MAINTENANCE OF HYDRAULIC SYSTEMS

The right way to perform maintenance on a hydraulic system utilizing the Maintenance Best Practices Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system. If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally accept hydraulic system failure rather than deciding not to accept hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure. I worked for Kendall Company in the 1980’s and we changed our focus from reactive to proactive maintenance on our hydraulic systems and thus eliminating unscheduled hydraulic failure. We will talk about the right way to perform maintenance on a hydraulic system utilizing the Maintenance Best Practices. Lack of maintenance of hydraulic systems is the leading cause of component and system failure yet most maintenance personnel don’t understand proper maintenance techniques of a hydraulic system. The basic foundation to perform proper maintenance on a hydraulic system has two areas of concern. The first area is Preventive Maintenance which is key to the success of any maintenance program whether in hydraulics or any equipment which we need reliability. The second area is corrective maintenance, which in many cases can cause additional hydraulic component failure when it is not performed to standard. Oil Pump Preventive Maintenance Preventive Maintenance of a hydraulic system is very basic and simple and if followed properly can eliminate most hydraulic component failure. Preventive Maintenance is a discipline and must be followed as such in order to obtain results. We must view a PM program as a performance oriented and not activity oriented. Many organizations have good PM procedures but do not require maintenance personnel to follow them or hold them accountable for the proper execution of these procedures. In order to develop a preventive maintenance program for your system you must follow these steps: 1st: Identify the system operating condition. a. Does the system operate 24 hours a day, 7 days a week? b. Does the system operate at maximum flow and pressure 70% or better during operation? c. Is the system located in a dirty or hot environment? 2nd: What requirements does the Equipment Manufacturer state for Preventive Maintenance on the hydraulic system? 3rd: What requirements and operating parameters does the component manufacturer state concerning the hydraulic fluid ISO particulate? 4th: What requirements and operating parameters does the filter company state concerning their filters ability to meet this requirement? 5th: What equipment history is available to verify the above procedures for the hydraulic system? As in all Preventive Maintenance Programs we must write procedures required for each PM Task. Steps or procedures must be written for each task and they must be accurate and understandable by all maintenance personnel from entry level to master. Preventive Maintenance procedures must be a part of the PM Job Plan which includes: * Tools or special equipment required performing the task. * Parts or material required performing the procedure with store room number. * Safety precautions for this procedure. * Environmental concerns or potential hazards. PM Procedures for Hydraulic Systems A list of Preventive Maintenance Task for a Hydraulic System could be: 1. Change the (could be the return or pressure filter) hydraulic filter. 2. Obtain a hydraulic fluid sample. 3. Filter hydraulic fluid. 4. Check hydraulic actuators. 5. Clean the inside of a hydraulic reservoir. 6. Clean the outside of a hydraulic reservoir. 7. Check and record hydraulic pressures. 8. Check and record pump flow. 9. Check hydraulic hoses, tubing and fittings. 10. Check and record voltage reading to proportional or servo valves. 11. Check and record vacuum on the suction side of the pump. 12. Check and record amperage on the main pump motor. 13. Check machine cycle time and record. Preventive Maintenance is the core support that a hydraulic system must have in order to maximize component and life and reduce system failure. Preventive Maintenance procedures that are properly written and followed properly will allow equipment to operate to its full potential and life cycle. Preventive Maintenance allows a maintenance department to control a hydraulic system rather than the system controlling the maintenance department. We must control a hydraulic system by telling it when we will perform maintenance on it and how much money we will spend on the maintenance for the system. Most companies allow the hydraulic system to control the maintenance on them, at a much higher cost. In order to validate your preventive maintenance procedures you must have a good understanding and knowledge of “Best Maintenance Practices” for hydraulic systems. We will convey these practices to you.