How Often Should You Inspect Your Hydraulic System?

Regular inspections are essential for maintaining the efficiency and longevity of hydraulic systems. These systems are prone to wear and tear, contamination, and other issues that can significantly impair their functionality. Regular hydraulic inspections—known as preventative maintenance—help to identify potential problems early, such as leaks or fluid contamination, before they lead to costly system breakdowns. By catching these issues early, you can reduce downtime, extend the life of the equipment, and optimise performance.

Here, we’ll go into more detail about the factors that influence inspection frequency, and additional considerations that enhance hydraulic system maintenance.

Determining the Frequency of Inspections

The frequency of hydraulic inspections can vary depending on several factors:

1. System Usage and Load Intensity - Equipment that operates under high stress or continuous use requires more frequent inspections.
2. Operating Environment - Equipment operating in harsh environments, such as those with extreme temperatures, moisture, or dirt, will need more frequent inspections. Contaminants can accelerate wear and tear, especially if the hydraulic fluid becomes compromised.
3. Age and Condition of the Equipment - Older systems or those that have had previous issues may need more regular checks. Regular maintenance and replacement of worn parts can help older equipment perform better and more reliably.
4. Manufacturer’s Recommendations - Always consider the guidelines provided by the manufacturer. These recommendations are based on the design and expected operation of the equipment.

Bear in mind that inspections don’t necessarily include all aspects of a hydraulic system. Certain parts and components will be inspected more frequently than others, as we’ll see below.

Hydraulic Maintenance Checklist

A hydraulic maintenance checklist should include the following:

• Fluid Levels and Quality - Check for proper hydraulic fluid levels and look for signs of contamination or degradation.
• Filters - Inspect filters for clogs and damage to ensure they are effectively removing contaminants from the hydraulic fluid.
• Hoses and Connections - Look for leaks, cracks, or worn-out hoses that can be critical points of failure.
• Pressure Levels - Verify that hydraulic pressure is within system specifications to ensure efficient operation.
• Hydraulic Cylinders and Valves - Examine for signs of leakage or wear. Proper function of these is vital for maintaining system performance and safety.
• Auditory Clues - Listen for any unusual noises such as whining, banging, or knocking during operation, which could indicate potential problems like cavitation, air in the system, or mechanical failures.

The most common points of failure in a hydraulic system are the hoses and the seals, so these should be given careful attention. With high-use systems, checking these components on a daily basis is generally advisable. Components such as tanks and certain valves can usually be checked less often.

Here are a few typical checklists for hydraulic systems:

Daily - Checking for leaks, maintaining fluid levels, inspecting hoses, tightening connections, and monitoring for abnormal noises or pressure issues.

Weekly - Inspecting fluid conditions, checking pressure settings, cleaning or replacing filters, lubricating moving parts, testing safety features, checking battery voltage, and inspecting hydraulic cylinders.

Monthly - Examining hydraulic oil for contaminants, reviewing system operating hours to determine if hydraulic oil and filters need changing, inspecting couplings, performing detailed system tests, and replacing worn parts as necessary.

It’s always best to have detailed checklists, divided by scheduling periods (i.e., daily, weekly, monthly, annually), to guide your inspection processes.

Hydraulic Replacement Parts

Keeping a stock of essential hydraulic replacement parts can significantly reduce downtime during maintenance. Key components include seals and O-rings, which prevent leaks and maintain pressure; hoses and fittings, which are susceptible to wear and environmental damage; filters, to keep hydraulic fluid free from contaminants; and pumps and motors, which are critical for system functionality. Furthermore, keeping spare valves onsite can quickly restore system efficiency, as they regulate the fluid's flow and pressure.

Using high-quality replacement parts from reputable manufacturers enhances system reliability and extends its lifespan.

It should be clear by now that regular hydraulic inspections are vital for the sustained operation and reliability of hydraulic systems. By establishing a routine based on usage, environment, equipment age, and manufacturer recommendations, and by following a sound hydraulic maintenance schedule, your organisation can prevent the majority of hydraulic system failures. Remember, preventative maintenance is always more cost-effective than emergency repairs.

Find all the replacement parts you need to keep your systems running efficiently with White House Products Ltd.