Causes and Solutions for Hydraulic System Overheating

"The equipment ran for two hours, and the hydraulic oil temperature soared to 80-90℃!" Overheating of hydraulic systems in equipment such as casting hydraulic presses, forging hydraulic presses, hydraulic metal balers, gantry shears, and fully automatic high-pressure chip balers is one of the most common problems in the industrial hydraulic field.

It's not as obvious as an oil leak—a small temperature anomaly can render your hydraulic pump, motor, and seals unusable within hours. Here are six core causes of hydraulic system overheating.

1. Insufficient Hydraulic Oil Cooling Capacity

1. Improper Hydraulic Oil Selection or Oil Deterioration

1. Internal Leakage Leading to Decreased Volumetric Efficiency

1. System Pressure Set Too High

1. Excessive Oil Flow Resistance

1. System Design Defects and Selection Issues

When your hydraulic system experiences overheating, it is recommended to check the following in order:

1. Ambient Temperature: Is ventilation adequate? Does the ambient temperature exceed the design limit?

2. Cooling System: Is the cooler clogged? Is the fan/pump functioning properly?

3. Hydraulic Oil: Is the oil deteriorated? Is the viscosity appropriate?

4. System Pressure: Does the actual pressure far exceed the load requirements?

5. Internal Leakage: Are there signs of internal leakage in the actuators?

6. Piping System: Is the filter clogged? Is the piping resistance excessive?

Here, we provide professional oil cooling solutions for insufficient hydraulic oil cooling capacity. When the cooling capacity cannot keep up with the rate of heat generation, the oil temperature will continue to rise. Common causes include: undersized or clogged oil cooler, motor failure, excessively high ambient temperature, and poor ventilation.

Diagnostic Methods

1. Measure the oil temperature at the inlet and outlet of the cooler; the temperature difference should be 8-15℃.

2. Check for blockages in the cooler fins and deformation of the heat sink.

3. Confirm that the fan speed is normal (for air-cooled systems).

4. Check that the cooling water circuit is unobstructed (for water-cooled systems).

Solutions

1. Clean the cooler fins regularly to ensure proper ventilation. In high-temperature environments, consider adding auxiliary cooling devices.

2. Recalculate the cooling power and modify the existing cooling system using a TOBEL hydraulic oil cooler.