If a hydraulic system malfunction occurs, follow these initial steps:

• Shut down the machine and disconnect the power supply to prevent escalation of the malfunction or safety incidents.
• Inspect the system's exterior and check hydraulic lines for signs of leaks and loose joints. Mark any leak locations found.
• Check the hydraulic tank oil level to confirm whether it is below the specified level and whether the oil is turbid, discolored, or contains impurities.
• Record symptoms such as cylinder inactivity, failure to increase pressure, or unusual noises for targeted troubleshooting.

Treat common problems based on the initial troubleshooting results:

• 1Low system pressure: Check for stuck or damaged relief valves. Disassemble, clean the valve core, remove impurities, and reinstall. Replace if severely worn.
• 2Slow or inactive cylinder: Check hydraulic pump operation and listen for abnormal sounds. Check for pipeline blockages and use compressed air to clear or replace clogged filters.
• 3Detected leaks: Replace damaged seals or tighten joints to ensure a tight seal and prevent continued loss of hydraulic oil.

Thoroughly inspect the core components of the hydraulic system:

• Hydraulic pumps: Inspect for wear on internal vanes or plungers. Replace pump body if scratches or deformation are present.
• Cylinders: Inspect for bent or strained piston rods and seals. Repair or replace damaged piston rods and replace all aged seals to prevent hydraulic oil leakage.
• Hydraulic valves: Test for movement flexibility. Use a multimeter to check solenoid valve coils for proper power supply. Replace burned-out coils to ensure proper control of oil flow and pressure.

After repairing or replacing faulty components:

• Refill hydraulic oil to the standard level. Ensure oil type matches equipment requirements and avoid mixing different oil types.
• Before starting, manually operate the hydraulic valve to purge air from the system to prevent cavitation.
• After starting, run at no load to observe cylinder operation and pressure stability at standard value.
• Check all joints and piping for leaks. Perform multiple packing and cycle tests to confirm stable hydraulic system operation.