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Hydraulic troubleshooting guide

Find your symptom, make safe basic observations and prepare the details our team needs to help.

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What problem are you seeing?

Choose an equipment group and expand a symptom. If you are unsure which component is responsible, start with Complete systems.

Pumps / Valves / Powerpacks / Complete systems

Before you begin

Follow your machine manufacturer’s operating and safety instructions. This guide does not replace the manual or a qualified technician’s assessment.

Stop operation for abnormal noise, leakage, smoke or unexpected movement. Follow the machine’s shutdown procedure and keep clear. Do not restart equipment just to reproduce a fault.

Maintenance, wiring, dismantling and pressure adjustments require trained personnel. Before intervention, isolate equipment, secure loads and release hydraulic pressure under the manufacturer’s procedure. Switching off the motor alone does not make the system safe.

Use only information available from a safe operator position or existing records. Do not remove guards, open electrical panels, loosen hydraulic connections or touch components to judge temperature.

Hydraulic pumps

Record: When the noise began, whether it occurred at start-up or under load, and the oil level shown by the external indicator under the manual’s specified checking conditions.

Possible causes: Low oil level is one possibility. Pump inlet conditions require model-specific assessment; a noise alone does not confirm pump failure.

Next step: Stop operation and send the pump model, symptom history and any existing maintenance records.

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Record: Whether every machine function stopped or only one, the selected operating mode and any displayed alarms.

Next step: Send the pump nameplate and the machine details. Do not loosen a line to check whether oil is flowing.

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Record: The existing gauge reading, its units, the cycle stage and the normal value specified in the machine documentation, if known.

Next step: Request a circuit-specific assessment before changing any setting. Do not assume a low reading proves a faulty pump.

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Record: The observed range and whether it occurred during movement, holding or another cycle stage.

Possible causes: Control behaviour can be relevant, but depends on the installed circuit.

Next step: Share the circuit diagram if available. Do not adjust controls to stabilise the reading without an approved procedure.

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Record: The approximate location from a safe distance and when it was first noticed.

Next step: Stop operation and arrange assessment. Send a photograph only when it can be taken safely; do not approach an active leak.

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Hydraulic valves

Record: The command selected, any operator-display message and whether other functions responded normally.

Next step: Send the complete valve model code and machine details. Electrical and hydraulic checks require trained personnel.

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Record: Which function is affected and whether the symptom began after maintenance or a component change.

Next step: Request assessment with the valve code and fault history. Do not dismantle the valve as a first check.

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Record: The cycle stage, existing pressure reading and any movement that accompanied the pressure change.

Next step: Keep clear of the load and request a system assessment. Include the circuit diagram if available.

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Record: Which movement changes, the selected setting and whether the issue affects one or several functions.

Next step: Send the valve details and machine operating history. Leave adjustment settings unchanged pending assessment.

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Record: Which assembly is affected, without approaching the leak or removing covers.

Next step: Stop operation and arrange inspection. Do not tighten connections while the system is pressurised.

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Hydraulic powerpacks

Record: The operator-panel status and exact alarm or fault code. Note whether the problem followed an outage or maintenance.

Next step: Send the powerpack and motor nameplates when safely accessible. Leave electrical testing to qualified personnel.

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Record: Whether the operator display shows the machine ready, and which functions fail to respond.

Next step: Share machine and powerpack details together. Use the complete-system section if the responsible component is unknown.

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Record: The displayed temperature, units, alarm code and operating time before the alarm.

Basic observation: From a safe position, note any obvious obstruction around the cooler ventilation area. Yuken’s YA Pack instructions require adequate airflow around its cooler.

Next step: Follow the machine’s alarm procedure and request assessment. Use the installed equipment’s temperature limits, not a generic value.

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Record: What is visible through an existing viewing point and whether the symptom followed an oil change or maintenance. Do not open the reservoir to inspect it.

Next step: Send the oil product details from maintenance records and the powerpack model for assessment.

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Record: The exact trip code and whether it occurred at start-up or during a particular operation.

Next step: Arrange qualified electrical and hydraulic assessment. Do not repeatedly reset the protection or bypass it.

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Complete hydraulic systems

Record: Which movement is slow, whether all functions are affected and any recent changes to the job or machine.

Next step: Send the machine details and existing cycle-time records, if available.

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Record: The affected motion and the stage at which the issue was observed.

Next step: Stop operation, keep clear and arrange assessment. Do not repeat the motion to obtain a video.

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Record: The operation being performed, any changed workload and existing gauge readings from the event.

Next step: Share the machine’s documented requirements. Do not increase pressure to compensate without technical assessment.

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Record: Which actuator was affected and whether it happened during a commanded hold or after shutdown.

Next step: Keep everyone clear of the load. Arrange qualified assessment and securing of the equipment under the machine procedure. Do not rely on the hydraulic circuit alone to support the load during work.

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Record: The last normal operation, the first fault, recent oil or filter changes, replaced components and any changed settings documented by the maintenance team.

Next step: Send a short timeline with the machine and component model codes. Preserve existing fault records for diagnosis.

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Get troubleshooting support

Send your equipment model, symptom, when it started, recent maintenance, and existing alarm codes or readings with units. Include nameplate photographs only when safely accessible.

Shree Hydraulics can help with troubleshooting enquiries and product selection. Products requiring servicing are sent to the applicable manufacturer for inspection and service.

Send an enquiry / Call +91 94825 45346

Technical references

Yuken safety precautions
Bosch Rexroth innoCube operating instructions
Yuken YA Pack instructions

These references support selected guidance. Product-specific settings and procedures apply only to the equipment covered by each manual. Use the current manual for your installed equipment.