Fluid Properties for Hydraulic fluids When choosing a hydraulic fluid, consider the following characteristics: viscosity, viscosity

index, oxidation stability and wear resistance. These characteristics will determine how your fluid operates within your system. Fluid property testing is done in accordance with either American Society of Testing and Materials (ASTM) or other recognized standards organizations. 1. Viscosity (ASTM D445-97) is the measure of a fluids resistance to flow and shear. A fluid of higher viscosity will flow with higher resistance compared to a fluid with a low viscosity. Excessively high viscosity can contribute to high fluid temperature and greater energy consumption. Viscosity that is too high or too low can damage a system, and consequently, is the key factor when considering a hydraulic fluid. 2. Viscosity Index (ASTM D2270) is how the viscosity of a fluid changes with a change in temperature. A high VI fluid will maintain its viscosity over a broader temperature range than a low VI fluid of the same weight. High VI fluids are used where temperature extremes are expected. This is particularly important for hydraulic systems that operate outdoors. 3. Oxidation Stability (ASTM D2272 and others) is the fluids resistance to heat-induced degradation caused by a chemical reaction with oxygen. Oxidation greatly reduces the life of a fluid, leaving byproducts such as sludge and varnish. Varnish interferes with valve functioning and can restrict flow passageways. 4. Wear Resistance (ASTM D2266 and others) is the lubricants ability to reduce the wear rate in frictional boundary contacts. This is achieved when the fluid forms a protective film on metal surfaces to prevent abrasion, scuffing and contact fatigue on component surfaces.

Characteristics

Units

Total Azolla ZS 68

Shell Tellus 68

ISO Grade

68

68

Density at 15 C

Kg/m3

884

886

Viscosity at 40 C

mm2/s

67.5

68

Viscosity at 100 C

mm2/s

8.7

8.6

Viscosity Index

---

100

97

Flash Point

242

223

Pour Point

-21

-24

Symptoms of Common Hydraulic Problems and Their Root Causes

Proactive maintenance emphasizes the routine detection

and correction of root cause conditions that would otherwise lead to equipment failure. In the case of hydraulic systems, there are three easily detectable symptoms that give early warning of root cause conditions. These symptoms are abnormal noise, high fluid temperature and slow operation.

Abnormal Noise
Abnormal noise in hydraulic systems is often caused by aeration or cavitation. Aeration occurs when air contaminates the hydraulic fluid. Air in the hydraulic fluid makes an alarming banging or knocking noise when it compresses and decompresses, as it circulates through the system. Other symptoms include foaming of the fluid and erratic actuator movement. Aeration accelerates degradation of the fluid and causes damage to system components through loss of lubrication, overheating and burning of seals. Air usually enters the hydraulic system through the pumps inlet. For this reason, it is important to make sure pump intake lines are in good condition and all clamps and fittings are tight. Flexible intake lines can become porous with age; therefore, replace old or suspect intake lines. If the fluid level in the reservoir is low, a vortex can develop, allowing air to enter the pump intake. Check the fluid level in the reservoir, and if low, fill to the correct level. In some systems, air can enter the pump through its shaft seal. Check the condition of the pump shaft seal and if it is leaking, replace it. Cavitation occurs when the volume of fluid demanded by any part of a hydraulic circuit exceeds the volume of fluid being supplied. This causes the absolute pressure in that part of the circuit to fall below the vapor pressure of the hydraulic fluid. This results in the formation of vapor cavities within the fluid, which implode when compressed, causing a characteristic knocking noise. The consequences of cavitation in a hydraulic system can be serious. Cavitation causes metal erosion, which damages hydraulic components and contaminates the fluid. In extreme cases, cavitation can cause mechanical failure of system components. While cavitation can occur just about anywhere within a hydraulic circuit, it commonly occurs at the pump. A clogged inlet strainer or restricted intake line will cause the fluid in the intake line to vaporize. If the pump has an inlet strainer or filter, it is important for it not to become clogged. If a gate-type isolation valve is fitted to the intake line, it must be fully open. This type of isolation device is prone to vibrating closed. The intake line between the reservoir and pump should not be restricted. Flexible intake lines are prone to collapsing with age; therefore, replace old or suspect intake lines.

High Fluid Temperature

Fluid temperatures above 180F (82C) can damage seals and accelerate degradation of the fluid. This means that the operation of any hydraulic system at temperatures above 180F is detrimental and should be avoided. Fluid temperature is too high when viscosity falls below the optimum value for the systems components. The temperature at which this occurs is dependent on the viscosity grade of the fluid in the system and can be well below 180F. High fluid temperature can be caused by anything that either reduces the systems capacity to dissipate heat or increases its heat load. Hydraulic systems dissipate heat through the reservoir. Therefore, the reservoir fluid level should be monitored and maintained at the

