Hydraulic systems are essential to countless industries, from construction and agriculture to manufacturing and transport. However, like any mechanical system, they are vulnerable to wear and tear. When something goes wrong, it often falls into one of three major categories: leaks, overheating, or contamination.

1. Hydraulic Leaks

What it is: A hydraulic leak occurs when fluid escapes from the system – whether from hoses, seals, fittings, or connections.

Common causes:

• Worn or damaged seals and gaskets
• Cracked or aged hoses
• Improperly tightened fittings
• Corrosion or physical damage

Why it matters:

Leaks not only reduce system efficiency, but also pose safety risks and lead to fluid wastage – increasing your operational costs.

Prevention tips:

• Perform regular visual inspections
• Replace seals, hoses, and fittings at the first sign of wear
• Use manufacturer-approved components and correct torque settings

2. Overheating

What it is:

Hydraulic systems generate heat through friction and pressure. Overheating occurs when this heat isn’t properly dissipated.

Common causes:

• Low fluid levels
• Poor heat dissipation due to blocked coolers or fans
• Incorrect fluid type or viscosity
• Excessive system pressure or continuous operation without cooldown

Why it matters:

Overheating can break down hydraulic fluid, damage seals, reduce lubrication, and lead to catastrophic equipment failure.

Prevention tips:

• Monitor fluid temperature with sensors or gauges
• Keep coolers and fans clean and unobstructed
• Check and top up fluid levels regularly
• Use fluids with the correct thermal properties for your system

3. Fluid Contamination

What it is:

Contamination refers to unwanted particles or substances within hydraulic fluid, such as dirt, metal shavings, water, or air.

Common causes:

• Inadequate filtration
• Poor maintenance or storage practices
• Faulty seals allowing water or dirt ingress
• Using the wrong or old fluid

Why it matters:

Contaminated fluid can wear down components, block valves, erode pumps, and lead to frequent failures.

Prevention tips:

• Use high-quality filters and replace them on schedule
• Store hydraulic fluid in sealed, clean containers
• Avoid opening hydraulic systems in dusty or wet environments
• Regularly sample and analyse fluid quality

Most hydraulic system failures can be avoided with routine maintenance, early detection, and the right operating procedures. By staying alert to signs of leaks, overheating, or contamination, you can reduce downtime, lower repair costs, and keep your system running smoothly.

Need hydraulic repairs on the Central Coast?

From breakdowns to routine maintenance – Heathwood Hydraulics has you covered. Whether it’s diagnostics, servicing, or emergency repairs – our team has the tools and experience to keep your hydraulics in top shape. Get in touch today for fast, local support.