How Do You Know If Your Hydraulic System Is Overcooled?

Maintenance of your hydraulic system is usually focused on preventing overheating and causing damage; however, the risk of letting your hydraulic fluid run too cold, a phenomenon known as overcooling, can cause just as much damage and can cause expensive downtime.

If your system is operating below its optimal temperature range (which is typically around 100°F to 140°F or 38^ to 60^), here are the key signs and symptoms that indicate you have an overcooling problem:

1. Slow and Sluggish Operation

This is typically the first sign that is noticed, particularly during the initial phase or in colder conditions.

• Symptoms: The machine or actuator is very slow when it is first turned on. The cylinders pull in a slow manner, winches expand haltingly and valves are slow to respond.

• Reason: Cold hydraulic fluid has a greater viscosity (it's more dense). This thicker fluid blocks the flow of lines, pumps, and even tiny orifices (like those found in proportional valves) and slows the entire system down.

2. Increased Power Consumption and Pressure Spikes

The thick fluid demands the pump to be more efficient in moving it, which strains the motor unit.

• Symptoms: You notice the electric motor drawing too much current, or you notice the diesel engine is struggling or using more fuel to run those hydraulic features.

• Reason: The high resistance due to the viscous fluid causes it to boost pressure in an unnecessary way, which causes the overload to the motor as well as possible spikes in pressure.

3. Condensation and Contamination

Moisture is an unintentional death knell within any hydraulic device, and cold temperatures can encourage it.

• Symptoms: Milky, cloudy or cloudy-looking hydraulic fluid is evident when you look at the reservoir's sight gauge. The life of the filter can diminish because of water absorption.

• The reason: When the system is cold, the air space that is above the reservoir's fluid lets condensate to develop on the tank's walls. The condensate is mixed with oil, which causes oxidation corrosion and less lubrication capability.

4. Excessive Pump Noise (Cavitation)

The extreme viscosity could stop the pump from filling up properly and cause a loud, destructive sound.

• Symptoms: A loud, grinding, or rattling sound emanating from the pump, especially at the beginning of starting the machine.

• Reason: The cold, thick liquid isn't flowing fast enough to completely fill the outlet chamber completely. This causes a vacuum, which causes air pockets to collapse rapidly ( cavitation) when compressed, which can cause significant damage over the course of.

5. Temperature Gauge Stays Low

The most obvious indicator is a simple low-temperature reading on your monitor.

• Symptoms: The built-in oil temperature gauge constantly reads below the manufacturer's minimum operating temperature, regardless of whether the machine has been running for a fair amount of time.

Solutions: What to Do About Overcooling

If you suspect that you're cooling too much don't overlook it. The most effective solutions are usually the use of preventative measures as well as minor adjustments:

• Install a reservoir heater: A simple immersion heater will pre-heat the fluid prior to its start-up, making sure the oil's temperature falls within the minimal operating range before the pump is activated.

• Utilize a Lower Viscosity Fluid (for the ambient temperature): Ensure your fluid's ISO Viscosity Grade is suitable for the temperature of the ambient that your machine can operate at. For cold-weather operations, it is possible to use the use of a low-pour point or multi-viscosity fluid.

• Set up a Warm-Up Process: Allow the system to run the pump on a low load setting for several minutes prior to starting to work. This will allow the fluid to naturally warm the fluid.

• Verify the bypass valve in the cooler: In certain systems there is a control valve that is thermostatically operated might be stuck within"open" position "open" setting, allowing unnecessary fluid through the cooler, even though it's cold.