September 14, 2004 

'Inside Hydraulics' Newsletter

1. Hydraulics on video
2. The proactive maintenance imperative
3. Interpreting case leakage from hydrostatic transmissions
4. Content for your web site or e-zine
5. Help us spread the word
6. Tell us what you think


Hydraulics on video

A series of hydraulic training videos are now available through our online store. Developed and produced in partnership with major hydraulic equipment manufacturers, these videos provide excellent visual instruction in the following subject areas:

  • Hydraulic fundamentals
  • Troubleshooting
  • Interpretation of hydraulic symbols
  • Fluid cleanliness
  • Hydrostatic transmissions

For more information, visit

2.   The proactive maintenance imperative

Over the last two and a half years, I have received a lot of feedback from you, my Newsletter readers. One question that pops up regularly is: "Why do you give away so much valuable information in your Newsletter and on your web sites?"

I've spent the better part of 16 years working in and running hydraulic repair shops i.e. rebuilding hydraulic components. During this time I kept seeing the same pattern: Failed component comes into shop along with concerned customer who wants to know why it has failed after a relatively short time in service. Based on what I saw after tear-down, I would explain the cause of failure - for example, high contamination levels, wrong oil viscosity, high temperature operation, cavitation, faulty circuit protection devices and so on. Customer leaves thousands of dollars poorer with rebuilt component and a hard-learned lesson on hydraulic equipment maintenance.

For as long as there are hydraulic equipment owners, mechanics and maintenance people out there who believe that hydraulics don't require any special kind of attention, this cycle will continue. In an effort to bridge the knowledge gap on what needs to be done to get maximum life from hydraulic components, I publish this Newsletter and have written Insider Secrets to Hydraulics and it's sequel, Preventing Hydraulic Failures.

Over the past 30 years, the performance, sophistication and operating pressures of hydraulic equipment have increased significantly. This is particularly true in the case of mobile hydraulic equipment. As a result, modern hydraulic equipment is not only more expensive to fix when it breaks, proactive maintenance is imperative to maximize service life and minimize operating costs. It's not realistic to expect (as many equipment owners do) to run a hydraulic machine for 10,000 hours, without checking anything more than the fluid level, and not have any problems.

Six routines must be followed in order to minimize the chances of your hydraulic equipment suffering costly, premature component failures and unscheduled downtime:

  • Maintain fluid cleanliness;
  • Maintain fluid temperature and viscosity within optimum limits;
  • Maintain hydraulic system settings to manufacturers' specifications;
  • Schedule component change-outs before they fail;
  • Follow correct commissioning procedures; and
  • Conduct failure analysis.

An effective, proactive maintenance program requires time, effort and some expense to implement. But it is cost-effective. The investment is quickly recovered through savings as a result of improved machine performance, increased component life, increased fluid life, reduced downtime and fewer repairs.

So if you own, operate or maintain hydraulic equipment, are serious about minimizing your running costs and your current maintenance practices are unsophisticated or non-existent, start implementing a proactive maintenance program today. Reading this Newsletter is certainly a step in the right direction.

"Thanks for the great work on the two publications, Insider Secrets to Hydraulics and Preventing Hydraulic Failures. I have been in the hydraulics business for the past 20 years and it is very difficult to find any decent material on hydraulic maintenance, troubleshooting and failure analysis. These two books cover it all in easy to understand language... I conduct hydraulic training courses and plan to purchase copies to distribute to my students to share your practical approach to understanding a not so understandable subject."

Paul W. Craven, Certified Fluid Power Specialist
Motion Industries, Inc.

3.   Interpreting case leakage from hydrostatic transmissions

To learn how to determine the condition of a hydrostatic transmission using case leakage, read Brendan Casey's article in the July-August Issue of Machinery Lubrication magazine, available here. To receive a complimentary subscription to this informative magazine (US and Canada only) go to:

4. Content for your web site or e-zine

Need some fresh content for your web site or e-zine? You now have permission to reprint these 'Inside Hydraulics' articles on your web site or in your e-zine, provided:

1. Each article is printed in its full form with no changes.

2. You send an e-mail to to advise us where you'll be publishing them.

3. You include the following acknowledgement at the end of each article:
About the Author: Brendan Casey has more than 16 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulic equipment. For more information on reducing the operating cost and increasing the uptime of your hydraulic equipment, visit his web site:

5. Help us spread the word

If you've found our 'Inside Hydraulics' newsletter interesting and informative, then chances are you have a colleague who would too. Help spread the word about 'Inside Hydraulics' by forwarding this issue to a colleague. If they share your interest in hydraulics, then they will surely appreciate being told about this newsletter.

New subscribers can get the newsletter by completing the form at

6. Tell us what you think

We would love to hear what you think of this issue of our 'Inside Hydraulics' newsletter. And of course, if you have any suggestions for future issues, please send us those too.

Just e-mail the editor at:

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