What Happens When a Hydraulic Solenoid Valve Fails

Solenoid valves are super important in hydraulic systems. They control how fluid moves, its pressure, and its flow. In excavators, these valves handle key tasks like moving the boom, bucket, or tracks. At Hantang, we’ve seen how a broken solenoid valve can stop work and cost a lot of money. This is especially true for brands like Komatsu, Caterpillar, or Hitachi.

This guide explains what happens when a solenoid valve fails. It covers signs of trouble, causes, how to check for issues, and ways to prevent problems. Hantang offers top-quality solenoid valves to keep your machines running smoothly.

Common Signs of a Failing Hydraulic Solenoid Valve

1. Slow or No Movement in Hydraulic Parts

When a solenoid valve starts to fail, parts like cylinders or motors may move slowly. Sometimes, they stop completely. For example, if an excavator’s travel function feels sluggish, the solenoid valve on the travel motor might be stuck. It could also be leaking inside.

2. Jerky or Uneven Motion

If the boom, swing, or arm moves in a choppy way, the solenoid valve might be the problem. This happens when the valve’s spool doesn’t slide smoothly. Dirt or wear inside the valve can cause this.

3. Fluid Leaks Near the Valve

Oil leaking around the valve is a big warning sign. This is common in older machines or rebuilt parts. At Hantang, we tell customers that leaks often mean worn-out seals or a damaged spool.

4. Hot Coil or Burnt Smell

If the solenoid coil gets really hot or smells burnt, it’s likely damaged. This can happen from too much voltage or bad wiring. A burnt coil stops the valve from working, shutting down a function.

5. Warning Codes or Alerts

Modern excavators have computer systems that show error codes. A failing solenoid valve might trigger these warnings. They could point to issues with pilot controls or proportional valves. Don’t ignore these alerts.

What Causes a Hydraulic Solenoid Valve to Fail?

Contaminated Hydraulic Oil

Dirty oil is a top reason solenoid valves break. Bits of dirt can clog the valve or make parts stick. Hantang suggests using clean ISO VG 46 hydraulic oil. Keep filtration at NAS 9 or better to avoid trouble.

Coil Burnout

Too much electricity, bad grounding, or wrong voltage can overheat the coil. This burns it out. A damaged coil loses its magnetic pull, so the solenoid valve can’t move.

Seal Wear or Internal Leaks

Over time, high pressure wears out seals like O-rings. This causes leaks inside the valve. Leaks lead to weak performance or no response from the system.

Wrong Installation

If the solenoid valve is installed incorrectly, it can get damaged. For example, wrong connections or misaligned mounts can break it when powered on. Hantang gives clear instructions to help install sensitive parts like proportional valves correctly.

How to Diagnose a Failing Solenoid Valve

Visual Inspection

Look at the solenoid valve closely. Check for burnt coils, oil leaks, or loose wires. If the valve body is rusty, dented, or full of dirt, it probably needs replacing.

Resistance Testing

Use a multimeter to test the coil’s resistance. Compare it to the valve’s specs. If the numbers are off, the coil might have a short circuit.

Manual Override and Flow Checks

Some solenoid valves have a manual override pin. Use it to see if the spool is stuck. Also, check the pressure before and after the valve. Weird pressure drops can mean trouble.

Component Swapping

In field repairs, try swapping the solenoid valve with a working one. This helps pinpoint the issue. Hantang technicians use this trick when testing valves for Komatsu PC and Hitachi ZX models.

What Happens If You Ignore Valve Failure?

System Instability

A broken solenoid valve messes with fluid flow and pressure. This can cause wild movements or slow responses. That’s dangerous on a job site.

Damage to Pumps or Motors

Leaks from a bad solenoid valve make hydraulic pumps work too hard. This wears them out faster. Hantang’s customers save money by fixing valves early to avoid bigger repairs.

Higher Fuel Use

A faulty solenoid valve makes the system less efficient. The engine has to work harder, burning more fuel. This also wears out the excavator faster.

How to Prevent Solenoid Valve Issues

✅ Use Genuine or Verified Parts from Hantang

Hantang supplies original new, rebuilt, and used solenoid valves. All are carefully checked for quality. Our stock includes Komatsu PC200-8 swing solenoid valves, pilot control valves, and travel motor solenoids.

✅ Keep Oil Clean

Always use filtered hydraulic oil. Replace filters often. Hantang suggests flushing the system after replacing a major valve to clear out any dirt.

✅ Check the System Regularly

Have your team test the solenoid valves every month. Check resistance, inspect connectors, and try manual operation. Hantang can provide checklists to make this easy.

✅ Watch for Early Signs

If your excavator hesitates or moves unevenly, act fast. Don’t wait for bigger problems. Contact Hantang for help troubleshooting or finding replacement solenoid valves.

Why Choose Hantang?

Hantang has been in the excavator parts business since 2016. We focus on high-quality, original parts with solid testing. Whether you need a main control valve, swing motor solenoid, or a full hydraulic pump, we’ve got you covered. Here’s why we stand out:

• Clear Product Info: We tell you if a solenoid valve is new, rebuilt, or used.
• Easy Payment and Shipping: We offer flexible options for small or large orders.
• Stock for Top Brands: We carry parts for Komatsu, Caterpillar, and Hitachi.
• Helpful Support: We provide testing videos, wiring diagrams, and technical advice.

If you want original, new solenoid valves, Hantang is the place to go.

FAQs

Q1: How often should I replace a solenoid valve?

A: Solenoid valves can last for thousands of cycles. But replace them if you see leaks, burnt coils, or uneven movement.

Q2: Can I replace just the solenoid coil without changing the whole valve?

A: Yes, if the coil is the only problem and the valve body is fine. For older or rebuilt parts, swapping the whole valve might save money in the long run.

Q3: Does Hantang offer warranty for solenoid valves?

A: You bet. New solenoid valves come with a 6-12 month warranty, depending on the type. Rebuilt parts are tested and have performance guarantees.