Understanding Hydraulic System Preventative Maintenance.

Hydraulic system preventive maintenance programs are designed to eliminate expensive emergency repairs and improve reliability and reduce maintenance costs. Reliability Program is pre-programmed routine maintenance. The necessary maintenance work is done during normal equipment down time (weekends, holidays, change of swing, etc.)

Many service company can start your preventative maintenance program, and more with an in-house staff Tribologist, your lubricant can quickly and correctly analyzed.

The 3, 6, 12, 18 and 24 months of preventive maintenance program is specifically designed for critical hydraulic systems, but the overall goal can be achieved with electric and pneumatic powered equipment also.

THREE (3) months INTERVAL

1. Fluid Sampling

    1.1. Install valve removal of fluid return line, upstream of the filter return line.

    1.2. Sampling of liquids: (link to oil-analysis) using an approach that analyzes trends (link here to page analysis of fluids)

        1.2.1. Take a sample of new, clean oil

        1.2.2. Use this report as your oil “basic”

            1.2.2.1. Select your “Go – No Go” levels:

                Silica
                Water
                T.A.N (acid)
                Additives
                Metals
                I.S.O. Cleanliness levels

    1.3. Verify the location of the filter and calibration. (link to the filter) filters must provide a minimum of 800 hours of operation under normal conditions. This is assuming that the system was flushed before commencement, Beta 3> 200 elements in-line filter used, and an effective Beta 1> 200 air breather is used. When the oil is clean, except for maintenance, the pollution levels to be coherent.

2. Clean equipment to full service and check for leaks.

    2.1. Look for things like broken plugs, loose connections, blocked oil passages in the engine and broken gauges. Repair if necessary.

    2.2. List the location of leaks, damaged or broken parts and state of general operation of the equipment.

    2.3. Check the status and parameters of pressure and temperature. This is important for troubleshooting, to ensure the hydraulic system is functioning properly.

    2.4. Check the fan assemblies for cooling the electric motor

    2.5. Check control valves for leaks at the seals, including the bases and tips of control, where the trees connect the valve body.

    2.6. Note anything unusual, listening to strange sounds and locate the source.

    2.7. In general, the devices, whether operating within its design.

3. Hose, Tubing and Fittings.

    3.1. Look for cracks or signs of aging such as brittleness. It is a sign that the tube has been in use for too long, or the area near the pipe is too hot. If the operating temperatures of equipment and environment is too high a class upgrade the pipes must be considered.

    3.2. Check hose connections for leaks and damage

    3.3. In case of a metal tube, look for crimping or other mechanical damage.

    3.4. Make sure the hose runs and follow the standard installation practices.

    3.5. Pipe to Pipe and Fittings, sure they have enough room to prevent wear and tear on other parts.

    3.6. For repair or replacement of damaged pipes and fittings, whether they can be protected by conversion or relocation of the trail.

        3.6.1. Many leaks occur because of clearance issues to enable them to strike or rub against anything.

Six (6) months (plus 3-month inspection interval above):

1. Motors, pumps, the state coupling and adaptation:

    1.1. Make adjustments and electrical controls. Observe mode coupling and alignment by measuring the manufacturer’s recommendations.

    1.2. Check mounting bolts and the engine feet to ensure they are in good condition and free from cracks.

        1.2.1. The bolts must be in place and tight.

Twelve (12) months (in addition to 3 and 6 months for inspection intervals above):

1. Tank Maintenance:

    1.1. Absolutely pure fluid, wipe with a lint-free cloth.

    1.2. Examine the internal baffle and repair, if needed.

    1.3. Inspect, clean and repair or replace everything inside the tank before you reinstall the tank lid.

    1.4. Clean the sealing surfaces and replace the seals or gaskets around the eyelids.

    1.5. Prevent new dirt back into the tank before closing up.

    1.6. Drain and clean the equipment, fittings, hoses, pipes and fittings.

    1.7. Perform a pressure and flow tests on water-cooled heat exchanger fouling to check the pipes.

        1.7.1. Send in for repair, if necessary

        1.7.2. Air / oil cooler? Back stroke all baffles, if necessary.

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Twenty-four (24) months (beyond the 3, 6 and 12 months inspection interval above):

1. Maintenance of main components:

    1.1. Maintenance of pumps

        – Check the pump (s) for leaks, broken and / or damaged accessories.
        – The pump rotating group can be rebuilt in place in May and seals can be replaced without removing the device from its support.
        – The recast of 24 months is best completed on a bench, complete with a new seal kit.

    1.2. Valve Maintenance

        – Dirty oil is the most common cause of valve insufficiency.
        – After removing the valve, clean and inspect.
        – Replacement of spare parts, including springs, seals and parts recommended by the manufacturer.

    1.3. Actuator maintenance

        – Check for leaks, broken or damaged fittings, damaged body parts, misalignment and wear.
        – Leaks usually occur at the shaft seals and sealing surfaces.
        – Seal leaks are caused by dry seals or joints damaged by a dirty work environment.

    1.4. Maintenance of electrical motors

        – Checks should include a visual inspection, vibration analysis, current measurement and temperature control on the frame and bearings.
        – As the majority of electrical failures are mechanical, it is important that access to journals and housing must be measured.
        – The frame and the tree must be free of cracks or areas weakened by corrosion.
        – The correctness of the shaft and rotor balance also affect performance.
        – Electrical tests must be performed by a commercial electrical service.
        – The tests should include the phasing out of control because the inspection, the condition of the winding coils, inspection and squirrel cage rotor.
        – The current in an AC motor increases with load, but diffuse load varies from 20 to 70% of full load current in various constructions, the slow and low HP motors have more power vacuum.
        – It is important to obtain values from the manufacturer before attempting measurements.