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Reduce Costs with Proper Hydraulic System Maintenance

- Dec 22, 2017 -

There is a lot to consider for an effective hydraulic system maintenance program. Though hydraulics can be complex systems, it is best to keep the program simple, have a plan and follow it. Remember that hydraulic fluid and systems are dependent on each other, so it’s critical to ensure procedures are put into place for both.

A lack of hydraulic system maintenance is the primary cause of component and system failure. The basic foundation to perform proper maintenance involves two primary functions:

1. Preventive Maintenance

Preventative maintenance (PM) is crucial to maintaining the service life of equipment and reducing costs associated with unplanned equipment shutdown. This is particularly important when maintaining a hydraulic system. Ignoring the hydraulics in a PM plan can cause catastrophic failure that may not be detected until it’s too late. A hydraulic fluid PM plan should follow the equipment and filter manufacturers’ recommended maintenance schedules, take into consideration the working environment and use test points (see below) to draw samples from the line for fluid testing. Regular standards and procedures should be documented and adhered to for the proper maintenance of any equipment with a hydraulic system.

2. Corrective Maintenance

System components should be inspected during preventative maintenance to address any anticipated issue before failure occurs. Ideally the need for corrective maintenance can be identified and addressed in preparation for a scheduled or planned shutdown. Be sure any repair of components is performed properly. If not, issues may arise that can cause even greater harm.

If a component needs to be replaced before it’s anticipate life cycle, the reason should be documented in the PM plan and corrective measures put in place to eliminate having the issue occur in the future.

Monitoring of Hydraulic Systems with Test Points

Pre-installed test points should be placed at regular intervals along the fluid line to monitor system conditions. Test point quick couplings are used to monitor pressure, vent a system or draw fluid samples for testing. They provide easy access and are used to identify problems before they occur. The couplings connect quickly and easily to measurement, control and switching devices, providing leak-proof connections before the ball check is open to minimize contamination of the hydraulic system. A self-locking metal cap seals the fitting to further protect the system from the environment. It is best practice to have pre-assembled test pressure monitoring kits on hand at all times. These kits are available with everything required for instant pressure checking regardless of style of the OEM’s existing hydraulic systems.

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