Common Hydraulic Equipment Mistakes
With over twenty years in the hydraulics industry, I’ve had the opportunity to observe and learn from the various mistakes and oversights hydraulic equipment users make during maintenance.
Mistake 1 – Changing the Oil
Car Lift For Sale Hydraulic oil should only be changed under a couple of circumstances: when the base oil degrades or the additive package is exhausted. Since oil degradation and additive depletion rates vary due to numerous factors, changing the oil based solely on service hours is akin to guessing in the dark.
Given the current high cost of oil, unnecessarily replacing oil that’s still viable is costly. Conversely, operating with degraded oil or depleted additives can shorten the lifespan of other hydraulic components. To determine when oil needs changing, rely on Car Lift For Sale oil analysis.
Mistake 2 – Changing the Filters
Hydraulic filters should not be changed on a fixed schedule. Doing so either wastes money by changing them too early or risks damage by changing them too late. To avoid this, Car Lift For Sale filters should be replaced once they are fully loaded with dirt but before they bypass.
A clogging indicator is a basic way to monitor this, but continuous pressure drop monitoring across the filter is a more precise method.
Mistake 3 – Running Too Hot
While most operators wouldn’t run an engine that’s overheating, they often overlook the overheating of Car Lift For Sale hydraulic systems. Excessive heat can rapidly damage hydraulic components, seals, hoses, and the oil.
The acceptable temperature range depends on the oil’s viscosity and the hydraulic system components. As oil temperature rises and its viscosity drops, it can no longer provide adequate lubrication. Most seals and hoses degrade at temperatures above 82°C, but overheating can occur at lower temperatures as well.
Mistake 4 – Using the Wrong Oil
Hydraulic oil plays a crucial role as both a lubricant and a medium for power transfer. The viscosity of the oil is vital as it impacts both performance and service life. Using oil with the wrong viscosity for the operating climate can lead to inadequate lubrication or increased power losses due to fluid friction and leakage.
Mistake 5 – Wrong Filter Locations
Not all filter locations are beneficial. Filters placed at the pump inlet or drain lines of piston pumps and motors can cause more harm than good. A restricted intake reduces the service life of pumps and can lead to catastrophic failures.
Filters on drain lines can also cause issues. Proper filter placement is crucial to prevent these problems. For detailed guidance, consult information on hydraulic filter locations.
Mistake 6 – Believing Hydraulic Components are Self-Priming and Self-Lubricating
Starting a hydraulic system without ensuring proper lubrication can lead to severe damage. It’s essential to follow correct start-up procedures and ensure that all components are properly lubricated and primed to avoid premature failures.
Mistake 7 – Neglecting Hydraulic Education
This article underscores the importance of staying informed about hydraulic equipment maintenance practices. Without proper knowledge, you risk wasting money and potentially damaging your equipment.
Proactive Car Lift For Sale maintenance focuses on the early detection and correction of root causes that could otherwise lead to equipment failure. For hydraulic systems, three primary symptoms often signal underlying issues: abnormal noise, high fluid temperature, and slow operation.
Abnormal Noise
Abnormal noise in Car Lift For Sale hydraulic systems is commonly due to aeration or cavitation. Aeration happens when air contaminates the hydraulic fluid, causing a disturbing banging or knocking sound as the air compresses and decompresses within the system. Other signs include foaming fluid and erratic actuator movement. Aeration accelerates fluid degradation and damages components through lubrication loss, overheating, and seal burning.
Air typically enters through the pump’s inlet. To prevent this, ensure pump intake lines are in good condition, all clamps and fittings are secure, and replace any aged or suspect intake lines. Additionally, check the fluid level in the reservoir and fill it if it’s low to prevent vortex formation, which can draw air into the pump. Also, inspect and replace the pump shaft seal if it’s leaking.
Cavitation occurs when the demand for fluid in a hydraulic circuit exceeds the supply, causing the pressure to drop below the vapor pressure of the fluid and forming vapor cavities that implode, producing a knocking noise. This can erode metal, damage components, and lead to mechanical failure.
Cavitation is often seen at the pump and can result from a clogged inlet strainer or restricted intake line. Ensure inlet strainers and filters are clean, and if an isolation valve is present, make sure it’s fully open to avoid vibration-induced closure. Replace any collapsing or old intake lines.
High Fluid Temperature
Fluid temperatures above 180°F (82°C) can harm seals and degrade fluid more rapidly. It’s crucial to avoid operating hydraulic systems at these temperatures. Excessive fluid temperature occurs when viscosity falls below the optimal level for the system’s components, which can happen well below 180°F depending on the fluid grade.
High fluid temperature may result from reduced heat dissipation capacity or increased heat load. Ensure the reservoir fluid level is adequate and there are no obstructions around the reservoir. Inspect the heat exchanger for blockages and verify that all cooling circuit components are functioning correctly.
Components that generate heat due to internal leakage, such as a leaking cylinder or improperly adjusted relief valve, should be identified and replaced. Aeration and cavitation, which also increase heat load, should be addressed by inspecting and correcting their causes.
To prevent damage from high fluid temperatures, install a fluid temperature alarm and investigate any high-temperature readings immediately.
Slow Operation
A decrease in machine performance often signals hydraulic issues, manifesting as longer cycle times or slow operation. In hydraulic systems, flow determines actuator speed and response, so a drop in speed indicates a loss of flow.
Flow loss can be due to external leakage, like a burst hose, or internal leakage in the pump, valves, or actuators. While external leaks are easy to spot, internal leaks are harder to diagnose without specialized tools. An infrared thermometer can help identify components with abnormal internal leakage, though it may be necessary to use a Car Lift For Sale hydraulic flow tester for accurate diagnosis.