Developing and Optimizing PMs for Hydraulic Equipment

Brendan Casey, HydraulicSupermarket.com

Introduction
Reliability Centered Maintenance (RCM) provides a framework that helps to ensure that
if a dollar is spent on improving reliability, that dollar is fully recovered plus an
acceptable return on investment. Placing preventative maintenance (PM) within the RCM
framework ensures that the cost of PM tasks do not exceed the cost of the consequences
of failure. However, if the new order of the maintenance department is to reduce and
eventually eliminate the need for maintenance services, then merely aligning task costs
with failure consequences is not enough. This paper outlines a preventative maintenance
program for hydraulic equipment that, where possible, reduces or eliminates the need for
constant investment in labor and materials the fatal flaw of traditional PM activities.

Maintenance Strategy and Process

Reliability Centered Maintenance
The primary objective of Reliability Centered Maintenance (RCM) is the economic
optimisation of machine reliability relative to organizational goals (Figure 1). RCM
provides a framework that helps to ensure that if a dollar is spent on improving reliability,
that dollar is fully recovered plus an acceptable return on investment. When
intelligently applied, the RCM model aids in the development of economical, equipmentspecific maintenance programs.

Figure 1. RCM flowchart.

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Condition-Based Maintenance
Deployment of advanced maintenance tactics within the RCM framework typically
involves the application of condition-based maintenance. Condition-based maintenance
encompasses proactive (PM) and predictive maintenance (PdM), the combined objectives
of which are machine life extension and early detection of faults and failures (Figure 2).
Placing condition-based maintenance within the RCM framework ensures that the cost of
PM and PdM tasks do not exceed the cost of the consequences of failure.

Figure 2. Condition-based maintenance.

Maintenance Improvement
According to Levitt (2003) and others, any equipment that requires periodic attention to
prevent breakdown is a failure of design engineering. Under this premise, the new order
of the maintenance department, is to reduce and eventually eliminate the need for
maintenance services, i.e. to fix the equipment permanently. This being the case, then
merely aligning PM task costs with failure consequences is not enough.

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The objectives of the following preventative maintenance program are to:

provide reliable hydraulic assets; and
reduce or eliminate the need for constant investment in PM tasks.

PM Development and Elimination

The following six preventative maintenance routines are essential to gain maximum
machine life and minimize the chances of premature failures and unscheduled downtime
of hydraulic equipment:
1. Maintain fluid temperature and viscosity within optimum limits;
2. Maintain fluid cleanliness;
3. Maintain hydraulic system settings to manufacturers' specifications;
4. Schedule component change-outs prior to failure;
5. Follow correct commissioning procedures; and
6. Conduct failure analysis.
Maintaining Fluid Temperature and Viscosity within Optimum Limits
Implementing this routine involves:
1. Defining an appropriate fluid operating temperature and viscosity range for the
ambient temperature conditions in which the hydraulic system operates;
2. Selecting a fluid with a suitable viscosity grade and additive package; and
3. Ensuring that both fluid temperature and viscosity are maintained within the limits
defined.
The viscosity of petroleum-based hydraulic fluid decreases as its temperature increases
and conversely, viscosity increases as temperature decreases. Limits for fluid viscosity
and fluid temperature must therefore be considered simultaneously. Low fluid viscosity
causes loss of lubricating film strength, which leads to boundary lubrication conditions,
scuffing and adhesive wear. Excessively high fluid viscosity can result in damage to
system components through cavitation.
Hydraulic fluid temperatures above 82C (180F) damage most seal compounds and
accelerate degradation of the oil. A single over-temperature event of sufficient magnitude
can permanently damage all the seals in an entire hydraulic system, resulting in numerous
leaks. The by-products of thermal degradation of the oil (soft particles) can cause
reliability problems such as valve-spool stiction and filter clogging.
Manufacturers of hydraulic components publish permissible and optimal viscosity values,
which can vary according to the type and construction of the component. As a general
rule, operating viscosity should be maintained in the range of 100 to 10 centistokes (460
to 80 SUS), however viscosities as high as 1000 centistokes (4600 SUS) are permissible
for short periods at start up. Optimum operating efficiency is achieved with fluid
viscosity in the range of 36 to 16 centistokes (170 to 80 SUS) and maximum bearing life
is achieved with a minimum viscosity of 25 centistokes (120 SUS).
In order to determine the correct fluid viscosity grade for a particular application, it is
necessary to consider:

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starting viscosity at minimum ambient temperature;

maximum expected operating temperature, which is influenced by system
efficiency, installed cooling capacity and maximum ambient temperature; and
permissible and optimum viscosity range for individual components in a system.

