What Causes A Hydraulic System Failure?

As hydraulic system experts, we understand the critical importance of preventing system failures. Let's explore the four main causes of hydraulic system failures and provide insights on how to avoid them, ensuring optimal performance and longevity of your equipment.

Key Causes of Hydraulic System Failures

General Abrasion

General abrasion occurs when hydraulic hoses rub against other components, leading to premature failure. To prevent this:

• Ensure proper installation of hose assemblies
• Minimise contact between hoses and other mechanical components
• Use protective sleeves or routing techniques to reduce friction points

Expert Tip: Regularly inspect hoses for signs of wear and replace them before failure occurs. This proactive approach can significantly reduce downtime and maintenance costs.

Heat-Ageing

Overheating can cause thermal expansion and premature ageing of elastomers and plastics within the hose material. To combat heat-ageing:

• Monitor fluid levels in the reservoir
• Ensure proper airflow around the reservoir
• Maintain an efficient cooling circuit

Industry Insight: Implementing a thermal imaging programme can help identify hotspots in your hydraulic system before they lead to component failure.

Incorrect Insertion Depth

Improper assembly, particularly incorrect insertion depth of fittings into hoses, can lead to system failures. To prevent this:

• Use hose insertion depth blocks
• Train technicians on proper assembly techniques
• Implement quality control checks during assembly

Best Practice: Create a standardised assembly procedure and checklist for all hydraulic connections to ensure consistency and reliability.

Hydraulic Fluid Contamination

Contaminated hydraulic fluid is the leading cause of system failures. It can degrade fluid quality, reduce valve performance, and cause overheating. To mitigate this risk:

• Clean components thoroughly before assembly
• Use high-quality filtration systems
• Implement a regular fluid analysis programme

Advanced Solution: Consider implementing real-time fluid monitoring systems to detect contamination early and prevent catastrophic failures.

Preventive Maintenance Strategies

To further showcase our expertise, here are additional preventive maintenance strategies we recommend:

Regular System Audits: Conduct comprehensive audits to identify potential failure points before they become critical.

Predictive Maintenance: Utilise sensors and data analytics to predict when components are likely to fail, allowing for timely replacements.

Training Programmes: Invest in ongoing training for operators and maintenance staff to ensure best practices are followed consistently.

Documentation: Maintain detailed records of system performance, maintenance activities, and component replacements to identify patterns and optimise maintenance schedules.

By implementing these strategies and understanding the root causes of hydraulic system failures, you can significantly extend the life of your equipment, reduce downtime, and optimise performance.

For more information on preventing hydraulic system failures or to discuss bespoke solutions for your equipment, contact our team of specialists. We're committed to helping you achieve maximum reliability and performance from your hydraulic systems.