Question 1

How do I prevent hydraulic cylinder contamination?

Accepted Answer

The best ways to avoid any fluid contamination are to ensure an exceptionally clean work environment during maintenance cycles. Make sure maintenance is performed in a controlled area at all times, rather than in an external setting. Other ways to avoid fluid contamination include:

Clean tools and equipment – improve cleanliness by also using clean tools
Utilise high-quality filters – make sure the filters you use are the very best, filtering out contaminants
Flush your hydraulic system – always flush out the system before adding in new fluid
Regular inspection and maintenance – by inspecting components regularly you can avoid any dirt or debris entering the system

Question 2

Does my hydraulic cylinder need refurbishment?

Accepted Answer

There will likely be obvious signs that your hydraulic cylinder requires replacing or refurbishing, such as the following:

Leaks – any hydraulic fluid trails or puddles of oil under the unit
Poor operation – not working as expected, whether it is slow, jerky or weak movement
High Temperature – if the cylinder is very hot, it might be a sign there is some internal friction
Noisy operation – banging or squealing noises may indicate internal components are grinding together
Damage – if any components look visually damaged, they may need to be replaced

Question 3

How do I replace the seals on a hydraulic cylinder?

Accepted Answer

Before starting any work, make sure the hydraulic cylinder is depressurised and disconnected from the hydraulic system or unit.

Once it has been secured, follow these steps:

Remove end cap
Take out piston/rod from barrel before disassembling
Remove seals using a removal tool such as a pick, noting the positions of each for easy reassembly
Clean all components using a suitable cleaning solvent and check surfaces for damage
Replace any seals that are damaged and prep for reassembly

Question 4

How do I service a hydraulic power pack?

Accepted Answer

There are many ways you can service your hydraulic power packs, or hydraulic system, on a regular basis. This includes:

Oil maintenance – regularly check the condition of your hydraulic fluid
Change filters – frequently change filters to avoid contamination
Replace seals – damaged seals can lead to leaks
Visual inspection of hoses and fittings – regularly inspect to avoid restrictions in flow rate
Monitor system temperature – avoid overheating which can lead to system damage
Listen to the pumps – this can indicate cavitation in a pump which can restrict fluid and cause further damage
Inspect valves – check temperature of valves or anything out of the ordinary, which could indicate contaminated fluid
Electric motor inspection – check for temperature increases, which can indicate faulty rotor bearings

Question 5

What size of HPU do I need?

Accepted Answer

The dimensions of a HPU can vary between a micro HPU, which is only measured in millimetres, and a standard unit, which can be towards 80-100 centimetres.

There are many considerations to make when sizing a HPU, mainly taking into account the including:

Pressure
Flow Rate
Power
Reservoir size
System configuration
Internal components

The best approach is to work out the requirements of the HPU in terms of output, which will indicate what components will be required to sufficiently match the application. You should also think about the environment it will be installed in, along with consideration for expansion or upgrade in the future, which may require more space.

Question 6

How much does a hydraulic power pack cost?

Accepted Answer

For a standard hydraulic power unit, you can expect to spend between £XX - £XX, if there are no additional modifications.

However, the cost of a Hydraulic Power Pack can vary depending on the size, shape and complexity of the unit. Once you have decided on the fuel type, size and system configuration, we will be able to provide an accurate quote for a HPU.

Question 7

How to choose the right hydraulic pump?

Accepted Answer

When choosing a hydraulic pump, you need to consider the type of hydraulic system it will be used for and what type of hydraulic fluid is being used to ensure the pump is compatible.

You should also consider the flow rate, pressure required and the operating conditions it will be working under, as well as deciding between a fixed or variable displacement pump.

Question 8

What are the benefits of hydraulic systems?

Accepted Answer

The main benefit of a hydraulic system is that it is a high pressure system and therefore, can produce a lot of energy to perform complicated and strenuous tasks.

Other benefits over different system types include reduced noise whilst in operation and reliability over a long period of time due to the efficiency of the system.

Question 9

How do I maintain a hydraulic system?

Accepted Answer

When maintaining a hydraulic system it’s important to focus on the clarity of the hydraulic fluid, as well as keeping the levels topped up. The hydraulic fluid should be changed if it becomes contaminated or topped up if the levels become too low.

By checking the system frequently you can replace filters, seals, hoses and fittings if any become damaged or faulty from general wear and tear. Other aspects that need to be monitored include the temperature, the pressure and check individual components for any faults.

Question 10

What are common hydraulic system issues?

Accepted Answer

The most common issue with a hydraulic system is that the hydraulic fluid becomes contaminated by air or water, leading to faults within individual components or the system as a whole.

Other issues include fluid levels getting low in the system and needing to be replaced, and temperature problems causing the system to be too hot or too cold. This can lead to severe issues over time, such as leaks or oxidisation of the hydraulic fluid from high temperatures.

Question 11

How do hydraulic systems work?

Accepted Answer

Hydraulic systems work by transferring hydraulic fluid through various components, such as an accumulator, motor, pump or valve, in order to generate energy and in many cases, movement.

They are specifically designed for high-pressure applications and environments where lots of energy is required to lift heavy weights or move large objects. Hydraulic systems have a wide range of applications but can be found in an excavator, crane, forklift truck and even car brakes.

Question 12

What are the different types of hydraulic systems?

Accepted Answer

Hydraulic systems can be categorised into three distinct groups; open-loop, closed-loop and regenerative.

An open-loop hydraulic system provides continuous flow from a fluid reservoir, whereas a closed-loop hydraulic system can hold the flow of hydraulic fluid and can also reverse the direction, giving the operator more control over the system.

A regenerative system is unique in that the hydraulic fluid goes directly into a directional control valve and is designed to regenerate the fluid in a component (such as a Hydraulic Cylinder) as quickly as possible, focusing on speed as the output.

Question 13

How to choose the right pneumatic coupling?

Accepted Answer

Here are some of the considerations to take into account before choosing a pneumatic quick release coupling:

• Seal - is the seal type compatible with the media (this is particularly important if you are planning to transfer chemicals)?

• Material - what are the couplings made from?

• Connection - is the connection type male or female?

• Size - pneumatic fittings usually range between 4 and 13 millimetres.

• Operating pressure range - what pressure range are the pneumatic fittings designed to operate in?

• Operating temperature range - what temperature range are the pneumatic fittings designed to operate in?

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