunately, means costly downtime. Although modern power hydraulics components are designed to operate in extreme conditions, they require proper treatment and regular servicing.
In today's blog post, BRhydraulic will look at the 5 most common causes of hydraulic system failures and suggest how to effectively prevent them.
1. Contaminated hydraulic oil – the silent killer of the system
It is estimated that dirty oil accounts for as much as 70-80% of all failures in hydraulics. Dust, metal filings, water, or sand that enter the system act like abrasive paste on precise components. These contaminants can block delicate spools in solenoid valves, damage cylinder linings, and drastically shorten pump life.
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How to prevent? Regularly check the oil condition and replace hydraulic filters according to the machine manufacturer's recommendations. Maintain absolute cleanliness when refilling fluid and check the tightness of filler caps and breathers.
2. Worn seals and leaks from cylinders
Hydraulic cylinders are designed to convert oil pressure energy into precise linear motion. Operating under heavy loads, extreme temperature fluctuations, and the aforementioned contaminants cause gradual degradation of seals. This manifests as oil leaks to the outside, internal leaks resulting in a drop in pressing force or uneven operation (so-called piston rod jerking).
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How to prevent? React to the first signs of "sweating" on the piston rod and protect it from mechanical damage. If the cylinder is worn out, it is worth investing in reliable solutions. The BRhydraulic offer includes solid cylinders of various diameters and strokes, made of precisely machined materials, which minimizes the risk of premature failures.
3. Overheating and burning out of solenoid coils
Coils are key control elements in solenoid valves. Their failure most often results in the valve not reacting to a signal from the control panel, and the machine becoming immobilized. The cause of a coil burning out can be a voltage surge in the installation, moisture, too high ambient temperature, and also - which happens very often - turning on the coil power when it is not properly seated on the valve stem.
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How to prevent? Check the condition of cables and plugs (e.g., DIN type). If the coil fails, its replacement is fortunately quick and inexpensive. In our store, we offer a wide selection of coils for valves of sizes NG6, NG10, NG16, NG25 and NG32 – powered by 12V DC, 24V DC, 110V AC or 230V AC voltages.
4. Incorrectly selected distributors and pressure surges
A poorly matched distributor (solenoid valve) to the pump's efficiency can cause flow throttling, excessive oil heating, and powerful pressure surges. The lack of appropriate safeguards is also dangerous. When under load, pressure backs up into the control system, it can lead to seal ruptures and housing cracks.
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How to prevent? Always match the solenoid valve's flow capacity to the system's parameters. It is also worth using check valves, which allow medium to pass in only one direction, stabilizing pressure and protecting the pump and the rest of the system from overload. At BRhydraulic, we offer precise spool solenoid valves (e.g., reliable 4WE6 or 4WE10 models) that will ensure smooth and safe control.
5. Too high operating temperature
At too high a temperature, hydraulic oil 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 medium bypass through the relief valve.
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How to prevent? Monitor the machine's operating temperature indicators. The optimal hydraulic oil temperature is usually between 40°C and 60°C. Any operation at temperatures significantly exceeding 80°C should be a warning sign for immediate diagnosis.
Summary
Most of the above problems can be easily avoided through regular maintenance, ensuring the cleanliness of the working fluid, and prompt reaction to even the smallest irregularities. However, when it comes time to replace or modernize the system, selecting the highest quality parts is key.
We invite you to familiarize yourself with the offer of the BRhydraulic store! You will find reliable cylinders, precise distributors (CETOP), durable coils, and check valves that will ensure long and trouble-free operation for your machines.
Do you have doubts or questions regarding the selection of the appropriate solenoid valve, coil, or cylinder for your machine? Contact us – our specialists will be happy to advise you!
