Troubleshooting charts for eight categories of

hydraulic problems
The following troubleshooting guides cover five categories of hydraulic
problems. Possible causes and remedies are listed for each type of trouble. Causes are
listed in order of probability; remedies are listed adjacent to the associated cause.

Abnormal / exessive noise

Source/Symptom: Pump

Possible Problem Recommended Action 

Replace dirty strainers.

Clean clogged inlet line.
Cavitation
Clean reservior breather vent.
Change to proper pump drive motor speed.
Tighten leaky inlet connection.
Fill reservoir to proper level.
Air in fluid
Bleed air from system.
Replace pump shaft seal.
Tighten coupling.
Coupling
Check condition of seals and bearings.
Pump worn or damaged Repair or replace.
 
Source/Symptom: Motor

Possible Problem Recommended Action 

Realign coupling.
Coupling misaligned or loose
Check condition.
Motor worn or damaged Repair or replace.
 
Source/Symptom: Mechanical vibrations

Possible Problem Recommended Action 

 Misaligned, loose Realign coupling and remove any unneccessary
coupling clearances.
Tighten pipe clamps and add more clamps where
Vibration of pipes necessary.
 
Source/Symptom: Relief valve

Possible
Recommended Action 
Problem

Install pressure gauge and adjust to correct valve setting

Improper pressure. Make sure setting is not too close to operating
setting pressure or to another valve setting.
Valve worn Repair or replace.
or damaged
 

Excessive Heat
Source/Symptom: Pulp

Possible Problem Recommended Action 

Pump worn or damaged Repair or replace.

 
Source/Symptom: Relief

Possible
Recommended Action 
Problem

Incorrect setting Install pressure gauge and adjust to correct setting pressure.

 
Source/Symptom: Flow losses between pressure and return sides

Possible Problem Recommended Action 

Pressure set improperly Set pressure to the diagram raiting.

Defective valve function or damaged Repair or replace it.
seals
 
Source/Symptom: Insufficient cooling

Possible Problem Recommended Action 

Cooling water system unavailable Make cooling water available.

Deposits in cooling water system Clean cooling water strainer and equipment.
 
Source/Symptom: Tank heater

Possible Problem Recommended Action 

Check program for proper command.

Heater on too much
Check disconnect for proper operation.
 
Source/Symptom: Viscosity too low

Possible Problem Recommended Action 

Oil damaged Drain and refill with fresh oil.

Water Find and repair water source, then drain and refill with fresh
contamination oil.

Improper oil Drain and refill with fresh correct oil.

 

Incorrect Flow
Source/Symptom: No flow

Possible Problem Recommended Action 

Replace dirty strainers.

Pump not receiving fluid Clean clogged inlet line.

Clean reservoir breather vent.
Pump motor not operating Repair or replace.
Pump-to-drive Check for damaged pump or drive.
 Replace and align sheared coupling.

Pump motor rotation incorrect Reverse rotation.

Check position of manually-operated valves.
Directional valve in wrong
Check electrical circuit for solenoid-operated
position
valves.

Entire flow passing Adjust relief valve over relief valve setting.
Check for damaged pump or drive.
Damaged pump
Replace and align coupling.

 
Source/Symptom: Low flow

Possible Problem Recommended Action 

Flow control set too low Adjust

Variable displacement mechanism malfunctioning Repair or replace.

 
Source/Symptom: Excess flow

Possible Problem Recommended Action 

Flow control set too Adjust

high
 
Source/Symptom: Flow losses between pressure and return sides

Possible Problem Recommended Action 

Maximum pressure set too high Re-adjust pressure setting per diagram.
Clean system.
Pressure valve cannot close due to
dirt or foreign particles Repair or replace parts.
Cylinder tube, piston or seal Repair or replace damaged part.
damaged
Seal damaged due to incompatible Replace with seals that fit the system or change
materials the hydraulic fluids to fit the seals.
 
Incorrect Pressure
Source/Symptom: No pressure

Possible Problem Recommended Action 

Replace.
Dirty pump strainers
Clean clogged inlet line.

Pump motor not operating Repair or replace.

Pump-to-drive coupling sheared Repair and align coupling.

Pump motor rotation incorrect Reverse rotation.

