The reliability of your hydraulic system in any piece of machinery is arguably as important as its performance and power. When hydraulic machines are an essential part of your operation and key to getting work done, unplanned shutdowns lead to costly repairs, loss of productive work, delays getting jobs completed, and other issues. It all adds up on the bottom line and hurts profitability. Here’s what you can do to improve reliability.
While the basic principles of how hydraulic systems work have remained much the same since the earliest machines appeared, modern hydraulic systems are much more complex. As a result, they are also more sensitive and unforgiving to contamination.
Fluid contamination contributes to the majority of system failures. You can read more about what fluid contamination is and how it affects your system in our recent article about it.
You should filter all hydraulic fluid, including new fluid, to one micron when filling the storage tank. One of the most effective types of filter is one that filters and flushes the fluid, removing both particulates and water. These filters are more expensive than standard filters, but when you weigh up the cost of downtime versus the peace of mind that your fluid is clean, the cost is worth it.
Water can get into the system from working outside in the rain, but it can also build up from humidity. Any water that gets into the machine will ultimately cause problems over time without drying. Any corrosion within the machine or oxidation of parts, fittings or hoses will eventually reduce the efficiency of the machine and lead to failures.
You can use desiccant breathers to remove any water and particulate contaminants from air entering machinery, sumps, and reservoirs before it ever reaches your hydraulic fluid. This will protect your machine from damage and prolong the life of your fluids.
Modern hydraulic systems operate in an optimal range, depending on the machine and the manufacturer’s specifications. When the system heats up and fluid passes 60°C, the heat reduces its useful lifespan. As fluid degrades, it doesn’t perform as required, which leads to performance issues, potential breakdowns or more frequent maintenance.
Heat also affects the way hydraulic fluid lubricates the machine and its viscosity to cling to moving parts. When moving metal parts rub against each other, metal particulates can build up in the fluid and damage the system. If left too long without filtration or maintenance, you’ll eventually have a major breakdown.
As the name says, preventative maintenance is essential for mitigating potential problems before they occur. But it’s only as effective as the extent of the parts you maintain. People sometimes neglect to include parts like reservoirs and heat exchangers in regular preventative maintenance. Maintaining these parts reduces the chance of failures and boosts system efficiency.
Here are some tips for preventative maintenance:
Nobody needs downtime in business. It’s expensive and disruptive. If you take the time to keep your machinery clean, dry and within the optimal operating temperatures, you’ll boost reliability and keep it running efficiently. And with thorough preventative maintenance, it all adds up to getting the job done on time.
