Hydraulic Systems Preventative Maintenance Checklist

Hydraulic Systems Preventative Maintenance Checklist
Proper maintenance of hydraulic systems is critical for extending equipment life and ensuring optimal performance. Maintenance is not a one-time task—it's a continuous process that requires discipline and consistency. Below is a checklist to help you maintain your hydraulic equipment effectively:

1) Develop a Maintenance Support Plan
Maintenance should be scheduled and ongoing. Create a dedicated maintenance calendar for every hydraulic system in your facility and adhere to it consistently.

2) Clean Reservoirs Before Oil Change-Outs
Reservoirs store hydraulic fluid and must be kept clean and contaminant-free. Every time you change the oil:

Drain the system completely.

Wipe the reservoir clean with a lint-free cloth or approved solvent.

Ensure all solvent is fully removed before refilling.

Neglecting this step can cause heat build-up, oil breakdown, sludge, and varnish formation.

3) Use and Replace Filters Regularly
Contaminants can severely damage pumps and other hydraulic components. To avoid costly repairs and performance issues:

Use suction strainers and full-flow filters.

Replace them on a regular maintenance schedule.

4) Check Oil Levels Consistently
This basic but often-overlooked task is crucial:

Make sure all machines have adequate fluid levels.

Refill as necessary, but never mix different oils.

Proper levels ensure smooth operation and prevent damage.

5) Sample the Oil Frequently
Regular oil sampling helps detect problems early:

Visually inspect for discoloration, contamination, or bad odors.

Send oil samples to a lab at least once a year—or quarterly for critical systems—for in-depth analysis.

6) Inspect Hoses, Tubing, and Fittings for Leaks and Wear
To ensure system integrity:

Check hoses, tubes, seals, breather caps, and fittings for leaks, frays, or cracks.

Schedule repairs immediately if damage is found.

7) Monitor System Temperature
Most hydraulic systems are designed to operate below 140°F (60°C):

Every 15°F above this threshold cuts oil life in half.

Use temperature gauges or infrared thermometers to monitor operating temperatures.

Aim to keep oil between 110°F and 140°F (43°C - 60°C).

8) Check the Pump
Ensure pump efficiency while the machine is running:

Listen for signs of cavitation (a high-pitched whine).

Look for aeration (foaming or tiny air bubbles).

If no flow meters are installed, measure the flow rate of the case drain line manually.

If the case drain flow exceeds 10% of the pump’s max volume, it's time to replace the pump.
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