While it’s true that hydraulic system fluid contamination can come from unfiltered oil, particles in the tank, and abrasion or chemical degradation of components, the most common source is hydraulic hoses. Grime and debris can be present in new hoses and introduced to the system during routine maintenance. As hydraulic fluid moves through the system, these contaminants slowly damage components and affect the overall performance of your hydraulic equipment.
Common Signs of Hydraulic Fluid Contamination
Signs of system contamination are not always obvious until you notice issues like sluggish operation or decreased performance. By then, you have bigger and more costly problems.
A regular visual inspection goes a long way in detecting contamination before it causes damage to equipment. We recommend testing hydraulic fluid before and after maintenance to detect the presence of contaminants. Here are signs to look for:
- Fluid Discoloration: A dark, cloudy, or milky appearance indicates contamination.
- Visible Contaminants: Though large particles can be seen with the naked eye, a professional oil analysis might be required to detect microscopic contaminants.
- Cracked or Leaking Hoses: Contamination damages hose material and accelerates wear as fluid moves through the system.
- Excessive System Vibration or Unusual Noises: Cylinders, hoses, seals, and other components do not operate properly when hydraulic fluid is contaminated.
How Clean Hoses Prevent Damage and Improve Performance
The performance and longevity of a hydraulic system are directly impacted by how well you maintain the fluid and components. Neglecting cleanliness might not cause immediate issues, but over time, the buildup of contaminants will result in damage to components or your entire hydraulic system.
Keeping hydraulic hoses clean:
- Prevents fluid degradation, protecting the functionality of hydraulic components and improving system performance.
- Allows fluid to move freely, resulting in more efficient power transmission and less energy consumption.
- Extends the lifespan of hoses and components, which means less frequent part replacement.
- Improves hydraulic system reliability and performance, reducing downtime and costly repairs.
How Oil-Air Products Maintains Clean Hose Assemblies
The steps below are critical to prevent contamination during the hose assembly fabrication process. Oil-Air Products has adopted these practices as part of our standard hose assembly fabrication process.
Wet Cutting vs. Dry Cutting Hose
Dry cutting hose generates the most dust and debris. Wet cutting uses liquid to suppress dust and debris movement, reducing the amount of cutting contamination introduced into the hose. We use specialized automated cut-off saws and lubricant, allowing us to cut hoses to precise lengths and reduce debris entering the hose.
Using the Correct Saw Blade
A sharp, smooth blade cuts more quickly and generates less debris. We use smooth blades on all automated cut-off saws to minimize debris during hose cutting.
Removing Contamination in the Hose
Even after concerted efforts to control hose assembly contamination during fabrication, a certain level of contamination will still be present inside the hose. Air flush, liquid flush, and projectile cleaning are the three most common methods for flushing hoses. However, none of these methods guarantees results under all conditions.
Since 2003, we have used an independent lab to verify the cleanliness of our hydraulic hose assemblies. The results of these cleanliness tests have shaped the processes and procedures we use to clean hoses. Our current method involves a combination of air flush and projectile cleaning to ensure contamination is removed from the hose assembly.
Gravimetric Hose Testing
Random testing is critical in ensuring the quality of hose assemblies. We have an in-house gravimetric cleanliness testing lab to improve processes and ensure that hose assemblies meet the highest level of cleanliness in compliance with ISO 4405.
Avoiding Contamination Outside of the Fabrication Process
Once the hose assembly fabrication and cleanliness process is complete, it is essential to maintain that level of cleanliness until installation. Oil-Air Products caps every hose end and places the assemblies in a clean container to maintain our high standards of cleanliness.
If you have questions about hydraulic maintenance or hose assemblies, our technical team is here to help. Give us a call to discuss your application.