With hydraulics, it is absolutely imperative that you get them regularly serviced and checked so that you know whether or not you need replacement or repair services and to ensure that minor issues do not develop into major faults. This is because a fault can quickly become an extremely costly breakdown over time. It is very important that a minor issue does not become a fault, as faults can quickly lead to an extremely expensive breakdown. Some owners of hydraulic equipment are under the assumption that hydraulics continue to run indefinitely, or at least with annual safety checks. This, however, is not the case. Frequent maintenance and inspection of your equipment is crucial, due to a number of checks that need to be carried out. In addition to this, it’s important that you know the tell-tell signs to look out for so you can monitor your equipment.
When your hydraulic equipment ceases to work, there is absolutely no time to waste in order to get it working again. You have the option to repair or replace – but which one should you opt for? More and more people are seeking professional help and guidance with their hydraulic equipment rather than purchasing new components or attempting to repair equipment themselves.
Let’s discuss how a hydraulic company can diagnose problems with a business’s equipment and rectify any issues you may be having. In order to help you make an informed decision next time you face a hydraulic equipment failure, read on.
Hydraulics play a key role in our society, so with this in mind, we will briefly run through some of the main indicators of potential repair or replacements you need to look out for:
If you are finding that you can hear a significant amount of noise coming from any particular part of the machine, this is a red flag. Moreover, with hydraulic pumps, this is a noisey and clear sign that something’s not quite right.
Hydraulic pumps are filled with fluids which of course come through the system at high speeds and pressures. That can generate a lot of noise; however, hydraulic pumps are designed to muffle the sound of this.
Throughout the process of this, sections of the machine wear down and stop performing their functions as well as they previously have done. When you notice noises coming out of the pump, you can pretty much guarantee that some part of your hydraulic pump needs to be repaired or replaced.
As soon as liquids become visible in the interior of the tank or pump, other than in the tubes where they belong, this can be a clear indication that something is wrong with the pump.
It can be as simple as a seal or valve becoming loose, to then more serious cases when there is a breakage within the line.
In turn, this can lead to a drop in pressure and malfunction of the whole system. This problem is a little bit harder to spot since the leak happens on the inside of the pump. Moreover, if you can examine your pump before taking a long trip, you can identify any problems before it gets worse.
If you notice some liquid on the outer surface of the pump, this indicates that the issue of the leak has progressed, and you need to take action immediately. Having a leak is a sign that the pump is on its way out.
If it needs to be repaired or replaced it is always best to have the problem assessed by an expert; you should always make sure, however, that you act as soon as you realise there is a problem. Both inside and outside leaks are important as they can start a chain reaction.
Leaking decreases the pressure, which, in turn, increases the temperature of the whole system. This affects the viscosity of the oil, further reducing the pressure in the system.
For a hydraulic pump to function as it needs to, it’s crucial to have a certain specific level of fluid viscosity. Since the viscosity of a fluid is dependent on the temperature and pressure, these two things need to be within the limits recommended by the manufacturer. If either of these two parameters are off, the pump will go through unwanted strain which may lead to failure.
Temperatures over 180°F or 82°C have a negative effect on the performance and should be deterred. These temperatures are frequently reached if the system is not cooled down properly. Make sure that there is no obstruction in the air around the reservoir of the hydraulic system and check the heat exchanger while you are at it.
Preventative maintenance activities are the most cost-effective technique for steering clear breakdowns and emergency repairs. Frequent service activities are ideally carried out during scheduled shutdown intervals or carried out with minimal disruption to any operations. Typical preventative maintenance tasks include:
- Fluid condition monitoring
- System performance monitoring (pressure, flow, cycle time)
- Filter replacement or potential filter improvement
- Hydraulic hose condition checking and replacement if necessary
- Pump and motor service and repairs
- Pump efficiency tests
- Accumulator safety monitoring
- Voltage and response checks
- System flushing and oil replacement
- Possible site survey and assessment of your service requirements
In the unfortunate circumstance that your hydraulic equipment breaks down, a quick response is key and, while no two situations are the same, early intervention and fast diagnosis of the root problem are the best ways to minimise cost and downtime associated with breakdowns.
Typical activities undertaken include:
- Fault finding
- Component repairs
- Replacement part sourcing
- Replacement part installation
- System flushing
- Temporary equipment modifications
- Equipment hire
- Hydraulic replacement
Hydraulic components require parts that are safe and free of defects. To ensure maximum performance and satisfaction, each cylinder, pump, motor and control valve requires inspection.
After the components are checked visually for any issues, micrometers and calipers are then used to determine adequate tolerance and abnormal wear. Any results of any inspection should be noted and thoroughly reviewed afterwards.
Fixing a hydraulic component takes reworking or replacing all of the parts necessary to return the component to ‘new’ condition in terms of performance and expected lifespan. In many cases, repairing a hydraulic pump, motor or cylinder can result in significant savings when compared with the cost of purchasing a new one.
The economics of proceeding with any hydraulic repair is very much dependent on the price of the repair, relative to the cost of a brand new component. As a rule, the more expensive the new component is in absolute dollar terms, the more likely it is that a repair will be cost effective. The cost of a hydraulic repair is determined by a number of factors including:
- The extent of wear or damage to the component or part
- The facilities and expertise of the hydraulic repair company
- And the repair techniques employed
HP Hydraulics – if you are based in Fareham, Southampton and Portsmouth and looking for hydraulic repair near me, we are the company for you.
HP Hydraulics specialises in the creation and repair of hydraulics systems for a great deal of industries. With over 30 years of experience, we have the skills to create the most complex of hydraulic systems, and ensure they are long-lasting. Based in Hampshire, we offer unrivalled expertise in the design and finishing of hydraulics systems in Fareham, Southampton and Portsmouth.
With a highly experienced and knowledgeable team who have worked with industrial, military, and marine clients, HP Hydraulics are the obvious choice when you’re looking for hydraulics manufacturing, equipment, repairs or finishing. No matter the issue you may be experiencing with your hydraulic equipment, we can help you get to the bottom of it. Get in touch with us today to find out more about what we can do for you.