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… you can avoid expensive production downtime!

Filter elements are technically high-quality products. In order for them to perform their function reliably, they must be handled professionally and carefully.

SMALL LIST, BIG IMPACT

Here are the six most important rules for operating hydraulic systems with filters:

• Always fill hydraulic fluids through a fine filter
• Replace filter elements after flushing a system
• Check the maintenance indicator daily after the operating temperature has been reached
• Carry out analyses of the fluid samples or online measurements using particle counters
• Always refill hydraulic fluids through a fine filter
• Follow the operating instructions exactly when replacing the filter elements

FLUSHING AND RUNNING IN

Before a hydraulic system is put into operation, assembly dirt must be removed by flushing. To do this, the filter elements are replaced with flushing elements, which are then reinstalled or replaced after flushing. The oil flow is cleaned with a portable bypass filter system, using a medium that is compatible with the subsequent hydraulic fluid. The assembly dirt collects in the system’s filter. Smaller or less sensitive systems can be flushed with built-in filters during the running-in period if the system is gradually operated without load up to the maximum delivery volume.

REFILLING HYDRAULIC OIL

To ensure the required purity class, hydraulic oil should always be refilled through a fine filter in the event of leaks. A filling unit or, if available, a return or line filter can be used for this. Maintenance indicators from various series help to monitor the condition of the filters.

PERMANENT MONITORING OF CONTAMINATION

Every filter should be equipped with an optical or optical/electrical maintenance indicator to monitor the remaining dirt holding capacity and to detect the need for an element change. Optical indicators are checked daily at operating temperature: a red pin is pressed in and shows the status – if it remains pressed in, the element is functional, if it pops out, the element must be changed after the shift. Electrical indicators also give a signal. Both types of indicators should be checked at operating temperature to avoid false alarms due to increased viscosity during cold starts. If cold starts are frequent, cold start suppression is useful.

ELEMENT CHANGE

If the maintenance indicator signals a dirty filter element, the remaining dirt holding capacity is usually sufficient for a few more working days. The filter element should still be changed promptly, as a delayed replacement can, in extreme cases, lead to the element collapsing. Such a collapse could damage the filter matrix and flush already trapped dirt into the system, often leading to a total failure.

For filters without a maintenance indicator, the following intervals for filter inspection should be observed:

• 24 hours after commissioning the system
• After the running-in period (50 – 100 operating hours)
• Normal maintenance (every 300 – 500 operating hours)

In any case, the element change must be carried out carefully and precisely according to the operating instructions.

CYCLIC MONITORING OF CONTAMINATION

With targeted monitoring, filters can also be used as a tool for monitoring wear on hydraulic system components. By regularly documenting the filter change intervals, the operator can determine whether the intervals are shortening, which indicates increased wear. A qualitative and quantitative analysis of the used filter and a fluid sample from the system can help to determine the origin of the dirt particles and identify the cause of the wear.

Based on the analysis results, the affected components can be repaired preventively to avoid total failures and production interruptions. Regular quantitative contamination determination of hydraulic fluids also contributes to this goal. Samples taken at specially designated sampling points or recorded through online particle measurement ensure compliance with the required purity class and the functionality of the system.

With suitable testing methods and specially developed devices, the economical operation of filters and hydraulic systems can be controlled and monitored. This way, your system always stays in top shape!

All necessary spare parts can be obtained quickly, easily and conveniently in the FILCOM online shop. Over 25,000 quality items ensure that every customer finds exactly the product that meets their needs.

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