Hydraulic System Maintenance Tips
Hydraulic system maintenance is important to keep your equipment up and running. Hydraulic systems typically fail due to contamination or wear, but that failure may occur in any of the following hydraulic components:
- The hydraulic pump and reservoir
- Hydraulic cylinder
- Hydraulic hoses, lines, couplers or fittings
- Hydraulic controls (valves)
- Hydraulic filters
- Hydraulic fluid
Issues with any of the above can cause breakdowns, ranging from inconvenient to dangerous.
Regular inspections, maintenance, and service can reduce the likelihood of serious breakdowns and ensure your hydraulic system remains in good operating condition.
Signs That a Hydraulic System Requires Maintenance
The most reliable way to catch hydraulic system issues is to be vigilant. Most hydraulic equipment will show clear signs of potential trouble that can be detected in a variety of ways. Some of those signs include:
- Leaks – Some leaks are internal and can’t be seen, but many are external and can be detected by sight alone. Often, the first sign of a hydraulic leak is fluid pooling around the hydraulic pump or reservoir. Respond immediately to any leaks that are seen because these are potential failure points in your system.
- Fatigue or obvious wear – Component fatigue and wear may also be obvious during a physical inspection. Clear signs of damage, such as cracks, are a concern. Loose fasteners suggest threading wear. In both cases, fatigued components can result in sudden, severe failure.
- Corrosion – Corrosion is a major threat to many hydraulic system components, including couplers, fasteners and the rod bore. Corrosion may form wherever a part is likely to face water exposure. Look for the tell-tale brownish smear that indicates rust. If corrosion is forming inside the bore, a bad seal is the likely culprit.
- Unusual sounds – Every hydraulic system makes noise while it’s working, but if your hydraulic equipment starts making noises out of the ordinary, it merits further inspection. Growling, banging or a high-pitched whining are particularly concerning, as these may indicate cavitation or a malfunctioning valve.
- Unusual odors – In some cases, you may smell the problem before you see or hear it. If your hydraulic system is giving off a strong, foul odor, it’s often a sign of overheating.
With experience, your crews will become familiar with the system’s operation, including the way your hydraulic equipment behaves while working. This knowledge is vital to identifying potential problems early.
Maintenance Tips for Hydraulic System Components
With hydraulic systems, on-time maintenance is key. This includes the following:
- Tip 1: Check fluid levels and quality regularly – Poor fluid levels can cause loss of power or inconsistent operation. And poor fluid quality may circulate contaminants through your hydraulic system. Contamination is a major threat to every hydraulic system and is impossible to completely avoid over time. As such, it’s important to regularly sample hydraulic fluid to assess its quality. It should be clear and odor-free.
- Tip 2: Inspect seals for signs of failure – A bad seal will increase bypass and allow contaminants to ingress into your hydraulic equipment. Seals are a common cause of hydraulic system failure, and they should be inspected regularly, especially if contaminants have already been detected.
- Tip 3: Inspect the rod for corrosion or wear – The hydraulic cylinder (or ram) can fail in dangerous ways if it’s compromised by excessive wear or corrosion. Check the piston bore and head for signs of rust or pitting. Also, assess if there is excessive wear on just one part of the rod, as this could indicate side loading.
- Tip 4: Take the system’s temperature – Using a thermal gun, take spot temperature readings of the reservoir fluid, the suction and drain lines, the heat exchanger inlet/outlet, and the system’s valves.
You’ll need a set of controls to compare to, so take an initial set of temperatures while the system is operating normally and during typical conditions. If overheating is suspected, take the system’s temperature in the same places, and compare them to your controls. - Tip 5: Flush out the reservoir – Flushing your hydraulic system is recommended following maintenance, following a prolonged lack of operation, or when fluid contamination is suspected. This involves draining all hydraulic fluid, cleaning out the reservoir, and flushing it out with a lower viscosity fluid before bleeding and inspecting the filters/reservoir for any signs of remaining contamination.
- Tip 6: Check the filters and replace as necessary – Clogged hydraulic filters can reduce flow and release contaminants into the hydraulic system. Some filters are built with indicators that provide an at-a-glance look at the filter’s condition. If any need to be replaced, do so right away.
- Tip 7: Inspect the connections – Hydraulic hoses are linked together using connectors, and these connectors tend to attract dirt and moisture. Make sure they’re fastened tightly (but not too tight) and are kept clean. While inspecting the hose connections, check that the hoses themselves are in good condition and not tearing or fraying anywhere.
Your operators may have enough experience with your hydraulic system to perform some of this maintenance. However, if your team doesn’t have the requisite skill or time, consider partnering with a hydraulic power equipment expert.
Establish a Preventative Maintenance Program to Prevent Failures
Prevention is far less expensive than repair, and that’s also true with hydraulic systems.
In this way, a preventative maintenance program will save your company money. But that’s not all. Preventative maintenance will also optimize the system’s performance – and your team’s productivity.
Here’s what a preventative maintenance program consists of:
- A clear maintenance schedule – Your preventative maintenance program, whether tracked by software or on paper, should detail a service schedule for all hydraulic system components, including pumps and cylinders. Use the manufacturer’s guidelines to arrange this schedule, which you can find in the operational manual.
Once this schedule is set in stone, stick to it. - A clear service history – Your preventative maintenance program should also be updated every time your hydraulic system(s) are serviced. If any problems are identified, they should be noted for future reference.
Also, if your hydraulic technician replaces a component during service, make a note of this as well. This will ensure any replacement parts are also serviced on time. - Accountability (put someone in charge) – Arguably the most difficult part of establishing a preventative maintenance program, accountability is essential to guaranteeing its success. One way to do this is to delegate the program’s oversight to someone who has the organizational and personal skills to enforce it.
A Hydraulic System Expert Can Protect Your Operations from Expensive Downtime
Most companies that rely on hydraulics have a hydraulic expert on staff, or partner with one to maintain their equipment.
Your hydraulic technician can perform full system inspections, isolate and diagnose a problem, provide replacement parts where necessary, and ensure your hydraulic systems perform at peak efficiency and safety.
Any downtime is expensive, and catastrophic failures can leave your operations at a standstill for an extended period. Your hydraulic technician will prevent that from happening.