Automotive Lift Repair Orlando | Integrating Hydraulics

Hydraulic Facts

• Mechanical-Hydraulic-Mechanical – Inputs and Outputs
• Three types of hydraulic energy:
  • Potential, Kinetic, and Heat
  • None are created or destroyed; they are merely converted
  • All energy input converts into output, either as gain (work) or loss (heat)
  • A confined flowing fluid generates heat, leading to a pressure drop
• Hydraulic systems must be sealed to function properly
• Fluid takes the path of least resistance
• Automotive Lift Repair Orlando Fluid is pushed into a pump rather than drawn in
• A pump generates flow, not pressure; pressure results from resistance to flow
• Systems can achieve the same power using:
  • High pressure and low flow
  • Low pressure and high flow
• Two basic types of hydraulics:
  • Hydrodynamics
  • Hydrostatics

Hydraulic Leaks

According to the National Oceanic and Atmospheric Administration (NOAA), over 700 million gallons (approximately 2.65 billion liters) of oil products enter the environment each year. About half of this volume results from improper and illegal transfers. The contribution from hydraulics, as reported by hose manufacturer Gates, is 98 million gallons (370 million liters) annually, highlighting the significant amount of oil that spills from hydraulic equipment. These Automotive Lift Repair Orlando statistics are alarming, especially considering that just one liter of oil can contaminate up to one million liters of water. How much hydraulic fluid do your machines consume in a year? The only way to know for sure, particularly if you manage multiple machines, is to measure and record all top-offs. However, these measurements are often not taken, making it difficult to control or manage consumption.

Common causes of hydraulic leaks include:

• O-rings: These leaks occur due to improperly sized or low-quality O-rings. To eliminate these leaks, it is essential to use appropriately sized and high-quality O-rings.

• DC Wall: This type of leakage results from variations in the hydraulic system. To eliminate this leakage, constant pressure must be maintained according to system requirements.
• Oil Contamination: This type of leakage occurs due to the presence of dirt and water in the oil. To prevent this, the oil must be clean and free of water.

Eliminating Leaks

Downtime required to repair leaks can be problematic, but often, this is simply used as an excuse for inaction. Nowadays, various methods can be employed to eliminate spills. If a hydraulic system has no connectors, it cannot leak. While some connectors are necessary, their number can be significantly reduced through the intelligent use of manifolds, cartridge valves, and stack valves, collectively known as integrated hydraulic circuits.

Use Reliable Connectors

Threaded connectors like NPT and BSPT are among the least reliable types for high-pressure hydraulic systems, as the threads themselves can create a pathway for leaks.

Connectors with Elastomeric Seals  

Connectors that incorporate an elastomeric seal, such as UN-O-rings, BSPP, ORFS, and SAE 4-bolt flanges, provide superior sealing reliability. For leak-free performance, it is advisable to replace pipe-thread connectors with those that feature elastomeric seals wherever possible.  

Proper Torque Application  

Incorrect torque is a common cause of leaks in 37° flare joints and pressure-type tube fittings. For flare joints, insufficient torque leads to inadequate contact at the seat, while excessive torque can damage the tube and connector through cold working. To ensure optimal sealing reliability, refer to the connector manufacturer’s torque specifications and follow them closely.  

Mitigating Vibration  

Vibration can stress Automotive Lift Repair Orlando hydraulic conductors, cause fatigue, and impact connector torque. If vibration is detected, it is crucial to address the underlying cause. This may involve installing hoses or rubber mounting blocks to eliminate vibration “bridges” between the hydraulic power unit, reservoir, and valves. Additionally, ensure that all conductors, especially pipes and tubes, are properly supported with adequate clips. This issue is significant enough to warrant mention in key standard.  

Maintaining Optimal Machine Temperature  

While the advantages of hydraulic connectors with elastomeric seals are clear, their reliability hinges on keeping hydraulic fluid temperatures within acceptable limits. When operating fluid temperatures exceed 85°C (185°F), the service life of most seal materials decreases dramatically. Moreover, a single instance of excessive temperature can damage seals throughout the hydraulic system, leading to multiple leaks. This serves as a reminder that a hydraulic machine running hot is an unreliable machine. Leakage in hydraulic systems can be likened to the common cold—despite significant technological advancements, we have yet to fully address this widespread nuisance. Although leakage has become less common and severe over time, it remains a concern for many Automotive Lift Repair Orlando component manufacturers, especially since leak-free fittings have been readily available for years. Seals, particularly rod seals on cylinders, pose a different challenge as they require a thin film of clean lubricant between the seal and rod surface. Without it, seals can wear prematurely, resulting in leaks. Conversely, a lubricant film that is too thick can also lead to leaks due to excess lubricant.  

Preventing Leakage from Components  

Finding an Automotive Lift Repair Orlando component that guarantees leak-free performance is not particularly challenging, as all major manufacturers offer products that meet SAE and ISO standards for reduced leakage. However, sourcing components that all provide leak-free performance across an entire machine can be difficult. A fitting, hose, pump, valve, or cylinder may operate leak-free in one application but leak in another. For instance, a cylinder that activates the main articulating element of an excavator’s arm may not leak, while a similar cylinder located at the other end of the arm may experience leakage due to significant pressure spikes from shock loading and impacts.  

Reducing Leakage Potential  

In addition to utilizing Automotive Lift Repair Orlando components designed for zero leakage, engineers can further minimize leakage risks by reducing the number of connections, as each connection represents a potential leak point. One effective strategy is to integrate multiple components into a single customized assembly. In the past, custom parts were only feasible in large quantities, but advancements in multi-axis machining centers and computer-aided design and manufacturing have lowered the break-even point for custom parts to well below 200 pieces. Another effective approach is to implement Automotive Lift Repair Orlando hydraulic integrated circuits (HICs), which reduce the number of leak points by directing hydraulic fluid through a specially machined block. Valves, switches, and other components are then mounted in cavities drilled into the block. HICs enhance design and performance in both mobile and industrial applications, as they not only reduce leakage but also improve reliability and facilitate troubleshooting.