Informative oil analysis

Contamination of hydraulic oil by solid materials such as dust or particles of metal or seals is one of the most frequent causes of damage. The source of the particles could be unfiltered fresh oil, an inadequate filter design, a poorly filled tank, erosion of components or the entry of dirt particles during assembly. The first step in rectifying this problem is to examine the whole system, including the use of particle counters on site if required. By doing this, you can be absolutely sure of the cause of the damage and take precisely the measures required to prevent the entry of dirt, such as installing filter systems.

Contamination of hydraulic oil with water causes corrosion, cavitation, sludge formation or premature ageing of the oil. Water contamination can be caused by condensation, oil-water coolers, cleaning with steam jets, severe temperature fluctuations, spray water entry or defective cylinder seals. To prevent water contaminating hydraulic oil, HANSA‑FLEX Fluid Service first performs an intensive inspection of the entire hydraulic system looking for possible causes. Then the experts draw up a list of suitable measures, such as the use of desiccant breathers or vacuum dewatering systems and, if you wish, implement them.

Too little oil in the tank, leaking suction lines to the pump or inadequate bleeding: too much undissolved air in hydraulic oil can lead to component damage. Air-enriched hydraulic oil is prone to premature ageing. There is also the risk of bubbles in the oil-gas mixture imploding (cavitation) due to pressure and temperature peaks or exploding under too much compression (diesel effect). From the design of the oil tank to the selection of suitable fluid right up to checking the effectiveness of the air separation components: HANSA‑FLEX’s experienced fluid and hydraulic experts advise you on how to avoid oxidation, cavitation or micro-diesel effects.

Excessive operating temperatures reduce the performance of hydraulic oil. The consequences: ineffective additives, accelerated oil ageing, acid formation in the oil and, last but not least, damage to components. Extreme pressure and temperature peaks lead to overstressing of the fluid. Excessive stress breaks up the chains of molecules in the oil, which adversely affects its flow characteristics. This can also lead to additives losing their effect, shorter oil change intervals and higher wear on components. Monitoring temperature and pressure, either as part of the oil analysis or using sensors, can be worthwhile in preventing the damaging effects of high temperatures.

Mixing different hydraulic oils often leads to a worsening of their physical properties. Mixing often happens unintentionally when topping up, removing or reattaching equipment or changing the oil. Even combinations of oil with the same classification can result in elastomeric components and hydraulic hose lines swelling, foam formation, less effective air separation or sludge in the oil. Mixing hydraulic oils also results in loss of all rights under the machine manufacturer’s warranty. No combination of oils can be guaranteed to be 100 % problem-free. Therefore, you should always avoid mixing different oils.