For example, consider an application where the minimum ambient temperature is 15C,
maximum operating temperature is 75C, the optimum viscosity range for the systems
components is between 36 and 16 centistokes and the permissible, intermittent viscosity
range is between 1000 and 10 centistokes.

Figure 3. Temperature/viscosity diagram for ISO viscosity grades. Note that the
gradient of the lines shown will depend on the viscosity index of the particular fluid
used.

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From the temperature/viscosity diagram (Figure 3), it can be seen that to maintain
viscosity above the minimum, optimum value of 16 centistokes at 75C, an ISO VG68
fluid is required. At a starting temperature of 15C, the viscosity of VG68 fluid is 300
centistokes, which is within the maximum permissible limit of 1000 centistokes at start
up.
Having established the correct fluid viscosity grade, the next step is to define the fluid
temperature equivalents of the optimum and permissible viscosity values for the systems
components.
By referring back to the temperature/viscosity curve for VG68 fluid in Figure 3, it can be
seen that the optimum viscosity range of between 36 and 16 centistokes will be achieved
with a fluid temperature range of between 55C and 78C. The minimum viscosity for
optimum bearing life of 25 centistokes will be achieved at a temperature of 65C. The
permissible, intermittent viscosity limits of 1000 and 10 centistokes equate to fluid
temperatures of 2C and 95C, respectively (See Table 1).
Viscosity Value
Min. Permissible
Min. Optimum
Opt. Bearing Life
Max. Optimum
Max. Permissible

cSt
Temperature (VG68)
10
95C
16
78C
25
65C
36
55C
1000
2C

Table 1. Correlation of operating viscosity values with fluid temperature based on

fluid viscosity grade.
Going back to our example, this means that with an ISO VG68 fluid with a VI similar to
that shown in Figure 3 in the system, the optimum operating temperature is 65C.
Maximum operating efficiency will be achieved by maintaining fluid temperature in the
range of 55C to 78C. And if cold start conditions at or below 2C are expected, it will
be necessary to pre-heat the fluid to avoid damage to system components. Intermittent
fluid temperature in the hottest part of the system, which is usually the pump case, must
not exceed 95C.
Once an appropriate fluid operating temperature and viscosity range has been defined, the
next step is the selection of a quality hydraulic oil. If the system contains highperformance components, such as piston pumps or motors, an oil containing at least 900
ppm (0.09% wt.) of the anti-wear additive ZDDP is recommended. The selection of an oil
with detersive/dispersive additives can be beneficial in mobile applications.
Having defined the parameters shown in Table 1 for a specific piece of hydraulic
equipment, damage caused by high or low fluid temperature (low or high fluid viscosity)
can be prevented, and recurring PM tasks in respect of this routine can be virtually
eliminated, by installing fluid temperature monitoring instrumentation with alarms and
shutdowns.

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Recommended temperature alarm limits are:

