Chances are, if equipment operators are experienced enough with their machinery to recognize when something isn’t right, a delayed response, an unexpected sound, a job taking longer than typical, they’ll also be trained in hydraulic systems. Unfortunately, many subtleties that compromise performance go unnoticed until total system failure occurs. Assessing what’s worth calling a hydraulic repair professional for and what’s needed after next routine maintenance can be tricky.
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If Performance Deteriorates
The most common signal that something’s not right occurs through performance of the equipment. A tipper that used to raise its bed in eight seconds now takes twelve. A crane that handled lifts quickly and smoothly starts hesitating or lurching unexpectedly. These are not simply annoyances; these are hydraulic systems begging for help.
Unfortunately, performance deterioration rarely self-corrects. When operators notice sporadic results or decreased efficiency, there’s more than likely a decrease in psi somewhere in the system, contamination from outside sources or wear and tear of components beyond tolerance. Heavy Hydraulics notes numerous developments where a simple part replacement could have saved a total system overhaul had there been a call to a professional before it was too late.
Temperature also plays a role. Hydraulic systems operate at warm temperatures while generating heat; however, if fluid runs in the system at a noticeably hotter level or temperature spikes, something’s generating friction and resistance too much. Components forced to work harder than anticipated will fail sooner, and often, systems attached will experience problems beyond the initial culprit.
If It Sounds Like Trouble
There’s a reason hydraulics make noise when they operate; systems contain power units and pumps to function, after all. However, there are certain sounds that mean business and need immediate attention. One high-pitched noise, for example, is a whine. Whining comes from pump cavitation which occurs when the hydraulic pump cannot get enough fluid within it. This situation dismantles pump components at an accelerated rate, potentially within hours of the sound’s arrival.
Banging or knocking noises typically come from pressure spikes in the system or shock. Systems provide jolting movements that can crack housings, blow seals, and pound valves into suboptimal arrangements. However, by the time something is making such noise above the operational sounds of a unit, problems have likely compounded.
Grinding means metal is grinding into metal. This is bad news, a pump with non-functioning bearings or a cylinder whose seals have torn and allow a rod to punch through the barrel indicates component disintegration in real time.
If There’s a Problem With The Fluid
Finding hydraulic fluid where it’s not supposed to be is problematic enough. Not all leaks are created equal, however. A drop or two underneath the fitting after the operator shuts it down for the day may be normal seepage that doesn’t require immediate operation. However, a consistent, drippy leak while the equipment is active is a problematic leak. Because this means seals or connections have failed in straining pressure containment. Puddles forming underneath heavy equipment are never good signs.
However, internal leakage happens when systems can bypass seals in valves and cylinders. This may not create external puddles, but it certainly reduces functioning. This appears like performance deterioration discussed previously, the pump works; the fluid moves; however, work output over time decreases.
Condition of the fluid makes statements all on its own. Dark, burnt-smelling hydraulic oil has been running too hot. Milky or cloudy fluid means the consequence of either condensation or water contamination. Finding metal shavings or pieces of other debris in the reservoir, even on a magnet from a drain plug, signals wear and tear somewhere in the system. These problems only worsen.
If There’s A Problem While The Hydraulic System Is Still Functioning
Some problems announce themselves while equipment operates, cylinders that drift down from a raised position indicate something’s wrong with their internal seal. Float controls indicate air in the system. Little operational power that only increases after the system is warmed up signals temperature-related failures.
Pressure gauge readings also signal when something isn’t working. Most operators know their typical PSI range for most hydraulic systems. When those shifts run lower than anticipated, or higher during expected pushes, there’s a problem. It’s clear the operator’s not getting the use and output expected.
Making The Call
Recognizing a problem early versus waiting for something to completely breakdown could save thousands, when small problems create unnecessary strain to other components, a failing seal becomes accumulated pump damage, contaminated fluid, ruined valves throughout the system. Assessing what’s worthwhile involves operators learning what they can and cannot visually confirm.
Professional diagnosis can confirm speculation before problems become compounded. Pressure can be gauged better at different intervals; fluid can actually be tested in a lab for quality; and visuals can note where wear is becoming problematic before it fails completely. The cost of such review is typically far less than the emergency repairs and downtime associated with something broken beyond repair.
Hydraulic systems are miraculous if maintained appropriately. However, they’re not without faults. When tolerances, fluid cleanliness or pressure exceeds recommended limits, the hydraulic system is forced to communicate that professional attention is needed. Learning how to recognize these signs, and acting on them, will keep equipment consistently running and maintain small breakdowns from becoming large nightmares.