Hydraulic Pressure Spikes: What Causes Them and How to Protect Your System

Sudden hydraulic pressure spikes can damage hoses, blow out seals, and destroy expensive components. If your system experiences violent jerks or loud hammering sounds, you’re likely dealing with unregulated pressure surges.

Main Causes of Pressure Spikes

  • Sudden valve closures: Instant shutoff traps fluid and builds shock pressure
  • Improper relief valve setting: Too high or stuck valves allow spikes to build unchecked
  • High-speed actuator reversal: Quick direction changes without flow control create surges
  • Air in the system: Compressible fluid causes instability and shock loads

What Pressure Spikes Can Damage

  • Hoses and fittings — may burst without warning
  • Pump internals — subjected to cavitation or overpressure
  • Valve spools — jam or crack under sudden load
  • Seals — forced out of position by sudden pressure change

How to Prevent Pressure Spikes

  • Install proper relief valves and verify set points
  • Add load-holding valves or cushioning circuits
  • Use accumulators to absorb shock loads
  • Train operators to avoid abrupt directional changes

Conclusion

Unchecked hydraulic pressure spikes shorten component life and raise safety risks. Smart circuit design, proper relief control, and routine inspection are the keys to keeping pressure under control — and equipment damage off the clock.

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