Effective Maintenance for Electrohydraulic Systems

Electrohydraulic systems are integral to many Australian industries, combining hydraulic power density with fine electronic control to deliver high-performance precision. Whether operating large drill rigs, servicing rail networks, maintaining naval vessels, or powering wind turbines across regional Australia, these control systems ensure equipment runs efficiently and safely.

However, to keep these systems operating at peak performance, proper maintenance is crucial. Regular checks and planned maintenance help identify and solve issues early – before they cause unplanned downtime or expensive repairs. From in-person inspections of hydraulic power units to remote monitoring control systems, consistent maintenance extends the life of your equipment and ensures operational reliability in even the harshest environments.

Common Electrohydraulic System Issues

In all electrohydraulic systems, spotting potential issues early can significantly reduce headaches down the line. Recognising early warning signs in these systems is critical. One of the first signs of trouble usually presents as erratic or sluggish system performance. This could indicate anything from a minor glitch in the controls to a more serious internal fault.

Another telltale sign is unusual noise or vibrations, which can point to wear and tear in valves, hydraulic pumps, or in electric motors. Unexpected shutdowns, and abnormal noise are also indicators of underlying problems.

Here are typical issues to watch out for:

• Fluid Contamination: Dirty or moisture-laden hydraulic fluid reduces system efficiency and damages internal components. Regular fluid sampling, online condition monitoring and filtration are essential in dusty, humid, or saline environments like mine sites or offshore oil and gas operations.
• Leaks: Hydraulic leaks can occur in hoses, fittings, or seals. Look for oil stains or spots around machinery. Even minor leaks can reduce pressure, leading to performance losses, system failure and environmental impacts.
• Component Wear: Hydraulic pumps, valves, and actuators naturally wear over time. Ignoring wear signs can result in decreased force output, system efficiency and erratic control, especially under heavy-duty loads. Creating a preventative maintenance program for components, especially in remote locations, is crucial to preventing major breakdown.
• Overheating: Excessive heat is a system killer. Poor cooling or overworked components can degrade seals, fluid, and sensors. Regularly monitor fluid temperatures and cooling system efficiency. Control systems warnings and cut-outs can also help prevent further damage from overheating oil.

By identifying and addressing these issues early, operators can ensure their hydraulic systems remain reliable and safe in demanding Australian operating conditions.

Essential Maintenance for Controls and Hydraulic Subsystems

Systematic maintenance of electrohydraulic controls is vital for precise, safe operation. Begin by inspecting electronic control interfaces for anomalies – incorrect sensor readings, open circuit faults, delayed responses, or control signal mismatches. These could signal wiring faults or failing sensors.

Next, focus on mechanical components:

• Hydraulic Power Units (HPUs): Check for steady pressure and flow consistency. Fluctuations may point to pump inefficiency or air in the system.
• Manifolds and Valves: Inspect for debris buildup or worn seals. Clean and test solenoids and pressure relief valves regularly to ensure correct operation.
• Hydraulic Pumps: Listen for unusual noises or vibrations, which often indicate cavitation or bearing wear.

Routine cleaning and adjustment checks of these components prevent premature failures and keep hydraulic system equipment operating efficiently.

Preventative Maintenance Best Practices

Australian industry leaders understand that preventative maintenance isn’t optional – it’s an investment in uptime, safety, and long-term savings. Here are key practices to integrate into your maintenance plan:

• Establish scheduled inspections: Use a fixed schedule for inspecting hoses, valves, filters, sensors and other power unit components. Scheduled maintenance reduces unexpected failures and aligns with asset management compliance and machine safety standards such as AS4024.
• Use high-quality fluids and components: Select premium-grade hydraulic fluids suited to Australia’s temperature extremes and dust conditions. Use OEM or certified replacement parts to maintain system integrity.
• Incorporate remote monitoring: The selection of the right sensors and components can allow users to detect problems before they occur. They can also assist with fault-finding during downtime.
• Train operators and maintenance teams: Equip your team with knowledge to detect early signs of failure – unusual sounds, pressure drops, or delayed actuation. Skilled staff can act before a small issue turns into major downtime. Make sure to equip your team with the right tools to fault-find complex systems.

When to Call in the Experts

While internal teams can manage routine maintenance, some problems require advanced diagnostics and repairs. Experts can provide in-depth analysis and offer solutions that might not be apparent at first glance.

Professional services offer several advantages. They possess specialised tools and experience to handle complex repairs efficiently, which helps put equipment back in operation faster. A professional evaluation can also pinpoint potential weak points, suggesting improvements or a maintenance program that ensures equipment performs reliably for longer.

If your system shows recurring faults, abnormal pressures, or persistent fluid contamination – or if you don’t have a site-wide equipment maintenance program, it’s time to consult hydraulic specialists.

At Custom Fluidpower, our team offers:

• Advanced fault-finding using diagnostic tools
• On-site system analysis and performance testing
• Retrofit and upgrade services for outdated or underperforming systems
• Preventative maintenance programs tailored to your industry

Professional servicing ensures long-term reliability and can uncover inefficiencies that in-house teams may miss.

Reliable Electrohydraulic System Support Across Australian Industries

From the red dust of WA mine sites to coastal shipyards and inland wind farms, electrohydraulic systems are powering Australia’s industrial future. By implementing a proactive maintenance strategy – inspecting key components, training staff, and calling in experts when needed – you ensure these systems operate at peak performance.

At Custom Fluidpower, we’re proud to support Australia’s leading industries with expert engineering services, quality components, and system optimisation solutions. Whether you’re running hydraulic power units on a rail maintenance fleet or electrohydraulic actuators on offshore rigs, we help keep your systems running smoothly.

Contact us today to learn how we can enhance your electrohydraulic maintenance strategy and extend the life of your critical assets.