液压和液压软管维护技巧

如果您拥有或运行重型设备，您就会知道液压系统正确运行的重要性。您依靠液压系统组件来挖掘、提升和移动材料。您还需要功能正常的液压系统来调动您的设备。

当今机械上的液压系统非常复杂。如果您执行彻底的液压维护和定期液压检查，它们也很可靠。这项维护工作包括仔细检查液压软管、定期更换液压过滤器和定期分析液压油。

但是，维护您的液压系统不仅仅是软管、过滤器和流体。您需要制定全面的液压系统预防性维护计划。让我们来看看您可以做些什么来确保您的设备的液压系统始终准备好工作。

液压系统概述

现代液压系统应用来自电机的扭矩倍增，并通过泵将机械能转化为流体能。加压油从泵通过封闭管线进入执行工作的膨胀缸。液压理论和实际操作源于帕斯卡定律，即封闭系统中的受压流体向各个方向传递相等的压力。

现代挖掘机、推土机、平地机或滑移转向机上的液压系统都以闭环或封闭原理运行。尽管今天的液压元件变得越来越复杂，但它们依赖于与旧技术相同的基本概念。以下是当前重型设备液压系统的概述：

• 液压马达： 大多数重型设备都将柴油发动机作为主要动力源。它们利用热量将储存在石油产品中的能量转化为机械能。液压系统使用机器的发动机来驱动一个对流体加压的泵。
• 液压泵： 液压系统泵对称为液压油的流体加压。液压泵对流体加压，而不是像气动系统那样压缩。加压液压油保持其质量，但具有更高的能量水平。
• 液压油箱： 每个液压系统都需要一个储油箱来储存其流体。该容器称为储液器，用于容纳未加压的储备液。水箱尺寸因机器尺寸和所需容量而异。
• 液压控制： 控制加压流体的阀门基本上起到液压系统的大脑的作用。典型的土方机械具有许多操作员控制的阀门。这些控制直接流量、调节体积和补偿压力。
• 液压管线： 管线将加压流体从泵输送到工作缸。液压管路系统由油管、软管、接头、接头和密封件组成。
• 液压执行器： 一旦管路输送加压流体，执行器就会将液压能转换回机械能。大多数设备操作员和服务技术人员将执行器称为“气缸”。这些油缸移动动臂、激活斗杆和操纵铲斗。
• 液压流体： 大多数液压油是石油基的。保持这种液体不受污染至关重要。脏油对液压元件来说是可怕的。
• 液压过滤器： 过滤器有助于保持液压系统清洁。许多液压组件在战略位置具有多个过滤器。拥有合适的过滤器对于设备的液压健康至关重要。

维护设备的液压系统对于具有成本效益和长期的机器性能至关重要。这样做需要时间，并且需要注意小细节。这些细节包括流体污染，这是液压系统故障的主要原因。

液压系统故障

所有液压系统故障的主要原因是流体污染。对于土方设备，由于流体污染导致的液压故障会造成更大的威胁，因为它会不断暴露在灰尘和碎屑中。

污染有不同的形式，可以通过多种方式进入液压系统。以下是您通常会发现破坏液压系统并导致系统故障的主要污染物形式：

• 进入的污染： 如果您使用土方机械，这些污染物是不可避免的。您的液压系统会吸收空气中的污垢、直接接触矿物材料甚至是有机污染。为了最大限度地减少进入污染物造成的损害，您需要时刻注意维护。
• 催化污染： 非固体污染物也会威胁您的液压健康。罪魁祸首是水和空气，以及热应激。水和空气中可能含有微小的污染物，例如铁和铜，它们会与液压油中的微粒发生反应并导致催化作用和磨损。
• 产生的污染： 这是一个恶性循环。小的污染物颗粒会形成更大的碎片。它们会随着时间的推移而增长，导致污染增加，从而严重影响您的液压系统。
• 自然污染： 一些新鲜油可能含有污染物，并且随着时间的推移，污染物会自然地积聚在您的油中。为避免此问题，请始终从信誉良好的供应商处购买优质产品并定期更换液压油。
• 内置污染： 一些污染物直接内置在您的设备中。制造过程中的微量物质无处不在，而且完全不可避免。示例包括制造碎片、装配污染、焊接飞溅物、铸砂、油漆粉尘，甚至清洁抹布纤维。

有许多污染源威胁着您的液压元件。经历定期磨损是重型设备行业的一部分。作为机械所有者、操作员或车队经理，维护您的设备并使其尽可能长时间运行是您职责的一部分。

所有液压设备都有计算的使用寿命。有些组件的设计可以持续到过时为止。其他人遭受过早故障，原因通常是缺乏预防性维护。

一些液压故障仅仅是不方便。其他人是灾难性的。一个成功的预防性维护计划可以降低您的故障率和发生的任何问题的成本。以下是重型设备行业的三种液压故障等级：

1. 降级失败： 所有机械设备最终都会退化并出现故障，包括适当维护的液压系统。管理退化故障的关键是监控组件并在它们失效之前对其进行修复或更换。
2. 暂时性故障： 偶尔会发生液压元件故障。当它们这样做时，它们会将压力转移到其他部件上，也会增加它们失败的风险。此过程称为瞬态或渐进式故障。
3. 灾难性故障： 一些液压故障似乎在没有警告的情况下发生。例如，软管可能会突然爆裂并排放加仑油。这些意外损坏可能会导致昂贵的维修费用和停机时间。

