Seven Tips for Keeping Hydraulic Tools in Good Working Order
Hydraulic pumps and tools are complex pieces of equipment. They’re also reliable pieces of equipment, as long as owners prioritize regular maintenance.
Most of this is well within the capabilities of most operators, so basic maintenance tasks can be handled quickly onsite. As for what those tasks include, we’ve put together a list of tips that can help owners extend the life of their hydraulic tools and maximize their reliability. Seven of them include:
1) Be Aware of the Pump's Normal Operating Pressure and Temperature
One of the first signs that something is going wrong with your hydraulic equipment is an anomalous temperature or pressure reading. But it’s easy to miss this sign if operators don’t know what the system’s typical operating temperatures and pressures look like.
This information may be tracked by monitoring software, but if not, taking the occasional manual reading is recommended. Designate “targets” on the hydraulic pump (the reservoir tank and heat exchanger inlet/outlets are good choices) for consistent measurement and use an infrared thermometer to take temperature readings.
Ideally, temperature readings should be taken on a particularly hot and particularly cold day, along with a couple of in-between mild days to build a comprehensive baseline.
As for pressure, the easiest way for operators to monitor it is with a pressure gauge. We’ll address that in more depth below.
If your team knows what normal operating temperatures and pressures look like, they’ll be able to spot values that suggest potential problems. And spotting potential problems before they cause damage is the first step in hydraulic maintenance.
Knowing the system’s operating pressures is critical for safety reasons. Hydraulic products are manufacturer-rated for maximum pressures and load-bearing capacities. In general, manufacturers strongly recommend limiting these pressures and loads to 80 percent of the equipment’s maximum. This gives operator crews plenty of extra wiggle room when loading the system.
2) Attach a Fluid-filled Pressure Gauge to the System
Pressure gauges are inexpensive and easy to monitor, making them a no-brainer in terms of safe system operation. As mentioned, every operator should know when the system is spitting out an unusual pressure reading. A pressure gauge simplifies and speeds up the process for users.
A fluid-filled gauge – glycerin is a common choice – is recommended for hydraulic pumps, for a couple of reasons. For one, a fluid-filled gauge will resist sudden changes in pressure better – an important trait in hydraulic systems. Also, gauges with high viscosity fluid – glycerin again – will reduce needle vibration and help operators make more accurate readings.
3) Make Sure the Inlet and Inlet Hose are Properly Configured
The pump’s inlet and inlet hose can be the source of many issues, including the nemesis of all hydraulic systems – cavitation. Cavitation is the result of small vacuum pockets forming inside the pump, which then implode with surprising force once disturbed. Experienced operators can recognize the tell-tale sound of cavitation, which rumbles like a low growl. But even experienced operators can’t guess at how much damage cavitation is causing inside the pump, hoses, and other system components.
One way to minimize cavitation risk is to ensure the pump’s inlet and inlet hose are cleaned and properly fitted. A hose that’s too long, prone to kinking (a problem with flimsy hoses), or is of insufficient diameter is more likely to produce vacuum.
Another simple tip – elevate the hydraulic reservoir above the pump. By doing so, the inlet will be gravity-fed as well as force-driven, essentially “flooding” the inlet and preventing vacuum from sneaking in.
4) Saddle Hydraulic Cylinders Before Applying Load to Them
Saddles are small components designed to attach to the piston rod and distribute the load evenly across its face. These inexpensive parts can prevent the piston rod from bulging (“mushrooming”) near the rod end and failing early.
They’re also easy and quick to install, so there’s no reason to mount a hydraulic cylinder without a saddle, so to speak.
5) Set Up the Right Loading Conditions for the Cylinders
There are additional measures operators can take to protect their hydraulic cylinders from damage. Using a mounting base, for example, will anchor the cylinder in place during loading, helping distribute force evenly and ensuring the cylinder doesn’t shift in the process.
Further, before supplying power to the cylinder, verify that the entire cylinder saddle is in contact with the load, and that the cylinder is sitting on solid, level ground.
These precautions will prevent common issues like side loading, which can place extreme stresses on bearings and other components.
6) Inspect, Clean and Protect Coupler Components
If dirt, dust particles, moisture or other contaminants find their way into hydraulic machinery, they can accelerate system wear, clog filters, and reduce flow efficiency. In many instances, contaminant ingress is what’s behind overheating or wear-related issues, but it’s easy enough to avoid with regular attention.
The best cure is prevention in hydraulic maintenance, and the best way to avoid fluid contamination is to prevent dust or dirt from entering in the first place. Aside from regular inspections and cleanings, it’s a good idea to use dust caps on all coupler components and fittings.
7) Regularly Check Hydraulic Fluid and Oil Levels
It takes seconds to verify that hydraulic fluid and oil levels are sufficient, yet it’s frequently overlooked by operators in a rush to remain productive. Oil provides lubrication, fluid powers the system, and both are critical for safe system operation. Manufacturers recommend the right type of oil and hydraulic fluid for their products – this information should be included in any equipment manuals.
If for no other reason, it’s a good idea to regularly check fluid levels to spot any potential leaks. With hydraulics, leaks can spring up anywhere, including inside the system where they are impossible to see. If fluid levels consistently measure on the low side, a leak could be lurking. In this case, a full system breakdown may be necessary to spot the exact source, but doing so can prevent overheating, power loss, and other serious problems down the line.
Hydraulic Tools are an Investment That Can Be Protected with On-time Maintenance
The better your hydraulic tools’ condition, the better its work efficiency and reliability while in use. Fortunately, most hydraulic maintenance is well within the reach of most operator teams. Regularly inspecting, cleaning, refilling, and proper operation are all part of the job, and all important for upkeeping hydraulic equipment.
When more serious problems emerge, such as persistent overheating or insufficient power delivery, a trusted hydraulic expert can break down the system for a closer look and diagnose the issue.