HYDRAULICS Hydraulic systems don’t often fail suddenly. Most problems build up slowly, and fluid contamination is usually at the centre of it. It doesn’t get much attention because it isn’t obvious. There’s no dramatic breakage. But it’s the most common reason hydraulic power packs become unreliable, inefficient, or need early replacement. Contamination tends to be treated as background noise. It’s understood in theory but rarely prioritised in day-to-day maintenance. It enters power packs in quiet, routine ways — from filling up with oil that’s been stored in an open container, or using a funnel that wasn’t properly cleaned, or simply through a worn breather letting in moisture and dust. Once inside, it moves with the oil through the pump, control valves, and any downstream circuits, slowly wearing down parts that were designed to run clean. Because hydraulic power packs are usually seen as self-contained and reliable, there’s often an assumption that if it’s running, it must be fine. But these units operate on tight tolerances. Even small particles — metal from internal wear, rubber from seals, dust from the environment — can cause lasting damage over time. They scratch surfaces, block ports, and disrupt valve performance. If water enters the reservoir, corrosion and fluid breakdown soon follow. In compact power packs where cooling is limited and filtration capacity is modest, the effect is more concentrated and often more severe. This usually plays out in familiar ways: the system runs hotter, the response slows, pressure drifts. Valves Hydraulic power packs rely on clean fluid to perform reliably. Yet contamination - from moisture, dust, or wear particles - is the silent culprit behind most failures. H&P explores why fluid cleanliness matters, the common pitfalls in maintenance, and how simple, consistent practices can extend power pack life and reduce costly downtime. 20 HYDRAULICS & PNEUMATICS June 2025 www.hpmag.co.uk Keeping power packs running smoothly through clean fluid A technician connects a hydraulic line to a skimmer unit, highlighting the vital role of fluid cleanliness and maintenance in ensuring hydraulic power packs reliably deliver the pressure and flow needed to operate such equipment.
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