How to get the most life out of hydraulic systems

It all begins with the spec'ing process


When it comes to hydraulic systems, care taken during the specification process can pay dividends in terms of maintenance and component longevity. That’s because when hydraulic system components are properly specified, the system operates at a higher level of efficiency, generates less damaging heat, and lasts longer.

The specification process should always begin with the work to be done. For example, a dump trailer, an ejector trailer and a live floor trailer may be similar in appearance, yet each requires very different hydraulic components. Choosing a pump and reservoir designed for a dump trailer application and fitting them on a live floor or ejector trailer application can have disastrous results.

When discussing hydraulic components with your supplier, always provide the make and model numbers of the equipment being powered, as well as the manufacturer’s recommended operating flow and pressure requirements. Also be sure to tell the supplier if more than one type of trailer may be used with the same tractor, as this will require a specialized system designed around the differing requirements.

Key parameters include flow requirements, operating pounds per square inch (psi) and length of duty cycle.

HYDRAULIC PUMP

Also to be considered is how the hydraulic pump will be driven. Typically, this will be through a power take-off (PTO), but it could also be through a belt-driven pump or via a driveshaft directly from the engine crankshaft.

The hydraulic pump produces the flow to perform the work. The rate of flow determines the speed at which the equipment will operate. Therefore, it is important to follow the equipment manufacturer’s recommendation.

An undersized pump may do the work, but slowly. An oversized pump may cause equipment to operate too fast, creating a potentially dangerous situation.

Also, oversizing the pump may result in higher system heat which, in turn, shortens the life of oil and components. In specifying a hydraulic pump, bigger is not better.

OPERATING PRESSURE

Operating pressure determines the force generated within the hydraulic system. This is another area where the equipment manufacturer’s specifications must be adhered to.

The pump selected must be able to tolerate the operating pressure up to the relief valve setting. Twisted pump shafts and excessive gear housing cut-out are common symptoms of pump over-pressurization and can be prevented by specifying the right pump to start with and maintaining relief valve settings within the range specified by the manufacturer of the equipment.

If a pump is losing efficiency or the system is operating slowly, adjusting the relief valve will not make it work faster.

DUTY CYCLE

The duty cycle of the equipment must be considered when specifying reservoir size and reservoir type, and when determining whether or not a heat exchanger may be required. Longer duty cycles result in higher temperatures. In order to dissipate heat, reservoir capacity may need to be increased.

Some applications with short or intermittent duty cycles will require only enough reservoir capacity to extend the hydraulic cylinder while leaving four to six inches of reserve in the tank. Applications with longer duty cycles require larger reservoirs or heat exchangers.

The determining factor is oil temperature. As long as the operating temperature stays below 140 degrees F the reservoir is adequate.

Reservoir material plays a role here as well. Aluminum tanks are more effective at dissipating heat than steel or polyethylene. Polyethylene reservoirs are lightweight and are a good choice for a dump trailer but should not be used in long duty cycle applications like live floors.

HOSES

Hose size and routing are additional essential considerations. First and foremost, hoses must be adequately sized. Hose diameters should be based on system flow, not port size.

Undersized inlet hoses can cause cavitation damage in a pump. Undersized pressure hoses create restriction and increase neutral system pressure which adds to system heat. Undersized return hoses can create restriction and damage the directional valve.

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