correct level. Check that there are no obstructions to airflow around the reservoir, such as a build up of dirt or debris. It is important to inspect the heat exchanger and ensure that the core is not blocked. The ability of the heat exchanger to dissipate heat is dependent on the flow rate of both the hydraulic fluid and the cooling air or water circulating through the exchanger. Therefore, check the performance of all cooling circuit components and replace as necessary. When fluid moves from an area of high pressure to an area of low pressure without performing useful work (pressure drop), heat is generated. This means that any component that has abnormal internal leakage will increase the heat load on the system. This could be anything from a cylinder that is leaking high-pressure fluid past its piston seal, to an incorrectly adjusted relief valve. Identify and change-out any heat-generating components. Air generates heat when compressed. This means that aeration increases the heat load on the hydraulic system. As already explained, cavitation is the formation of vapor cavities within the fluid. These cavities generate heat when compressed. Like aeration, cavitation increases heat load. Therefore, inspect the system for possible causes of aeration and cavitation. In addition to damaging seals and reducing the service life of the hydraulic fluid, high fluid temperature can cause damage to system components through inadequate lubrication as a result of excessive thinning of the oil film (low viscosity). To prevent damage caused by high fluid temperature, a fluid temperature alarm should be installed in the system and all high temperature indications investigated and rectified immediately.

Slow Operation
A reduction in machine performance is often the first indication that there is something wrong with a hydraulic system. This usually manifests itself in longer cycle times or slow operation. It is important to remember that in a hydraulic system, flow determines actuator speed and response. Therefore, a loss of speed indicates a loss of flow. Flow can escape from a hydraulic circuit through external or internal leakage. External leakage such as a burst hose is usually obvious and therefore easy to find. Internal leakage can occur in the pump, valves or actuators, and unless you are gifted with X-ray vision, is more difficult to isolate. As previously noted, where there is internal leakage there is a pressure drop, and where there is a pressure drop heat is generated. This makes an infrared thermometer a useful tool for identifying components with abnormal internal leakage. However, temperature measurement is not always conclusive in isolating internal leakage and in these cases the use of a hydraulic flow-tester will be required. The influence of internal leakage on heat load means that slow operation and high fluid temperature often appear together. This can be a vicious circle. When fluid temperature increases, viscosity decreases. When viscosity decreases, internal leakage increases. When internal leakage increases, heat load increases, resulting in a further increase in fluid temperature and so the cycle continues.

Proactively monitoring noise, fluid temperature and cycle times is an effective way to detect conditions that can lead to costly component failures and unscheduled downtime of hydraulic equipment. In most cases, informed observation is all that is required.

How to Troubleshoot a Hydraulic Pump

Hydraulic pumps are used in heavy industry. The hydraulic pump in its most basic form moves fluid from a low pressure, called the suction, into a potential high pressure, or the discharge. The high pressure is created by any resistance of flow. Resistance of flow is caused by the closing of actuation valves and a clogged or blocked system. Many factors dictate the efficient use of the pump for performing its task. By following a set process you can troubleshoot the hydraulic pump from one end to the other. Important Parts Required

Hydraulic oil filter Pressure gauge End wrenches Allen wrenches Tank thermometer Infrared thermometer
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Check the condition of the hydraulic oil filter. These filters are typically placed on the low-pressure discharge end of the system. After the high-pressure fluid has done its work, it exits from a hydraulic motor or cylinder, then passes through a screw-on type filter. Another filter to check is the suction screen filter. This metal screen is composed of finely sized holes on a steel screen. Small particles that could collect in the metal tank reservoir are caught before entering the pump. If these two filters are clogged they will cause pressure problems in the pump. Test the operation of the pressure relief bypass valve. Attach a pressure gauge to the pressure relief valve port. Use the Allen wrenches to remove the setscrew plug. Insert the gauge and tighten with the end wrench. Turn the system on and confirm the correct setting of the relief valve. The pressure gauge should not register any fluid pressure if the valve is set correctly. A low setting on the valve will cause fluid to bypass the main hydraulic system and exit into the reservoir tank. Read the fluid's temperature with the tank thermometer. Hot hydraulic fluid can cause burning or scorching of the seals inside the pump. High fluid temperature may indicate a bypassing of the pumps' seals. Some hydraulic systems may also employ a radiator type device for cooling the fluid that sets inside the reservoir tank. A separate circulation pump is used to move the fluid through the radiator. Inspect all pump seals and bearings. A slight leak at a bearing position and seal will indicate that there is a problem with the pump. The leak can last a long time before imminent pump failure occurs. Typically a leaky seal is an indication that a bearing is failing, either in the pump itself or the motor driving the pump.

Check individual system components with an infrared thermometer. What may be perceived as a pump problem may be another component. Heat is created by the bypassing of fluid through an individual actuator or cylinder. Test all components for excessive heat during the operation of the hydraulic system

Signs & Symptoms of Overheated Hydraulics

Hydraulic machinery relies on pressure to generate force. Hydraulics have been an important addition to the mechanical work force, as they fulfill a wide range of functions. Hydraulics machinery uses the transfer of fluid to generate pressure and force. Common devices that rely on hydraulics include industrial presses, exercise equipment and construction machinery. The mechanical complexity of hydraulic machinery means the equipment must be inspected regularly to prevent leaking of fluid and overheating.

