Hydraulic power systems are the foundation of construction, agricultural, and industrial production machinery. They allow for smooth and precise transfer of enormous loads while maintaining relatively compact device dimensions. Unfortunately, even the highest-class components can fail if we forget about their proper operation and servicing.
Are you wondering why the cylinder in your machine suddenly lost its smooth movement, and the solenoid valve stopped responding? In this guide, BRhydraulic experts have prepared a list of the most common faults and proven ways to avoid them.
1. Contaminated oil – the silent killer of components
It is estimated that even 70-80% of all hydraulic system failures are caused by contaminated working oil. Particles of metal filings, dust, sand, and even water entering the system can act like grinding paste on the precise internal components of valves and pumps.
What are the symptoms?
- Sticking of spools in hydraulic distributors.
- Accelerated wear of seals and formation of internal leaks.
- Unusual pump operating noise and increased system temperature.
How to prevent it? The basis is regular replacement of filters (suction, pressure, and return) and careful maintenance of sterility when topping up oil. Remember that saving on filters always results in costly replacement of valves and cylinders.
2. Failures of coils and solenoid valves (CETOP)
Directional solenoid valves are responsible for the "brain" of operations – they control the flow of the working medium. When the system stops responding to an electrical signal, the problem usually concerns a damaged electromagnetic coil or a physical blockage of the distributor spool.
What to pay attention to during diagnosis?
- Proper power supply: Make sure that the system receives the correct voltage in accordance with the coil specification (most often 12V, 24V, or 230V).
- Physical condition of the coil: A common problem is the so-called burned-out coil. This results from overheating, which most often occurs when impurities block the valve spool, preventing the armature from closing the magnetic circuit.
Hint: In our offer, you will find a wide selection of reliable solenoid valves and replaceable coils that fit valves of various types and sizes, quickly restoring the machine to full efficiency.
3. Leaks and loss of hydraulic cylinder force
When the machine clearly loses its "power," the culprit is most often the actuator itself. The theoretical extension force of the cylinder in hydraulic engineering is calculated using the basic formula:
F = p * A
Where:
- F – generated force
- p – operating pressure of the medium in the system
- A – active piston surface area
If you notice a sudden drop in force (despite the correct pressure generated by the pump) and characteristic, jerky movements of the piston rod (jerking), internal seals have almost certainly been damaged. This causes the oil to "escape" between the cylinder chambers instead of pushing the piston.
How to avoid this? Use only proven hydraulic cylinders made of precisely machined steel components. Solid seals minimize the risk of internal leaks, even when operating under maximum load.
4. Load lowering and check valves
Standard spool distributors have natural, microscopic construction clearances necessary for their operation. This results in the phenomenon of spontaneous, slow lowering of, for example, a raised excavator arm, which is an undesirable and dangerous phenomenon.
Solution:
The key to stabilization are twin check valves (commonly known as hydraulic locks). They allow free flow of oil in only one direction, tightly "locking" the cylinder in a given position until the operator applies pressure to the other line. This is the simplest, passive, and most reliable way to protect components from overload failure.
5. Tidy up the "hydraulic spaghetti"
Effective system diagnosis is extremely difficult when the entire installation is based on a tangle of flexible hoses and dozens of pipe fittings. Each such threaded connection is a potential risk of leakage, pressure loss, and air ingress into the system.
The use of connection plates and hydraulic blocks (compliant with the CETOP standard) is the basis of modern machine design. Mounting solenoid valves directly on a solid steel block:
- Reduces the number of required hoses.
- Significantly reduces the risk of leaks (minimizing fittings).
- Guarantees quick and trouble-free replacement of a damaged valve.
Summary
Extending the life of a hydraulic system does not require magic – it is based on the cleanliness of the working oil, regular maintenance, and the elimination of leaks at the source. However, the best investment is to use solid, proven components. By choosing appropriately selected cylinders, CETOP solenoid valves, hydraulic locks, and connection plates from a trusted source, you gain the certainty that your machine will handle the toughest tasks.
Planning a system modernization or looking for spare parts? Check out the full offer of the BRhydraulic store and assemble a reliable system for your machine!