通过简单直接的预防性维护计划，您可以显着降低液压故障率。通过遵循一些简单的步骤，您可以在早期阶段检测到退化故障，延迟瞬态故障事件并避免灾难性故障。从日常液压系统维护和检查开始。

日常液压系统维护和检查

预防性维护对于保持液压系统的活跃和可靠至关重要。维护您的液压系统可防止在没有警告的情况下发生早期故障。故障预防可降低您的维修成本、最大限度地减少计划外停机时间并支持您的盈利能力。

维护您的设备是一个持续的过程和持续的承诺。您需要制定包括操作前和操作后检查以及定期维护的例行程序。一个平衡良好的预防性维护 (PM) 计划有两个主要部分：

• 问题预防： 维护您的液压系统并防止出现问题需要了解您的机器及其需要的工作。您可以在用户手册中找到有用的维护信息。花点时间了解设计您的设备的工程师希望您做什么。
• 问题修正： 一旦发现潜在问题，请确保立即采取纠正性维护措施。不要等待修理或更换出现缺陷的液压部件。未能解决发展中的问题可能会在最糟糕的时候导致代价高昂的故障。

为了节省时间和金钱，制定软管和液压系统的常规预防性维护计划至关重要。以下是实施此类计划的一些提示：

• 定义计划涵盖的内容： 制定例行维护计划的第一步是准确定义它将涵盖的内容。一般来说，所有维护或检查计划都涵盖三个方面：例行定期维护、定期检查和主动更换部件。
• 安排检查： 下一步是安排您的日常和预防性维护活动。为定期维修、一般检查和零件更换制定单独的时间表。请查阅您的用户手册并从您的经销商处获得专家建议，以了解多久安排一次预防性维护和检查活动。
• 记录维护活动： 任何和所有检查、维修或维护活动都应记录在一个位置。如果您拥有不止一件设备，那么每件都需要自己的记录。记录服务和检查活动有助于让您对预防性维护负责。它还有助于养成优先考虑预防性维护和检查的习惯。
• 指定负责人： 如果没有指定负责人，任何预防性或日常维护计划都是不完整的。谁负责维护和检查将取决于公司的规模，但应该始终是最熟悉设备的人。小型企业通常让业主运营商或委托人负责管理维护和检查。大公司通常会聘请首席技术人员来监督维护活动。

有效的预防性维护计划的另一个方面是分析任何磨损或缺陷的原因。如果您确定了问题的原因，您将能够更好地防止将来出现类似问题。

寻找什么和知道何时更换液压元件

确定何时更换液压部件可能具有挑战性。知道要寻找哪些警告标志会有所帮助。随着您在设备维护方面获得更多经验，您将更好地注意和解释这些信号。您需要寻找的一些迹象包括：

• 液压油变色： 如果您看到您的液压油突然变色，请考虑这是一个危险信号。随着油的老化，一些液体变色是正常的。然而，乳白色或起泡的外观表明水或空气污染了您的液体。立即停止工作，直到您解决了这种情况。
• Hydraulic oil leaks: Healthy hydraulic systems should never leak. If you see stains or liquid pooling, fix the cause of these drips as soon as possible. Little leaks have a way of becoming a big mess in no time.
• Hydraulic line deterioration: Any wear signs on your hydraulic lines is a signal to stop and fix them. That includes your whole hydraulic line sub-system of tubing, hoses, seals, connections and fittings. A worn component in this closed system can burst without any warning other than a slight bit of wear evidence.
• Hydraulic component fatigue: To find fatigued components, look for symptoms such as loosening and cracks. Remember that your hydraulic system operates under pressure and that fatigued parts rarely survive much pressure.
• Hydraulic component corrosion:  Rust is a mortal enemy of hydraulic systems. Moisture amplifies corrosion and can eat through your hydraulic system’s metal components quickly. Check your fasteners and connections for that reddish-brown sign that corrosion has started and is compromising your system’s integrity.
• Hydraulic system noise: All operating hydraulic systems emit noise. With experience, you’ll know what your healthy hydraulics sound like. You’ll also know when something sounds wrong and when something requires immediate attention.
• Hydraulic system smell: The smells related to your hydraulic system can help you detect trouble. Burnt oil and overheated components can be smelled right away. Immediately stop work and look to see what’s causing the smell.
• Hydraulic control change:  You or your operator will know something’s wrong when your hydraulic controls change their behavior. Your hydraulic controls are vibratory extensions that deliver constant signals to your hands and feet. Any unusual control pattern is a tap on your shoulder telling you to look into what component is acting up.

If you have experience with heavy equipment, you’ll know when something doesn’t look right. The trick is to constantly watch for problems — this is what your preventative maintenance plan is all about.

