Common Problems in an Excavator’s Hydraulic System and How to Fix Them

Summary:

This blog highlights common issues in an excavator machine’s hydraulic system, including low pressure, leaks, overheating, and slow response. It provides solutions to maintain hydraulic excavators like JCB excavator, Tata Hitachi excavator, and CAT excavator. Regular checks ensure optimal performance of construction excavators, minimizing downtime and repairs. For maintenance tips, explore Desi Machines.

Introduction

The hydraulic system is the heart of an excavator. It directs the flow of power for the excavator’s movement, lifting capability, and productivity. A malfunctioning hydraulic system means inefficient equipment, leading to delays in operations and increased maintenance costs. Hydraulic systems are among the most pressurized and continually loaded parts of the excavator’s work systems. Even a small fault in the hydraulic system can lead to huge failures.

Common hydraulic problems, such as low pressure, overheating, leaking, and unresponsive controls, can greatly impact productivity in hydraulic excavators. Such problems reduce efficiency and result in expensive repairs and more downtime, increasing the project schedule.

In this blog, we will cover several hydraulic system problems that an excavator can develop, their causes, and available solutions. Whether it’s hydraulic fluid leaks, slow operation, or overheating, knowing the causes of these problems can help operators maintain their machines and avoid unexpected breakdowns. For working without any disruptions and efficiently, the excavator needs regular maintenance and timely repairs. Now, let us get into the common hydraulic problems and their solutions.

Common Problems in a Hydraulic System and Solutions

The hydraulic system on an excavator is particularly important for its functioning. Any failure could lead to a drop in performance, costly repairs, and delays on the project. The following hydraulic problems are some of the most common seen in excavators, causes of the problems, and solutions to fix them.

1. Low Hydraulic Pressure

Causes: 

• A clog in the filter obstructs the fluid flow.
• Low hydraulic fluid levels can cause low pressure.
• The pumps, if worn out, might fail to generate enough force.

Solutions: 

• Regularly checking and cleaning the hydraulic filters can help to avoid blockage.
• It is mandatory to maintain optimum hydraulic fluid levels as specified by the manufacturer.
• Checking malfunctioning and worn-out pumps is necessary. Replacing worn-out pumps should be initiated.
• When hydraulic pressure begins to decrease, the excavator’s efficiency begins to drop. So regular maintenance should be done to maintain optimum productivity.

2. Overheated Hydraulic Fluid

Cause:

• If the hydraulic oil is contaminated or degraded, then it reduces the cooling capacity of the excavator.
• The load is too high for the system to function.
• Cooling components like fans or radiators malfunction.

Solutions: 

• Always use quality hydraulic oil as recommended by the manufacturer.
• Avoid overloading the machine and applying undue stress on the hydraulic system so that it functions well.
• Regularly inspecting radiators, fans, and coolers for efficient functionality.
• Heating the hydraulic fluid could cause the hydraulic fluid to break down in viscosity, damaging the precious components over time.

3. Slow or Unresponsive Hydraulics

Causes:

• The air presence may interfere with the liquid flow in the hydraulic system.
• Worn-out seals can cause fluid leakage, which may cause a loss of pressure.
• A malfunctioning control valve is unable to exert effective pressure regulation.

Solutions: 

• Release air from the system as prescribed in the operator manual.
• It is necessary to replace any damaged seals to ensure proper pressure.
• Check control valves routinely for any irregularities and repair or replace those found to be faulty.
• Early detection of the slow response of the hydraulic system is necessary to prevent

4. Hydraulic Fluid Leak

Causes:

• Cracked or damaged hydraulic hoses can cause leakage of the fluid.
• Loose fittings can make the fluid leak.
• Leakage can happen if the seals are worn out.

Solutions:

• Periodic inspection of hoses is necessary, and replacement is required if.
• Loose fittings should be tightened to avoid leakage and loss of fluid.
• Replacement of seals is necessary if they show any signs of wear and tear.

5. Jerky Movements.

Cause:

• Dirty hydraulic oil can lead to inefficient operations and hence erky movement.
• Inappropriate settings of hydraulic pressure can cause inappropriate movements.
• Irregular movement can be caused by damaged hydraulic cylinders.

Solution:

• Drain and replace with clean, high-quality hydraulic oil.
• Set the pressure setting of the system according to the manufacturer’s recommendation.
• Inspection of hydraulic cylinders for internal damage and repair or replacement if necessary.

6. Pump Noise or Vibration

Cause:

• Cavitation resulting from air trapped in the hydraulic fluid.
• Loose pump mounts result in major levels of vibrations. The levels of hydraulic fluid are not sufficient, resulting in more friction.

Solution:

• A good draining of the hydraulic system must be done to remove air pockets.
• The pumps must be mounted to the system with little vibration.
• Fluid levels must be correct to reduce high wear and tear.

Conclusion

The hydraulic system defines an excavator’s efficiency and performance and is at the same time one of the most easily affected components. Problems such as low hydraulic pressure, overheating, slow response, leakage, and jerky movements highly hamper production and incur downtime. However, upon prompt detection and a little maintenance, most of these issues can be reduced or avoided altogether.

Regular maintenance is indispensable for the hydraulic system of an excavator to remain under peak performance. MA maintenance routine including daily checks of hydraulic fluid levels, filters, hoses, pumps, and cooling systems will prevent small inconveniences from growing into catastrophic breakdowns. Operators should also adhere to the manufacturer’s recommendations regarding hydraulic oil selection, pressure-setting procedures, and air-bleeding procedures for maximum performance.