Over-temperature alarm - temperature at which viscosity falls below minimum
optimum.
Over-temperature shutdown - temperature at which viscosity falls below minimum
permissible.
Under-temperature - temperature at which maximum, permissible viscosity is
exceeded.
In addition to the reliability gains that can be achieved through defining and maintaining
optimum fluid viscosity, continuous monitoring of hydraulic fluid temperature can reveal
problems such as increased internal leakage, aeration and cavitation, making it an
effective and inexpensive condition-monitoring technique.
Maintaining Fluid Cleanliness
Implementing this routine involves:
1. Defining targets for particle and water contamination appropriate for the type of
hydraulic system;
2. Monitoring the actual contamination levels against target levels; and
3. Instigating remedial action as necessary to maintain target cleanliness levels.
Water in hydraulic fluid causes weakened lubricating film-strength, which leaves critical
surfaces vulnerable to wear and corrosion. Water can react with additives in the oil to
form corrosive by-products, which attack bearing metals. When selecting water
contamination targets, the type of hydraulic system and reliability objectives for the
equipment need to be considered. Controlling water contamination below the oils
saturation point at operating temperature is recommended. If the system contains highperformance components, such as piston pumps or motors, a target of 100 ppm is
desirable.
Particles accelerate wear of hydraulic components. The rate at which damage occurs is
dependent on the internal clearances of the components within the system, the size, shape
and quantity of particles in the fluid and operating pressure.
Some level of particle contamination is always present in hydraulic fluid, even in new
fluid. The level of contamination, or conversely the level of cleanliness, considered
acceptable depends on the type of hydraulic system and reliability objectives for the
equipment. Typical fluid cleanliness levels for different types of hydraulic systems,
defined according to ISO and NAS standards, are shown in Figure 4. Note the correlation
between fluid cleanliness level and the level of filtration in the system.

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TYPE OF HYDRAULIC SYSTEM

Silt sensitive
Servo
High pressure (250400 bar)
Normal pressure (150-250 bar)
Medium pressure (50 -150 bar)
Low pressure (< 50 bar)
Large clearance

MINIMUM RECOMMENDED
CLEANLINESS LEVEL
ISO 4406
NAS 1638
13/10
14/11
15/12
16/13
18/15
19/16
21/18

4
5
6
7
9
10
12

MINIMUM
RECOMMENDED
FILTRATION LEVEL IN
MICRONS ( 100)
2
3-5
5-10
10-12
12-15
15-25
25-40

Figure 4. Recommended hydraulic fluid cleanliness and filtration levels.

Consider an application with a normal-pressure system and a target cleanliness level of
ISO 16/13. According to Figure 4, a filtration level of 10-micron with an efficiency of
10 100 is required to achieve a cleanliness level of ISO 16/13. This means that unless
there is at least one filter in the system with a rating of 10 100, it is unlikely that a
cleanliness level of 16/13 will be achieved. If an audit of the existing filters reveals that
this level of filtration is not present somewhere in the system, then either the level of
filtration must be upgraded or the target cleanliness level revised downward. In practice,
it may be necessary to increase the efficiency of the filtering media (at target particle
size) if the contamination level is too high, or decrease efficiency if the fluid is cleaner
than required by the application, to optimize contamination control costs.
Having defined fluid contamination targets for a specific piece of hydraulic equipment,
regular PM tasks in respect of monitoring and controlling contamination can be
minimized through:
practical elimination of contaminant ingression; and
filter element condition-monitoring.
Eliminating Contaminant Ingression. Common points of contaminant ingress and
methods of exclusion are listed in Figure 5.
Filter Element Condition Monitoring. Return line filtration is a feature of most
hydraulic systems. Warning of filter-bypass is typically afforded by visual or electric
clogging-indicators. These devices indicate when pressure drop across the element is
approaching the opening pressure of the bypass valve. If the bypass valve opens at a
pressure drop of 3 bar the clogging indicator will typically switch at 2 bar. Replacing
these indicators with pressure gauges or transducers enables continuous condition
monitoring of the filter element. This enables trending of fluid cleanliness against filter
element pressure-drop, which can be used to optimize oil sample and filter change
intervals. Continuous monitoring of filter pressure drop can also provide early warning of
component failures and element rupture. Monitoring of pressure and offline filter
elements can be accomplished through the installation of differential pressure gauges or
transducers.

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Contaminant
Water

Source
Atmosphere.
Condensation.
Airborne moisture (marine
and tropical environments).
Wash down jets.
Coolant leaks.
Top-up fluid.

Soft particles

Oil oxidation and additive

depletion by-products.

Hard particles

Airborne (reservoir).
Airborne (cylinders).
Top-up fluid.