1. Abnormal Noises
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Hydraulic machinery generates lots of heat because of the friction created from the mechanical movements. One symptom of overheating hydraulic machinery is a banging or knocking sound when the hydraulics is being used. This is most often caused when air contaminates the hydraulic fluid from a small leak. The knocking sound occurs when this air in the system compresses and decompresses. Having air in the fluid accelerates the degradation of the machinery and contributes to overheating.

Increased Fluid Temperatures

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Most hydraulic machinery comes equipped with a temperature gauge to indicate the fluid temperature. According to Machinery Lubrication Online, hydraulic fluid temperatures that exceed 180 degrees Fahrenheit indicate the system is overheating and is at risk of being seriously damaged. High fluid temperatures reduce the viscosity of the machinery and increase friction, which generates heat. Some of the most common causes are low reservoir levels, which dissipates the machine's heat, or a build-up of dirt obstructing the airflow of the heat exchanger.

Sluggish Performance
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As a hydraulic system experiences more friction from the internal components, it begins to slow down and stutter during intensive jobs. You likely will notice the machine is performing all tasks, including basic ones, at a slower rate. The increased strain put on the system will cause numerous overheating problems and degrade key components. Most often the problem is with leaking hydraulic fluid

around one of the gaskets or a burst hydraulic hose, which shuttles the fluid to different components.

Pressure Drop
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Hydraulic equipment relies on generated pressure to fulfill most of the laborintensive duties. Low-pressure levels within the system force the mechanical system to work harder, which will quickly overheat the system and cause damage to key components. A sharp drop in pressure often is a sign of a leak somewhere in the hydraulics of the equipment. Check all gaskets and hydraulic hoses for leaks.

Troubleshooting Hydraulic Cylinders

Hydraulic cylinders are widely use in industry and the making of machinery, are capable of producing motion and force through the movement of pressurized fluids. Common uses for a hydraulic cylinder include machinery and passenger elevators. The cylinders are controlled by valves which regulate fluid pressure; movement is regulated by the distribution of those fluids through piping or hoses. Regular use of a hydraulic cylinder can eventually lead to operational failure and identifying the causes quickly can help to resolve any problems

Important Parts Required

Cylinder mountings

Emery paper Belt sander Hexagonal wrench Replacement rod seals Temperature-resistant PTFE rod seals Replacement hoses Clean oil or alternative fluid
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Poor rod alignment is one of the most common causes of hydraulic cylinder leakage and this can ultimately affect the life of the bearings and rod seals. Check hydraulic parts for signs of excessive fluid loss on a regular basis. If signs of leakage are apparent, carry out a visual check on the rod and pay particular attention for grinding marks or surface scratching. Add additional mountings to provide cylinder stability and remove scuff marks with coarse emery paper. Rod seal leakage is often a simple matter of wear and tear. Drain hydraulic fluids back to the holding tank and remove the cylinder head using a hexagonal wrench. Remove the old rod seal and replace with a new part. Refit the cylinder head and return the hydraulic cylinder into service. Regular damage to rod seals may indicate burring on the rod itself. Remove these with a belt sander and smooth scratching marks with coarse emery paper. Fluid contamination is one of the most common causes of hydraulic rod failure. Foreign particles with abrasive qualities will wear down the rod seal and cause leaks. Water contamination will cause seals and "O" rings to harden prematurely. Check system filters to ensure there are no obvious signs of particle build-up. Change oils or other fluids on a regular basis and ensure valves are serviced at frequent intervals to maintain hydraulic cylinder integrity. Excessive use of a hydraulic cylinder can lead to high levels of heat being generated. This can make the system fluids very warm and inevitably leads to rod seals becoming brittle once they cool down. Swap existing rod seals for alternatives that are suitable for dealing with high temperatures. PTFE coated seals are capable of withstanding much higher temperatures than a standard rubber seal. High operating pressure is another common cause of leaks. Regulate valve pressure and examine pipes and hoses for obvious obstructions. On new hydraulic machinery, high pressure may be the result of undersized hosing. Swap for an alternative with a larger diameter to reduce the pressure to a safe working level.

Hydraulic Troubleshooting Chart & Problem Guide

Noisy Pump

1. Hydraulic pump may be cavitation and getting air into the system. 2. Low oil 3. To heavy of oil 4. Cold oil 5. Suction filter clogged or Suction line undersized if new system. 1. Contaminants stuck in relief valve 2. To light of oil 3. Oil cooler if equipped dirty or fan not running 4. Dirty oil 5. Low oil level 6. Excessive pump wear 7. Relief valve set to low 1. Relief valve pressure set improperly or relief failing 2. Low oil supply 3. Hydraulic pump is worn or damaged 4. Valve not shifting all the way 5. Clogged flow controls if present 1. Air leak in hydraulic pump suction side 2. Oil level low 3. Wrong oil put in tank 4. Pump shaft seals or access plates could be drawing air into the system.

Oil heating up

Hydraulic Pump not responding quickly enough or not enough flow present.

Oil Foaming, air in oil (white color)