Hydraulic Safety Precautions and Maintenance Tips

 Working with hydraulic systems requires careful attention to safety precautions to avoid accidents and ensure efficient operation. Here's a detailed guide on hydraulic safety, covering key areas to watch out for and how to maintain your system effectively.



General Hydraulic Safety Precautions

  • Read the safety data sheet: Always refer to the safety data sheet for the hydraulic oil used in your system.
  • Minimize skin contact: Avoid direct skin contact with hydraulic oil. If exposed, wash the affected area immediately.
  • Use proper cleaning agents: Avoid using gasoline, kerosene, or similar products to remove oil or grease from your skin. Opt for soap and water instead.
  • Handle oil-soaked clothing appropriately: Remove oil-soaked clothing promptly to reduce exposure.
  • Wash before meals: Always wash your hands and face before eating, especially after handling hydraulic oil.
  • Proper disposal of tools and oil: Clean hydraulic tools thoroughly and dispose of rancid oil according to guidelines.
  • Avoid inhaling vapors: Protect yourself from inhaling mist or vapor from hydraulic systems.
  • Seek medical advice: If you encounter any potential health hazards, consult a medical professional.

Safety Precautions When Disconnecting Hydraulic Joints

  • Ensure no pressure in the system: Before disconnecting any joint in a hydraulic system, ensure that there is no hydraulic pressure. Even if the pump is off, accumulated or external loads can still create pressure.
  • Secure movable parts: Secure any part that might move when pressure changes occur.
  • Discharge pressure lines: Use direction control valves to discharge lines, and isolate the part being worked on from the power source.
  • Display warning notices: Ensure appropriate warning signs are displayed during maintenance.

Key Risks in Hydraulic Systems

  • Contamination: One of the most common issues in hydraulic systems, contamination can lead to 75% of hydraulic failures.
  • Heat and Leakage: Both internal and external heat and leaks can degrade the system. Monitor the condition of the hydraulic oil regularly.
  • Filter Monitoring: Keep an eye on filter indicators and replace filters as needed.

Regular Hydraulic Maintenance Checklist

Filters

  • New systems: For new systems, change all filters after the first 50 hours of operation.
  • Regular intervals: Change filters at regular intervals or when the dirt indicator shows deflection.

Pumps

  • Temperature and noise: Check the temperature and noise levels while the pump is running. If the pump is too hot or noisy, inspect it for leaks or signs of wear.

Pressure Valves

  • Leak inspection: Inspect pressure valves for leaks by checking if the output pipe is cold, especially on normally closed valves.
  • Correct settings: Ensure the valve is properly set, and the adjustment screw has not been tampered with.

Volume Control Valves

  • Check speed: Ensure that hydraulic actuators are operating at the correct speed and that the adjusting screw is secure.

Direction Control Valves

  • Cylinders creeping: If cylinders creep or move unexpectedly, this could indicate wear in the direction control valve.

Accumulators

  • Nitrogen pressure: Regularly check the nitrogen pressure in the accumulator. Always use nitrogen for recharging.

Coolers and Heaters

  • Fan operation: For air coolers, verify that the fan is working and that the air leaving the cooler is warm.
  • Efficiency check: For water coolers, if efficiency drops, the oil temperature may rise, indicating a problem.
  • Heaters: Check the setpoint and operation of heaters.

Oil

  • Regular changes: Regularly change the oil and always use the same type of oil as initially used in the system.
  • Condensation drainage: Drain condensation water from the bottom of the tank periodically.

Pipes and Hoses

  • Check for wear: Inspect all pipes and hoses for any mechanical wear or damage. Ensure hoses are not twisted or kinked.

Following these guidelines will help keep your hydraulic systems safe and functional, reducing the risk of accidents and equipment failure.

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