TROUBLESHOOTING FOR HYDRAULIC EQUIPMENT
Problems with hydraulic equipment can be grouped into eight categories, such as pump discharge failure and excess
heat generation. The table below sums up the trouble causes and repairs and checks.
Problem Cause
1. The rotation direction is incorrect.
2. The pump shaft is not rotating.
3. The suction filter is clogged.
4. Air is in the suction line.
5. The working fluid is too viscous to flow into the
pump.
6. The pump is placed too high.
1. The pump does not
discharge the working fluid. 7. The pump rotation speed is too low.
8. The amount of the fluid in the reservoir is
insufficient.
9. Air is not bled at the pressurized side; suction
cannot take place.
10. The variable displacement pump is improperly
adjusted.
11. Parts are worn or damaged.
1. The suction line or the suction filter is clogged.
2. The suction line is too narrow or long.
3. The capacity of the suction filter is insufficient. Replace the filter with a new one whose capacity is
2. The pump produces noise 4. The pump is placed too high.
(cavitation). 5. The capacity of the boost pump is insufficient.
6. The working fluid is too viscous to flow into the Replace the fluid or heat it with a heater.
pump.
7. The pump rotation speed is beyond the specified Drive the pump at the specified rotation speed.
level.
8. The air breather in the reservoir is clogged.
1. Suction pipe connection is loose.
2. There are foams in the reservoir.
3. Pump produces noise 3. Air is leaking in through the shaft seal.
(aeration). 4. Air is not completely bled from the casing.
5. There are bubbles in a line.
6. The pressure is beyond the specified level.
7. A coupling produces noise.
8. Pump parts are worn or damaged.
73 ■ TROUBLESHOOTING FOR HYDRAULIC EQUIPMENT
Repair/Check
Make sure that the direction is correct.
Check and modify the shaft key and coupling.
Remove the clogging.
Fix the pipe connection (screwed part and packing).
Replace the fluid or heat it with a heater.
Decrease the suction height (head).
Drive the pump at the specified rotation speed.
Add the fluid to the recommended level.
Take the air out of the highly pressurized line by
loosening the line.
Check and correct the adjustment.
Repair or replace the parts.
Remove the clogging.
Replace the piping so that the vacuum level is kept
below the specified value.
twice or more as large as the pump discharge flow.
Decrease the suction height (head).
Repair or replace the boost pump.
Clean the breather.
Fix the connection (screwed part and packing).
1. The oil level is low: add the working fluid to the
recommended level.
2. The reservoir is equipped with no baffle plate, or
the reservoir is too small: install an defoaming
filter or replace the reservoir
Replace the shaft seal.
Run the system with no load until air is removed
completely.
Set up an air bleeding circuit for a closed line.
Drive the pump at or below the specified pressure.
Align the shaft or replace the coupling.
Repair or replace the parts.
 Problem
4. Excess heat is generated.
5. The solenoid directional
valve is not in working
order (burnout of the coil).
6. The pressure control valve
is not in working order.
7. The actuator (cylinder) is
not in working order.
8. Maintenance and
management of the
hydraulic system
Cause Repair/Check
1. Internal leakage in the pump increases. Repair or replace the pump because its volumetric
efficiency is deteriorated.
2. Internal leakage in the valve increases. Repair or replace the valve.
3. Internal leakage in the actuator increases. Repair or replace the actuator.
4. The sliding part of the pump is seized up Repair or replace the pump.
(scoring).
5. The pump or bearing is seized up. Replace the bearing.
6. The working fluid in the reservoir is insufficient. Add the fluid or place a larger reservoir.
7. Oil cooler selection is improper. Replace the oil cooler with a new one with a larger
heat-exchange capacity.
8. The oil cooler performance is inadequate. 1. Check the water temperature and volume and
take an appropriate action.
2. Overhaul the cooler and remove water strains
and other contaminants.
3. Clean the radiator of the fan cooler.
9. The cooling water in the oil cooler is insufficient. Check whether the temperature difference between
a. The water solenoid valve is not in working the cooling water inlet and outlet is proper.
order. Check and repair the valves and electric systems
b. The automatic water supply valve with a to make sure that cooling water flow is increased.
temperature detector is not in working order.
c. The thermostat is not in working order.
10. The heater is not in working order. Check and repair the heater and thermostat.
11. The unload circuit is not in working order. 1. Check and repair the valves.
a. The unload set pressure is too high. 2. Correct the pressure setting.
b. Pressure setting is improper, resulting in a 3. Replace the failed components.
shortened unloading time. 4. Check and repair the electric systems.
c. The accumulator is not in working order, or
its capacity is insufficient.
d. Gas pressure of the accumulator is low.
e. The pressure switch is not in working order.
12. The viscosity of the working fluid is low, Replace the working fluid.
resulting in increased leakage.
13. The set pressure level is too high. Correct the pressure setting to an appropriate level.
1. Spool operation is failed because of dust. Clean the spool and replace the coil.
2. The voltage is too high or low. Set the voltage at a proper level and replace the coil.
3. Insulation failure is caused by water. Eliminate the failure cause and replace the coil.
4. Direction control is failed due to an excess flow. Adjust the flow rate at a proper level or place a
larger valve.
5. Direction control is failed due to a hydraulic lock. Install a filter or replace the existing filter to a seat
type.
1. The pressure falls below the setting level. ・Overhaul the valve.
a. The valve is not properly seated. ・Replace the valve and seat.
b. The orifice is clogged with dust. ・Replace the worn or damaged parts.
c. Stick-slip is taking place because of dust.
d. The valve spring is damaged.
2. The pressure oscillates (caused by other than
the factors above).
a. The working fluid contains air. a. Remove the air from the fluid.
b. The capacity of the bent line is too large. b. Make the bent line thin or short or squeeze it.
c. The valve resonates with other valves. c. Replace the valve spring to change the
characteristic frequency.
d. Flow is excessive. d. Adjust the flow to a proper level or place a larger
valve.
1. Knocking is caused by air in the working fluid. Remove the air from the fluid.
2. Knocking is caused by packing resistance. Apply molybdenum disulfide coating to the piston
or replace the packing.
3. Knocking is caused by the bump at the load Perform the centering of the actuator and make
side. the load line smooth.
4. Knocking is caused by a poor condition of the Repair the tube.
inner surface of the tube.
5. Knocking is caused by improper operation of Inspect and eliminate the failure cause.
the control valve.
6. Air in the working fluid causes thrust reduction. Remove the air from the fluid.
7. Insufficient pressure causes thrust reduction. Inspect and eliminate the failure cause.
8. Internal leakage causes thrust reduction. Repair the failure (replace the packing).
Perform the following actions for maintenance and management of the hydraulic system.
1. Keep the working fluid clean (see Chapter 14 HYDRAULIC FLUIDS).
2. Make sure that operating conditions are correct, and keep the system in an order that allows
appropriate action to be quickly taken if required. The following values should be known for
system maintenance and management.
(1) Saturation temperature in a reservoir (comparison with the room temperature).
(2) Input power supplied when a fixed displacement pump is unloaded or when a variable
displacement pump is fully cut off (ampere).
(3) Input power at maximum load (ampere).
(4) Drain rate for a variable displacement pump (L/min (U.S.GPM)).
(5) Pump noise level [noise level at unloading and maximum loading (dB(A)) and noise quality]
These values increase with lower pump efficiency and more internal leakage in valves.
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