There are many reasons that can cause the hydraulic system to overheat. Analyzing, summarizing, and summarizing, the main reasons can be categorized as follows:

1. Problems in the design of the hydraulic system: 

(1) The hydraulic oil tank has a small capacity and insufficient heat dissipation volume;

(2) The hydraulic oil pipes are too long, too thin, or have too many bends, leading to increased flow resistance;

(3) There are no unloading measures in the system, so the actuator continues to overflow when not in operation;

(4) Low processing and manufacturing precision of hydraulic components result in high frictional heat generation between moving parts or excessive leakage, leading to low volumetric efficiency.

2. Improper hydraulic system debugging and settings: 

If the system pressure is adjusted too low or too high, it can cause increased heat generation. When the pressure limit is set low, the hydraulic cylinder will not be able to overcome the resistance when the load exceeds the safety valve set pressure, and the hydraulic oil will flow back to the tank through the safety valve overflow; conversely, when the pressure setting is high, the hydraulic oil flow speed increases, leading to increased energy loss and heat generation.

3. Incorrect selection of hydraulic oil viscosity rating: 

Not selecting the right viscosity hydraulic oil based on environmental temperature can lead to increased oil flow resistance if the viscosity is too high or increased leakage if the viscosity is too low, both causing the oil temperature to rise.

4. Deterioration of oil quality: 

Over time, the hydraulic system will be contaminated by wear particles, external impurities, moisture, etc., causing a gradual deterioration of the hydraulic oil performance and an increase in flow resistance.

5. There is too much dust on the fins of the cooler：

Causing a decrease in the heat dissipation area. Some equipment is located in harsh working environments, with floating objects falling on the oil tank and radiator, blocking the small holes on the fins. In addition, some oil stains are difficult to remove, preventing the fan from blowing in cold air and affecting the cooling effect.

6. Insufficient fan speed: 

Slipping fan belts or hydraulic motor oil leakage driving the fan can cause insufficient fan speed, reducing the cooling effect.

7. Non-smooth return oil pipeline: 

Issues such as peeling rubber layers in the return oil pipeline or clogging of the return oil filter can increase flow resistance, causing the hydraulic oil to bypass the radiator and flow directly back to the tank through the system bypass valve.

8. High environmental temperature or presence of heat sources: 

Continuous operation of equipment under overload conditions for a long period of time can cause high ambient temperatures, leading to an increase in system temperature. Additionally, other devices emitting a large amount of heat around the hydraulic oil tank and cooler can also contribute to increased system temperature.

9. Severe wear leading to excessive internal leakage in the hydraulic system: 

Many parts of hydraulic pumps, control valves, cylinders, motors, etc., rely on clearance seals. Once the wear on these hydraulic components increases, internal leakage increases significantly, causing the oil temperature to rise, the viscosity of the oil to decrease, and the internal leakage to become more severe. This forms a vicious cycle, making the oil temperature rise rapidly, which is the main reason for the rapid increase in the hydraulic system temperature.

1. Hazards of Excessive Hydraulic Oil Temperature· XIRO (xiromachinery.com)

2. How to deal with high oil temperature· XIRO (xiromachinery.com)

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