How To Maintain Hydraulic Components

Proper maintenance of a hydraulic pump is crucial for reaching maximum pump efficiency. Every component is reliant on another, so if just one component is damaged, the others will be damaged as well. Regular maintenance is necessary to prevent damage from occurring or getting worse.

Contaminants and Moisture

Prevention is the best way to properly maintain a hydraulic system. This means taking the steps necessary to keep contaminants out of the system (…if not, the performance of your system will suffer due to a number of factors):

• Clean the area around dipsticks, fill plugs, and hydraulic filters before removing them to check or change hydraulic fluid. Make sure that hydraulic fluid containers are tightly sealed when stored. Pour the fluid directly into the system.
• Change the fluid and filter after the first 50 hours of use. The manufacturing process may allow contaminants to enter the hydraulic system. Changing the fluid after 50 hours will eliminate these contaminants. From there, change the hydraulic fluid and filter at regular intervals according to the directions in the owner’s manual.
• Check the oil before each use. Ensure that the fluid is in good condition, and that fluid levels are at a sufficient level. If the fluid is foamy or milky, there could be a leak where air is entering your system, causing jerky and slow hydraulic operation. Insufficient levels of oil will cause severe damage to the pumps.

Air within the system carries moisture. When the system cools down following an operation, the moisture will condense and mix with the hydraulic fluid, resulting in the milky appearance mentioned previously. Test for water by pouring a 1/8 cup of hydraulic fluid into a metal can, then heat it with a propane torch. If you hear popping or crackling, the fluid has water and must be changed immediately.

Check the temperature of the hydraulic fluid often, for signs like the oil being too hot to touch, or a burning smell. These symptoms point to a problem with the cooling system or pressure level. Inspect the hydraulic oil cooler or reservoir, making sure that they are clean. Remove dirt and other debris inhibiting airflow surrounding them. If the fluid is too hot for an extended period, the fluid will break down and won’t be able to lubricate properly.

Pumps

Pumps should be inspected for obvious external wear and damage, as well as cavitation. Cavitation  occurs when the the pump does not receive the necessary amount of fluid from the reservoir. Follow these steps every 50 hours:

• Listen to the pump while the hydraulics are in operation. Rattling or a sound similar to marbles or rocks bouncing around the pump is a sign of cavitation. Shut the system down immediately if you hear either of these sounds.
• Check the fluid level and filter if they are limiting or restricting the flow.
• Examine for previous modifications to the reservoir, inlet lines, or pump. Alterations to these components will affect the pump inlet flow.
• Leaks, bends, pinching, and other discontinuities will restrict the flow. Regularly clean your system’s strainer if you have one.

Cylinders and Motors

Cylinders have seals and rings which may be damaged by excess pressure and contaminants in the fluid. Check that your hydraulic fluid is clean, and inspect where the cylinder rods move in and out of their housing for leaks. Cylinders should not have dings, dents, and other kinds of damage, which will allow fluid and pressure to escape.

An attitude of prevention is essential for protecting your O-rings. Learn more about four ways to prevent seal failure here.

O-rings are susceptible to a variety of elements, including UV rays, temperature, and humidity, so they must be stored in a very particular way. Real Seal has covered proper O-ring storage here.

Valves

Valves may be abraded or may leak internally, which will result in low hydraulic pressure. Contaminants may become lodged in the valves and restrict the flow. Maintain clean hydraulic fluid to ensure properly-functioning valves.

Other Components

Hoses, lines, fittings, and couplers must be inspected for damage. Hoses and lines may be dented from falling tools, contact with other equipment, and a number of other factors. Lines should be inspected for cracking, cuts, or dents, which will restrict the flow or leak pressure. Hoses may be damaged in the same ways, in addition to overheating, extended wear, and defective manufacturing. Hoses may also be internally damaged, causing pieces to contaminate the system. 

Buy Your Hose Components From an Industry Leader

Purchasing quality components will help prevent damage and the need for repairs. Contact Real Seal, and our team of experts—including an in-house chemist and technical staff—will help you purchase the right seals and components to keep your hydraulic system running smoothly.