General Safety Rules for Hydraulic Technicians

When working on a machine’s hydraulic circuit, review the drawings and specifications of the interconnected parts.

Turn the electrical switches related to the equipment on and off (the electric motor and electrical control elements).

Isolate and disconnect the unit you’ll be servicing from the central hydraulic system (the relevant valves and connecting elements). Mark the components you disconnected by drawing a sketch showing where they were removed from.

If the hydraulic pump is driven by a motor, remove the couplings between them before beginning maintenance. This will prevent accidents that could occur from a sudden start-up.

Be aware that vertically positioned cylinders can move downward due to gravity and, if present, the effect of the load on them, and take the necessary precautions (blocks, etc.) to brake this movement.

While the pressure is at zero, check the system for leaks, cracks in pipes and hoses, and looseness in pipe connections. Don’t forget that these cracks can cause great harm to the surroundings under high pressure and can pierce through like a bullet.

Seal all pipe ends and the inlet/outlet ports of valves and other components so they’re protected from the environment and won’t let foreign matter enter.

When removing components in the circuit, mark them to indicate where they were removed from, and make sure to reinstall them in their original locations after the repair. For example, if a valve’s spool is installed incorrectly, it can cause major accidents in presses.

If you know there’s a spring inside a part you’re disassembling, don’t forget that sudden release can throw small parts at you, and take the necessary precautions for this.

While performing maintenance and repairs, and while running the system, follow the recommendations in the manuals provided by the manufacturer.

Readjust all pressure regulating valves using a well-calibrated pressure gauge.

After repair and maintenance, or when running the system for the first time, review the components and the system very carefully.

Always use the most suitable tools when performing maintenance and repairs.

When removing and installing hydraulic components, don’t use impact or force that would damage them.

When replacing connecting bolts and coupling elements, pay attention to the proper dimensions, pressure limits, operating temperatures, and safety factors.