No matter how thorough your PM plan is, it’s easy to miss something. You might not see something when it’s right before your eyes. Here are some tips to help you find problems that you might not usually see and extend the life of your hydraulic system components.

Tips on Increasing Longevity with Hydraulic System Components

Increasing the longevity of your hydraulic system components is a core aim of any preventative maintenance and corrective measures program. Without question, staying on top of issues provides a tremendous return on your time and money investment. Look into these helpful tips, which are sure to increase your hydraulic component’s longevity.

Hydraulic pumps:

• Listen for unusual or sudden noise changes coming from the housing.
• Watch for vibrations developing in the pump drive and mounts.
• Inspect your hydraulic pump for excess temperature or high heat signs.

Hydraulic cylinders:

• Watch for rusty cylinder sleeves, which are a sure sign of moisture-induced corrosion.
• Store your machines with retracted cylinders if possible.
• Inspect cylinders for wear patterns that indicate side loading.

Hydraulic lines:

• Check metal tubing lines for loose fittings and couplings.
• Tighten leaky fittings before replacing or repairing them.
• Make sure seals are in good shape and not showing wear.

Hydraulic hoses:

• Check your flexible hoses for routing and kinks.
• Watch for blisters and immediately replace frayed hoses.
• Ensure your hoses are sized properly for their specific demand.

Hydraulic reservoirs:

• Always keep your hydraulic fluid reservoir topped off to limit condensation.
• Reservoirs can loosen from vibration, so always check the connections.
• Keep your reservoir sealed when in operation and only open it in clean conditions.

Hydraulic filters:

• Always purchase filters designed and intended for your specific system.
• Do not tempt fate by using inferior or “jobber” hydraulic fluid filters.
• Never, ever change your hydraulic oil without installing new filters.

Hydraulic fluid:

• Buy high-quality hydraulic fluid that made specifically for your system.
• Pay special attention to any suspicious substance that appears in your oil.
• Invest in regular hydraulic fluid analysis conducted in a certified laboratory.

Having a professional lab analyze your hydraulic fluid is an economical investment with high returns. Because hydraulic oil is your system’s lifeblood, you want to make sure it’s as healthy as possible. A thorough fluid analysis is a must-do maintenance measure that you can’t afford to miss.

Hydraulic Fluid Analysis

It’s more than a wise move to have your hydraulic fluid tested. It’s a no-brainer. This simple procedure done at regular intervals picks up minute contaminant traces that you couldn’t possibly otherwise detect. It’s also a low-cost operation with quick turnaround time.

Hydraulic fluid analysis gives you an immediate and early sign that you’re developing hydraulic problems. Getting a hydraulic health warning gives you time to schedule repairs without interrupting job flow. A fluid analysis also monitors positive indicators that give you the peace of mind that your equipment is healthy.

It’s an easy process to get your hydraulic fluid analyzed. You follow the prescribed collection directions, submit the oil to your lab and then receive the report. With an oil analysis, you can expect these tests:

• Oil wear rate analysis:  This test looks for trace metals or wear-element particles in your hydraulic fluid. Metal is a sure sign of component wear. It’s an indicator that you need to check for components that are wearing out.
• Oil cleanliness analysis:  Dirt is your oil’s worst enemy. A cleanliness analysis identifies mineral pollutants like dust, soot and chemical compounds hidden in your hydraulic fluid. This test tells you if changing oil is immediately required or if you have time left in this category.
• Oil condition analysis: There’s a difference between condition and cleanliness. A condition analysis can uncover impurities at the microscopic level. Even if your oil looks clean, these contaminants, which include oxidation, nitration and sulfur by-products, can still cause significant problems.

Your oil has to be clean to keep the rest of your hydraulic components happy and healthy. Cleanliness is just that important to hydraulic performance, and so is having a clean hydraulic service environment.

The Importance of a Clean Hydraulic Service Environment

Servicing your machine’s hydraulic system in the field is risky. An open and uncontrolled environment exposes all your hydraulic components to dust and dampness, which are notable threats to unprotected hydraulic components.

Your machinery will be far better off having its hydraulics serviced in a shop. An enclosed shop at a professional dealership offers you superior hydraulic protection in a clean environment. You can’t possibly achieve clean-room conditions out in the field.

MacAllister Machinery knows how important cleanliness is for long-term hydraulic performance. Since 1945, when we opened our first Indiana Caterpillar dealership, we’re maintained a reputation for shop service that’s second to none. Although we do offer convenient field service for Cat® heavy equipment, we strongly recommend you have your hydraulic systems serviced in a shop.

Preventative Maintenance for Hydraulic Components From MacAllister Machinery

MacAllister Machinery is a full-service sales, maintenance and repair facility. We have the facilities, equipment and expertise needed to service all your hydraulics and perform your hydraulic hose maintenance in a clean environment. We also do hydraulic fluid tests and can evaluate your hydraulic system’s condition.

Contact MacAllister Machinery today for full hydraulic services. Call us at 800-382-1896 or reach out to us online.