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When a hydraulic elevator's plunger is too small for its intended load, it can lead to higher system pressures developing. This is due to the hydraulic system trying to generate enough force to lift the heavier-than-expected load with a plunger that lacks the appropriate size to accommodate it. In hydraulic systems, pressure is generated by force divided by area; therefore, if the area of the plunger is insufficient, the system compensates by requiring higher pressure to achieve the necessary lifting force.

Higher pressures can lead to several potential issues, including increased wear on system components, potential safety hazards, and the risk of failure in the hydraulic system. It can also affect the efficiency and reliability of the elevator operation. Proper sizing of the plunger is essential to ensure that the hydraulic system operates within safe and efficient parameters, thus preventing the complications associated with excessive pressure.