Check position of manually-operated valves.
Directional valve in wrong
Check electrical circuit for solenoid-operated
position
valves.
Entire flow passing over relief Adjust relief valve setting.
valves
Check for damaged pump or drive.
Damaged pump
Replace and align coupling.
  
Source/Symptom: Low pressure

Possible Problem Recommended Action 

Reducing valve set too low Adjust.

Reducing valve worn or damaged Repair or replace.
Relief valve or unloading valve set too low Adjust.
Check pump
compensator.
Variable displacement mechanism malfunctioning
Repair or replace.
Pump, valve, motor, cylinder or other component worn or
Repair or replace.
damaged
Water contamination Drain, fluss and refill
  
Source/Symptom: Erratic

Possible Problem Recommended Action 

Air in fluid Tighten leaky connections.

 Fill reservoir to proper level.
Bleed air from system. 
  
Source/Symptom: Excess pressure

Possible Problem Recommended Action 

Reducing valve or unloading valve set too high Adjust 

Check pump compensator.
Variable displacement mechanism
Repair or replace malfunctioning.
 

Faulty Operation
Source/Symptom: No movement

Possible Problem Recommended Action 

See troubleshooting guides for incorrect flow

No pressure or flow
and incorrect pressure.
Check mechanical, electrical and/or hydraulic
Limit device / sequence device limits and sequence devices.
inoperative or improperly set
Adjust, repair or replace.
Mechanical bind not operating Locate and repair bind.
Cylinder or motor damaged Repair or replace.
Low flow See troubleshooting guide for incorrect flow. 
 
Source/Symptom: Slow movement

Possible Problem Recommended Action 

Fluid may be too cold or dirty.

Fluid viscosity too high Check heating/cooling system.

Change to clean fluid of correct viscosity.
Insufficient pressure See troubleshooting guide for incorrect pressure.
Lack of lubricant Lubricate machine ways or linkage.
 Cylinder or motor damaged Repair or replace.
 
Source/Symptom: Erratic movements

Possible Problem Recommended Action 

Erratic flow See troubleshooting guide for incorrect flow.

Air in oil See troubleshooting guide for air in oil.
Improper pressure See troubleshooting guide for incorrect pressure.
 

Foaming Oil
Source/Symptom: Tank

Possible Problem Recommended Action 

Oil level in tank too

Add oil as required.
low
 
Source/Symptom: Suction line

Possible Problem Recommended Action 

Crack of leaking suction line Repair or replace.

 
Source/Symptom: Improper or degraded oil

Possible Problem Recommended Action 

Inadequate anti-foaming agent Replace with proper oil.

 

Directional Control Valve Position not Changing

Source/Symptom: Coil not picking up

Possible
Recommended Action 
Problem

Electric failure Fix electric failure and check mechanial spool motion.
 
Source/Symptom: Valve spool stuck

Possible Problem Recommended Action 

Impurities between spool and bore Replace valve if necessary.

Throttle set too tight between the main and pilot valve Set the throttle at the
of the two coil solenoid valve correct rating.
 
Source/Symptom: Proportional valve not responding

Possible Problem Recommended Action 

Valve not receiving set value from program Locate and fix electric failure.
Set value received but valve not responding Replace the proportional valve.
 

Computer Alarm Messages

Computerized control systems usually have alarm screens which record alarm
messages. The following table lists recommended actions to take to resolve common
hydraulic alarm.

Alarm Message Recommended Action 

Pressure filter blocked

Replace old filter with new filter insert.
(identified by pump)
Pressure filter blocked for
Replace old filter with new filter insert.
circulation pump
Circulation/Filter pump fault Motor output gives alarm to control desk if that
MCC pump is not running.
Circulation/Filter pump stopped
Check circulation/filter pump for problems.
with main pumps running
Check cooling pump operation.
Check the cooler water strainer.
Hydraulic unit temperature high Check water thermostat operation.
Check that none of the pressure relief valves were
set too low. If required, correct the setting.
Return filter blocked Replace old filter with new filter insert.
Hydraulic oil level low
Determine what is causing the drop in oil level. Add
Hydraulic oil level low - pumps clean oil. The pumps will stop automatically if the
stopping level drops to the shutdown level.
 Pump fault MCC or standby
Motor output gives alarm to control desk if that
pump fault MCC (identified by
pump is not running.
pump)
 
For more information on fluids safety and troubleshooting, contact your Valmet
representative for training options.