When a hydraulic system fails, it can bring work to a standstill. Whether it’s a leaking pump, pressure loss or overheating motor, getting the issue diagnosed and repaired quickly is key to keeping downtime to a minimum.
In this guide, we’ll cover what hydraulic motor repairs and hydraulic pump repairs involve, the costs and the common warning signs to look out for.
What Is a Hydraulic Repair?
Hydraulic repair is the process of finding faults within a hydraulic system and restoring damaged components to proper working order. These repairs generally fall into two main categories: pump repairs and motor repairs.
Hydraulic repair services usually include:
- Fault finding and diagnostics
- Stripping the unit down
- Cleaning internal components
- Replacing worn or damaged parts
- Rebuilding the unit
- Pressure and performance testing
Repairs are commonly needed across industries such as:
- Construction
- Agriculture
- Manufacturing
- Mining
- Transport
- Plant and machinery
Common Hydraulic Faults and How to Spot Them
Hydraulic systems will often show warning signs before a full breakdown happens. Spotting issues early can help reduce repair costs and prevent unexpected downtime.
Some of the most common hydraulic faults include:
Unusual noises
Whining, knocking or grinding noises can point to issues such as worn internal parts. If a hydraulic system suddenly sounds different to normal, it’s usually a sign that something isn’t right.
Overheating
Excessive heat is one of the biggest causes of problems. Overheating can happen due to restricted flow, pressure issues or poor cooling.
Slow or jerky movement
If your machinery becomes slow to respond or starts moving differently, it may be a sign of pressure loss or leaking seals within the system.
Pressure drops
Low pressure can reduce the performance of the whole system. Common causes can include worn pumps and blocked filters.
Hydraulic fluid leaks
Leaks are often caused by damaged seals or loose fittings. Even the smallest of leaks can lead to bigger problems if not fixed quickly.
For a more detailed look at common hydraulic issues, read our related guide on hydraulic system problems and solutions.
The Hydraulic Repair Process: Step by Step
Every repair is different, but most professional hydraulic repair services follow a similar process.
1. Inspection and Diagnosis
The first step is identifying the fault. Engineers will inspect the unit and look for signs of wear, contamination, overheating or internal damage.
2. Strip-Down & Assessment
The unit is then fully dismantled so internal parts can be checked properly. This helps identify exactly what has failed and what needs replacing.
3. Cleaning & Contamination Removal
Hydraulic systems can be sensitive to contamination, so every component is thoroughly cleaned before rebuilding starts.
4. Repair or Replacement of Components
Damaged parts such as seals, bearings, valves and rotating groups are repaired or replaced where needed. Worn mating surfaces may also be reworked to help restore performance.
5. Reassembly & Pressure Testing
Once rebuilt, the unit is tested under pressure to make sure it’s performing correctly before being returned to service.
For a more in-depth breakdown, here’s what you should expect as part of a hydraulic pump repair.
How to Prevent Hydraulic Failures
While some hydraulic failures are unavoidable, regular maintenance can help reduce the risk of major breakdowns. This includes:
- Regular checks to look for fluid contamination, low levels or signs of deterioration
- Changing filters to prevent dirt and debris from circulating through the system
- Checking hoses, seals and fittings for leaks to catch problems early
- Routine servicing to give engineers the chance to spot wear and tear before it becomes a serious issue
How Much Do Hydraulic Repairs Cost?
Hydraulic repair costs can vary depending on the type of equipment, the severity of the fault and the parts required.
Some repairs may only involve replacing seals or bearings, while others may need a full rebuild of the hydraulic unit. Because of this, repair costs can range from hundreds to thousands of pounds.
The only real way to know the extent of the cost is to have the unit professionally inspected. At CJ Plant, all hydraulic units are inspected free of charge before we provide a quote to carry out any hydraulic repairs required.
What Affects the Cost Of Hydraulic Repairs?
Various factors affect the cost of repairs, including:
- The type of system: More complex systems will take more time and labour to repair
- The extent of the damage: Minor leaks or worn seals are much simpler to repair than severe internal damage
- The parts required: The availability and type of replacement parts can also affect costs
Need Hydraulic Repair Services?
If your hydraulic system is showing signs of failure, getting it inspected early can help prevent more serious damage and longer downtime.
Take a look at how to choose a hydraulic repair company or contact the CJ Plant team to arrange a free inspection. With over 20 years of experience, our team can diagnose, repair and rebuild hydraulic units quickly and professionally