How do you identify the source of a hydraulic leak and repair it?

Locating and fixing a hydraulic leak involves a process to be sure of safety and effectiveness. The following is how you can proceed:

Locating the Cause of a Hydraulic Leak:

Inspect Visually – Search for noticeable evidence of leaks such as oil droplets, pools, or wet areas on hoses, fittings, and seals.

Perform a Cardboard or Paper Towel Test – Pass a piece of cardboard or paper towel over suspected leak areas while the system is operating to find fluid escape.

Look for Spray or Mist – Pinhole leaks will produce a fine mist; never check for leaks by hand, as high-pressure fluid can enter the skin.

Listen for Hissing Noises – A high-pressure leak can create a hissing or whistling sound.

Check with UV Dye and Blacklight – Certain hydraulic fluids have UV dye, or you can introduce it, which will make it easier to find the leak under a blacklight.

Check Pressure Drops – An unexpected pressure drop in the system can be a sign of a leak.

Fixing the Hydraulic Leak:

Depressurize the System – Always switch off the machinery and drain system pressure before any repairs.

Tighten Loose Fittings – A quick solution for small leaks is to tighten a loose-fitting with the proper torque.

Replace Damaged Seals or O-rings – Worn seals or O-rings are frequent causes of leaks and should be replaced by suitable spares.

Replace or Fix Damaged Hoses – If a hydraulic hose is leaking or cracked, replace it with a new hose rated for the proper pressure.

Replace Cracked Parts – Cylinders, pumps, or valves with cracks or heavy wear can be replaced or professionally repaired.

Proper Sealants – Use hydraulic sealants or thread tape (if applicable) to seal threaded connections to avoid leaks.

Refill and Test – Refill hydraulic fluid if necessary after repairs, and test the system under normal operating conditions to ensure no additional leaks.

Preventive Maintenance Tips:

• Check hydraulic hoses, seals, and connections routinely.
• Maintain fluid levels within recommended ranges.
• Replace worn-out items before they fail.
• Utilize the proper hydraulic fluid to prevent premature wear and leakage.
• By doing so, you can easily locate and fix hydraulic leaks, promoting the best system performance and avoiding expensive downtime.