Hydraulic Systems: Why Regular Maintenance Is Essential

Hydraulic systems are intricate networks consisting of valves, hoses, components, and piping. How hydraulic machines operate varies widely by the make and model, but all hydraulic systems run based on the same overarching principle: The generation of force through the use of non-compressible fluids.

These fluids supply the enormous energy required to operate these machines. In addition, they bear the brunt of lifting the heavy weights necessary for hydraulic system performance.

Without hydraulic fluids, these engines cease to work at all.

Even with sufficient hydraulic fluid, these machines remain subject to component breakdowns. Breakdowns cause time and productivity loss in addition to the cost of repairs. Re-starting the machine may require replacement parts and extensive machine overhauls.

To prevent such a catastrophe, it’s crucial to avoid the #1 cause of hydraulic machine component failure: fluid contamination.

How Hydraulic Fluid Works

Hydraulic fluids are designed to be incompressible. This strength allows the fluid to transfer energy throughout the entire system.

In many machines, the fluid is stored in a reservoir until the hydraulic system begins operating. Once in use, a pump extracts the liquid from the reservoir and transfers it to other system components. The fluids are effective at different operating speeds, pressures, and temperatures.

Contamination: The #1 Cause of Hydraulic Component Failure

As with any other machine, hydraulic systems suffer wear and tear. Vehicles tend to have more component breakdowns as they age, and hydraulic system owners see their valves, hoses, and piping corroded as time passes. With vehicles, the contamination of motor oil and transmission fluids results in damage to parts; with hydraulic systems, the contamination of the hydraulic fluid has the same devastating effect.

Fluid contamination causes 75% of hydraulic system failures.

Avoiding System Malfunction

Fluid selection plays a key role in stopping hydraulic component failure. The market offers several options, and the correct choice depends upon the application. For best results, consult with the equipment OEM to select the appropriate fluid.

For most machines, petroleum-based hydraulic fluids serve as the gold-standard. However, some situations require special hydraulics. For example, when a fire-resistant fluid is called for, water glycols, water-oil emulsions, and synthetic hydraulic fluids are often recommended.

How Contaminants Enter the System

Though selecting the correct fluid is essential, even the best hydraulics remain subject to contamination over time. Contamination enters hydraulic fluid in several ways. Firstly, hydraulic fluids have impurities related to built-in contamination from sources such as metal filings, small burrs, sand, pieces of Teflon tape, and other contaminants. These impurities are present even in new machines.

On the other hand, ingress contamination comes from the external environment, and includes substances such as dirt. These impurities enter through broken seals or breather caps. Contaminants may also be present in the reservoir tank or worn cylinder rods.

Water may also cause problems by entering the system as it cools down after operation. In addition, as air condenses, acids, sludge, and oxidation cause rust, which further contaminate the lubricant.

Maintaining the Hydraulic System

Keeping a hydraulic system clear of damaging impurities requires cleansing the system regularly. Cleaning ensures a longer useful life, as well as optimizing the system’s function.

For hydraulic system operators, the best maintenance investment is in replacing filters according to the manufacturer’s’ guidelines, which they typically denote in hours of operation. Alternatively, some hydraulic filters have differential pressure switches that indicate when it is time for service. Regardless, following OEM guidelines ensures the smoothest operation and greatest longevity.

Servo Kinetics: Making Hydraulic Systems Last

Nothing is more important to your hydraulic system’s longevity and performance than maintenance. As with any other machine, hydraulic equipment breaks down over time. While some components wear out inevitably, the number of components that break down and the frequency of downtime are drastically reduced by keeping fresh, clean hydraulic fluid coursing through your equipment.

Servo Kinetics helps customers extend the life and increase the functionality of their hydraulic systems. Our maintenance program ensures hydraulic systems last, and when the inevitable replacement time comes, we provide the highest performing machines that last the longest. Call and speak to a specialist today! Special Offers available.