Hydraulic system inspection and maintenance are essential for equipment longevity, safety and efficiency. Hydraulic systems rely on intricate components to lift, move and maneuver heavy parts such as booms, buckets and sticks. Maintaining hydraulic machinery protects components and prevents complications such as fluid contamination, corrosion, leaks, overheating and system failure so you can depend on your equipment for optimal performance.
Importance of Maintaining Hydraulic Components
Hydraulic system care is crucial for equipment upkeep, safety, efficiency and cost savings. Hydraulic systems generate the fluid power machines need to generate enough force to lift heavy parts, and this force enables machines to move parts safely and effectively. A hydraulic system’s entire function relies on several intricate components, and keeping these components in top shape enables you to do the following:
- Prevent hazards and increase employee safety
- Avoid equipment breakdowns and boost uptime
- Save money on high-cost repairs, parts and equipment replacements
Understanding Key Hydraulic Components
Modern hydraulic machines operate on a contained or closed-loop principle, and they feature the following components:
- Hydraulic pump: A hydraulic pump pressurizes hydraulic oil so a machine can use this fluid to generate force. The pressure the pump generates increases the hydraulic oil’s energy level but enables it to retain its mass.
- Motor: A hydraulic system uses a machine’s engine to motorize the pump so it can pressurize fluid. Most machines contain a diesel engine as their main power source.
- Reservoir: Each hydraulic system holds its reserve, non-pressurized fluid in a storage tank known as a reservoir. The size of the reservoir depends on the machine’s size and fluid capacity.
- Lines: Pressurized fluid moves through lines as it travels from a machine’s pump to its work cylinders. A hydraulic system consists of hoses, tubing, couplers, seals and fittings.
- Controls: Operator-controlled valves control a hydraulic system’s functions. Valves control the pressurized fluid by directing flow, regulating volume and compensating pressures.
- Actuators: Actuators — also known as cylinders — are the components that move and manipulate parts such as booms, buckets, and sticks. Actuators transform hydraulic energy into mechanical energy after the lines supply pressurized fluid.
- Fluids: Hydraulic systems depend on clean, uncontaminated fluid to operate smoothly. Most hydraulic systems operate with petroleum-based fluid.
- Filters: Filters help protect hydraulic systems and fluids from contamination, and many systems feature several strategically placed filters for optimal equipment health.
Best Practices and Tips for Hydraulic Part Maintenance
Referring to a machine’s user’s manual is the best way to determine its specific inspection and maintenance needs. However, you can get started with the following maintenance tips and best practices:
Perform Regular Inspections
Regular inspections enable you to identify maintenance and repair needs to prevent complications. You should check your equipment’s user’s manual for precise inspection recommendations, but most equipment requires inspections on the following schedule:
- Daily: Each day, you should check your hydraulic system’s oil temperature and levels. You should also ensure the system is leak-free and check the fluid in the hydraulic reservoir.
- Weekly: You should inspect a hydraulic system’s pipes, hoses, connections and fittings weekly. During weekly inspections, it’s important to look for leaks, bubbles, twisted hoses and wear.
- Monthly: Each month, it’s important to check a hydraulic system’s filter, oil level and oil clarity. It’s also essential to ensure the oil has a smooth rather than gritty texture.
- Every 400-600 operational hours or every three months: Since hydraulic hoses are exposed to high temperatures and pressure, you should inspect them every three months or each time your machine completes 400-600 working hours.
- Every 10,000 operational hours: You should inspect piston pumps every 10,000 working hours, which is typically every 14 months.
Provide Adequate Lubrication
Lubrication reduces wear and friction between moving parts, making it crucial for your equipment’s longevity. Use high-quality lubricant to protect the following parts:
- Pumps and valves
- Cylinder rods
- Piston motors and pumps
Prevent Fluid Contamination
Fluid contamination is one of the leading causes of hydraulic system failure, so replacing fluid or oil if you notice any signs of debris or contamination is crucial. The most important part of hydraulic equipment maintenance is preventing and removing contamination from your hydraulic fluid, oil and components. You can boost your hydraulic system’s fluid health with the following tips:
- Buy quality parts from reputable suppliers
- Change your hydraulic fluid regularly according to your user manual’s recommended frequency
- Clean the system’s filter bowl
- Remove debris or blockages from the filter’s indicator
- Replace the filter according to your user’s manual’s instructions
- Remove debris from hydraulic oil dipstick and openings to keep them clean
Schedule Preventive Maintenance
Preventive maintenance keeps your equipment in top shape and prevents further complications. Your maintenance team or a professional service technician should perform the following preventive maintenance based on your equipment’s needs:
- Top off fluid levels when they become low
- Replace seals if you notice any corrosion, damage or leaks
- Ensure there are no leaks or foaming in the system’s hydraulic reservoir
- Replace parts that have leaks or frays
- Check for high temperatures in the electric drive motor to determine if bearings or housing require attention
- Check hydraulic lines for pressure fluctuations or ballooning
- Tighten or loosen fittings as needed
When to Replace Hydraulic Parts
Knowing which warning signs to look for can help you determine the best times to replace hydraulic components. You may need a part replacement if you notice any of the following signs:
- Oil discoloration: Some hydraulic oil discoloration is normal, but you should change your fluid immediately if you notice any sudden, drastic color changes or a bubbly or milky appearance. These changes can indicate that your oil is contaminated with air or water.
- Oil leaks: Pooling liquid or stains are signs that a component is leaking and needs a replacement or repair. A leaking gasket, seal or hose typically needs a full replacement, but may only need to patch or replace part of a pipe depending on how significant the leak is.
- Line deterioration: Hydraulic line system components, such as hoses, tubing, connections, fittings and seals, require replacement if they begin to wear. Worn line components can burst at any moment, so you should fix them as soon as you notice them.
- Corrosion: Rust can quickly eat through metal parts, especially when moisture is present. You should replace any fasteners or connections that start to turn a reddish-brown color.
- Component fatigue: Signs such as component cracks and loosening indicate a need for replacement. Replacing fatigued components ensures your system can handle the pressure it operates under.
- Unusual noise: Healthy hydraulics emit noise, but you should check your system if you notice any unusual noises during operation.
- Odor: Overheated components and burnt oil produce a strong odor. You should immediately halt operation and check your system if you notice this odor.
- Changed hydraulic control behavior: Unusual hydraulic control patterns signal that a component needs attention.
Purchase Parts from Thompson Machinery
Inspecting your equipment, scheduling regular maintenance, addressing complications and using high-quality components are essential parts of hydraulic component upkeep. Thompson Machinery offers reliable Cat parts and expert hydraulic service to help you maintain your hydraulic equipment, keep it running smoothly and prevent machine downtime. Contact Thompson Machinery to learn more about our available hydraulic system parts and services.