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Cranes rely heavily on hydraulic systems to lift heavy loads, extend booms and perform slewing movements. Poor hydraulic maintenance is one of the top causes of sudden crane breakdowns on construction sites. Proper daily checks and maintenance can effectively reduce system failures and extend the service life of your crane.
1. Keep hydraulic oil clean and replace it on schedule
Contaminated hydraulic oil is the biggest killer of hydraulic components. Dust, metal debris and water inside the oil will scratch pumps, valves and cylinders.
Always use the hydraulic oil grade recommended by the manufacturer. Inspect oil color and viscosity regularly. Replace oil and filter elements according to working hours, especially for machines operating in dusty or humid regions.
2. Inspect hydraulic seals and hoses frequently
Seals and rubber hoses are vulnerable wearing parts. High pressure, heat and UV exposure will lead to aging, cracking and oil leakage.
Check all oil seals, gaskets and hydraulic hoses before operation. Replace swollen, cracked or leaking hoses immediately. Do not try to repair damaged hoses temporarily, as burst hoses may cause dangerous lifting accidents.
3. Avoid overloading and improper operation
Overloading will generate extreme pressure spikes inside the hydraulic circuit, damaging hydraulic pumps and relief valves. Sudden boom movements also shock the whole hydraulic system.
Operators must follow rated load charts. Avoid rapid start, stop and sharp slewing. Warm up the hydraulic system at low pressure before heavy lifting in cold weather.
4. Monitor hydraulic pressure and temperature
Abnormal pressure or overheating indicates hidden faults. High temperature will accelerate oil deterioration and seal aging.
Check pressure readings during routine inspections. If the hydraulic oil temperature keeps exceeding the standard range, stop working and check the cooler, oil level and possible internal leakage.
5. Prepare critical hydraulic spare parts for site backup
Common hydraulic spare parts should be stocked on-site to shorten downtime:
• Hydraulic filter elements
• Seals kits for cylinders
• Hydraulic hoses and connectors
• Relief valves, solenoid valves
• Hydraulic pumps and motor repair kits