Method of Exclusion
Seal all reservoir penetrations and hatches. Protect
reservoir from weather if possible.
Maintain reservoir fluid level at maximum to minimize
headspace. Avoid short-run operation if possible.
Install desiccant breathers.
Install desiccant breathers or headspace bladders.
Instruct operators to direct jets away from breathers.
Substitute oil to water exchangers with oil to air.
Scheduled change-out of oil to water exchangers.
Maintain high standards in the storage and handling
of lubricants.
Control air, water and hard particle contamination.
Monitor fluid temperature and prevent high
temperature operation.
Seal all reservoir penetrations and hatches. Install air
breather filtration of 3 microns or better. Install
headspace bladders in extreme environments.
Install rod protectors (bellows) to protect cylinder rods
and wiper seals from damage, and provide an
additional barrier to contaminant ingression
Maintain high standards in the storage and handling
of lubricants. Pre-filter all top-up fluid.

Figure 5. Common points of contaminant ingress and methods of exclusion.

Maintaining Hydraulic System Settings to Manufacturers' Specifications
Implementing this routine involves:
1. Developing a procedure for checking the operation and adjustment of the various
circuit protection devices installed in the hydraulic system; and
2. Checking these settings at an appropriate service interval.
Faulty or incorrectly adjusted circuit protection devices can result in reduced machine
performance and cause damage to components through over-pressurization, cavitation
and aeration. Over-pressurization occurs when the pressure developed in any part of a
hydraulic circuit exceeds design limits. Over-pressurization can result in burst hoses,
blown seals and catastrophic failure of hydraulic components.
Cavitation occurs when the volume of fluid demanded by any part of a hydraulic circuit
exceeds the volume of fluid being supplied. This creates a partial vacuum within the
circuit, which causes the fluid to vaporize. Cavitation causes metal erosion, which
damages hydraulic components and contaminates the hydraulic fluid. In some cases,
cavitation can result in catastrophic failure of pumps and motors.
Aeration occurs when air contaminates the hydraulic fluid. Aeration can cause loss of
lubrication resulting in scuffing, adhesive wear and localized heating of sliding surfaces
and close fitting parts.
Machine manufacturers usually publish detailed instructions for checking and adjusting
hydraulic system settings. This information typically includes a list of equipment required
to carry out the checks. A set of pressure gauges is often the only equipment required. If
this information is not available for a specific piece of equipment, an appropriate

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procedure needs to be developed. If necessary, consult a fluid power engineer for

guidance.
Regular checking of hydraulic system settings not only ensures that the machine is
operating efficiently, but also gives early warning of faulty circuit protection devices before they cause component failures. Settings should be checked during initial
commissioning and when a system is re-commissioned, following a component changeout or major maintenance work. The frequency of routine checks depends on the type of
system and reliability objectives for the equipment. A service interval of 2,000 hours is
adequate for most systems.
Having defined an appropriate procedure and service interval for checking the settings of
a specific hydraulic system, labor and materials required to perform this task can be
minimized through:
installation of pressure-test and other temporary connection points in relevant
locations of the hydraulic circuit; and
permanent installation of pressure and flow monitoring instrumentation, where
appropriate.
Scheduling Component Change-Outs Prior to Failure
Implementing this routine involves:
1. Determining the useful service life of each component in the hydraulic system using
historical and/or predictive data; and
2. Scheduling their change-out when useful service life has been achieved, rather than
running to failure.
This routine is particularly pertinent to rotating components, i.e. pumps and motors.
When a pump or motor fails, large amounts of metallic particles are generated. These
particles circulate in the hydraulic fluid, often causing damage to other components
before the systems filters can remove them. In extreme cases, the contamination load can
clog the filters, which results in unfiltered fluid being circulated through the system.
A pump or motor that fails in service is almost always more expensive to rebuild than one
that is removed from service in a pre-failed condition. A failure in service usually results
in mechanical damage to internal parts of the component. As a consequence, parts that
would otherwise have been serviceable have to be replaced. In extreme cases,
components that would have been economical to repair become uneconomical to repair,
increasing the cost of component replacement by as much as 50%.
In a condition-based maintenance environment, the decision to change-out a pump or
motor is usually based on deterioration in volumetric efficiency or remaining bearing life,
whichever occurs first. Expected bearing life is influenced by a number of factors,
including the type and construction of the component, installation arrangement, and
circuit design, operating load and duty-cycle. Once these variables are known, bearing
life can be predicted by calculation. This information is usually available from hydraulic
component manufacturers on request. To minimize the chances of hydraulic components

