Hydraulic Service

Hydraulic systems depend on multiple components working together correctly. Pumps create hydraulic flow, valves control direction and pressure, cylinders and motors produce movement, and hoses carry fluid throughout the system.

A problem with any one of these components can affect the performance of the entire machine.

Horizon provides service and troubleshooting for hydraulic systems and components, including:

• Hydraulic cylinders
• Hydraulic pumps
• Hydraulic hoses
• Hydraulic valves
• Hydraulic motors
• Hydraulic power units
• Hydraulic jacks
• Hydraulic presses
• Hydraulic tools
• Fittings, adapters, and couplers
• Seals and internal wear components

The appropriate service depends on the equipment design, reported symptoms, operating conditions, component condition, and availability of repair parts.

Replacing a hydraulic component without identifying the cause of the failure can lead to unnecessary expense and repeated equipment problems.

Hydraulic troubleshooting may involve evaluating the complete system rather than focusing on a single part.

Common hydraulic problems include:

• Slow or weak equipment operation
• Loss of hydraulic pressure
• Reduced hydraulic flow
• Jerky or inconsistent movement
• Hydraulic cylinders that drift
• Equipment that will not lift or hold a load
• Excessive pump or motor noise
• Hydraulic systems that overheat
• Foamy or aerated hydraulic fluid
• External fluid leaks
• Repeated hose or seal failures
• Valves that do not shift or respond correctly
• Equipment that performs differently under load
• Hydraulic components that fail prematurely

These symptoms may result from worn components, incorrect adjustments, contamination, restricted flow, damaged hoses, improper fluid, air entering the system, internal leakage, or other system conditions.

Hydraulic fluid leaks should not be ignored. Even a small leak can lead to fluid loss, contamination, reduced equipment performance, environmental concerns, and safety risks.

Common leak points include:

• Hydraulic hoses
• Hose fittings and adapters
• Cylinder rods and glands
• Pump seals
• Motor seals
• Valve bodies and manifolds
• Quick couplers
• Reservoir connections
• Hydraulic power units
• Threaded and flanged connections

The source of a leak should be properly identified before parts are replaced. Fluid may travel along a hose, frame, or component and appear in a different location from the actual failure point.

Never use your hand to search for a hydraulic leak while the system is pressurized. High-pressure hydraulic fluid can penetrate the skin and cause a serious medical emergency.

A hydraulic system can have pressure without enough flow, or flow without enough pressure to perform the required work.

Pressure and flow problems may be caused by:

• Worn hydraulic pumps
• Internal cylinder leakage
• Relief valve problems
• Restricted suction lines
• Clogged filters or strainers
• Damaged hoses
• Incorrectly sized components
• Worn hydraulic motors
• Contaminated hydraulic fluid
• Air entering the system
• Excessive internal clearances
• Incorrect system adjustments

Accurate equipment information and a clear description of the symptoms help narrow down the potential cause of the problem.

Excessive heat can damage seals, reduce fluid life, increase internal leakage, and shorten the service life of pumps, motors, valves, and other hydraulic components.

Common causes of hydraulic overheating include:

• Low hydraulic fluid levels
• Incorrect or degraded fluid
• Restricted fluid flow
• Relief valves operating continuously
• Internal leakage
• Worn pumps or motors
• Clogged filters
• Insufficient cooling
• Contaminated hydraulic systems
• Incorrectly sized components
• Excessive operating loads

Continuing to operate overheating equipment may cause additional damage. The system should be inspected before normal operation resumes.

Contamination is one of the most common causes of hydraulic component wear and premature failure.

Dirt, metal particles, moisture, degraded fluid, and other contaminants can damage precision surfaces inside pumps, valves, motors, and cylinders.

Signs of possible contamination include:

• Discolored or cloudy hydraulic fluid
• Metal particles in the fluid
• Repeated component failure
• Sticky or inconsistent valve operation
• Premature seal wear
• Excessive system noise
• Loss of pressure or efficiency
• Unexplained equipment overheating

Replacing a failed component without addressing contamination can damage the repaired or replacement part.

Routine hydraulic maintenance can help identify problems before they result in major equipment failure.

Maintenance and inspection may include:

• Checking hydraulic fluid condition and level
• Inspecting hoses for abrasion, cracks, bulges, or leaks
• Examining fittings and connections
• Checking cylinders for rod damage and external leakage
• Listening for unusual pump or motor noise
• Monitoring hydraulic system temperature
• Inspecting filters and breathers
• Looking for loose mounting hardware
• Checking equipment for slow or inconsistent operation
• Reviewing repeated failures or recurring leaks

Maintenance requirements vary by equipment type, operating environment, duty cycle, and manufacturer recommendations.

Once the source of the hydraulic problem has been identified, the appropriate solution may involve repairing, rebuilding, resealing, or replacing the affected component.

Horizon can help evaluate:

• Whether the component is repairable
• The extent of internal or external damage
• Availability of seals and replacement parts
• Whether rebuilding is economically practical
• Whether a replacement component is available
• Whether another system problem contributed to the failure

The lowest-cost option is not always the best long-term solution. A repair should restore dependable operation without creating unnecessary risk of repeated downtime.

Horizon provides hydraulic service and repair support for equipment used in:

• Construction
• Agriculture
• Manufacturing
• Industrial maintenance
• Utility work
• Material handling
• Landscaping and land clearing
• Truck and trailer applications
• Pressure cleaning
• Electrical construction
• Equipment rental
• Mobile machinery
• Shop and maintenance operations

Service availability depends on the equipment, hydraulic system, component type, and extent of the required work.

Before contacting Horizon, gather as much information as possible about the equipment and hydraulic system.

Useful information includes:

• Equipment manufacturer
• Equipment model number
• Equipment serial number
• Hydraulic component manufacturer
• Component model or part number
• Description of the problem
• When the problem began
• Whether the problem occurs continuously or intermittently
• Any unusual noises, leaks, heat, or changes in performance
• Recent repairs or component replacements
• Clear photographs of the equipment and identification tags

Accurate information helps us determine the appropriate next step and whether the equipment or component should be brought in for evaluation.

Contact Horizon Hydraulic Sales & Service when your hydraulic equipment is leaking, operating slowly, losing power, overheating, making unusual noise, or failing to perform correctly.

Provide the equipment information, component numbers, photographs, and a detailed description of the problem whenever possible.