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failing in service, predictive and/or historical data (where available) should be used to
schedule change-outs.
Having defined the useful service life of the major components in a specific hydraulic
system, PM task costs in respect of this routine are only required where component life
extension beyond that expected is highly desirable. For example, where the component
replacement cost is extremely high or machine availability for maintenance is limited.
Following Correct Commissioning Procedures
Implementing this routine involves:
1. Developing equipment-specific commissioning procedures; and
2. Training maintenance personnel to effectively carry out these procedures.
Incorrect commissioning during start-up can result in damage to hydraulic components
through cavitation, aeration and inadequate lubrication. In many cases, this damage will
not show itself until the component fails hundreds or even thousands of service hours
after the event.
A common misconception among maintenance personnel with limited training in
hydraulics is that because oil circulates through hydraulic components in operation, no
special attention is required during installation beyond fitting the component and
connecting its hoses. This is not the case.
Following correct commissioning procedures ensures that hydraulic components are
commissioned properly during installation or when a system is re-started after
maintenance. Improper commissioning is one of the most common causes of infant
mortality in hydraulic equipment.
To prevent component damage during initial start-up, obtain the machine manufacturers
commissioning procedures and train maintenance personnel to carry them out effectively.
If this information is not available for a specific piece of equipment, appropriate
procedures need to be developed. If necessary, consult a fluid power engineer for
guidance.
Having developed commissioning procedures for a specific piece of hydraulic equipment
and provided the necessary staff training, ongoing costs associated with this routine are
limited to training of new maintenance employees.
Conducting Failure Analysis
Implementing this procedure involves setting up a system that ensures:
1. All failed components are submitted for analysis; and
2. Feedback is adequately reported in a timely manner.
Root cause failure analysis is an essential element of any preventative maintenance
program. The logic for this is simple - if a failure occurs and the cause of failure is not
identified and rectified immediately, then the replacement component is likely to suffer a
similar fate.
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The objective of a preventative maintenance program is to reduce the occurrence of

premature component failures and unscheduled downtime. Even with the best
preventative maintenance program, a premature failure can still occur. Manufacturing
defects, circuit design faults and operator abuse are typical causes.
When a failure does occur, it is essential that a thorough analysis be conducted in order to
determine the root cause. Establishing the cause of failure enables remedial action to be
taken to prevent similar failures. Conducting failure analysis on hydraulic equipment is a
specialized task that requires a detailed understanding of hydraulic circuits, the
construction of hydraulic components and their modes of failure.
Reputable hydraulic repair shops can usually provide this service, which in most cases
will be included in their price to rebuild the component. If a new component has been
fitted and the failed component is not going to be repaired, failure analysis should still be
carried out. If necessary, consult a specialist in this area.
Once it is set up, there are no ongoing PM task costs in respect of a failure analysis
program.

Conclusion
Traditional PM activities require a constant investment in labor and materials. Aligning
the cost of these activities with the cost of the consequences of failure ensures that task
costs do not exceed failure costs. However, the economic reality of global competition
demands that continuous improvement is the new maintenance goal. This paper advances
an approach to the preventative maintenance of hydraulic equipment that provides
reliable assets and reduces or eliminates the costs associated with recurring PM tasks.
About the Author: Brendan Casey has more than 16 years experience in the
maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more
information on reducing the operating cost and increasing the uptime of your hydraulic
equipment, visit his Web site: www.InsiderSecretsToHydraulics.com

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References
Casey, B. (2002). Insider Secrets to Hydraulics, pp. 1-33.
Available: http://www.insidersecretstohydraulics.com
Casey, B. (2004). Preventing Hydraulic Failures, pp. 24.
Available: http://www.preventinghydraulic failures.com
Levitt, J. (2003). Complete Guide to Predictive and Preventive Maintenance, pp. 3-5.
Troyer, D. and Fitch, J. (2001). Oil Analysis Basics, pp. 16-17.

Copyright Brendan Casey www.HydraulicSupermarket.com 2005