The Power of Predictive Maintenance in Hydraulic Systems: Predicting

The Power of Predictive Maintenance in Hydraulic Systems: Predicting Failures with Oil Analysis

The Power of Predictive Maintenance in Hydraulic Systems: Predicting Failures with Oil Analysis

Hydraulic systems used in industrial facilities today require high performance and precision. The slightest failure in these systems can lead to production downtime and serious costs. For this reason, classical periodic maintenance approaches are now being replaced by predictive maintenance methods. The most basic component of these methods is oil analysis.

As Hidroman, we aim to provide our customers not only with products but also with integrated solutions for system health. Our predictive maintenance service both reduces maintenance costs and extends the life of the systems.

What is Predictive Maintenance?

Predictive maintenance is a maintenance strategy that aims to monitor the condition of components in the system before they fail and to determine maintenance needs in advance through data analytics. Its main difference is that:

Type of Care	Definition
Preventive Maintenance	Time-based, periodic control and part replacement
Breakdown Maintenance	After the component deteriorates, it is intervened
Predictive Maintenance	System health is monitored with real-time data, early diagnosis is made

Hydraulic Oil: Mirror of System Health

Oils used in hydraulic systems do not only provide power transmission; At the same time, it takes on critical tasks such as cooling, sealing, corrosion protection of the system and lubrication of components.

However, over time:

Microscopic particles accumulate in the oil.
Water, air and chemicals can get into the oil.
Heat and oxygen disrupt the chemical structure of the oil.

These changes are a harbinger of system failures. Therefore, the oil should be analyzed regularly.

What parameters are measured in oil analysis?

Analysis Parameter	Explanation
ISO 4406 Cleanliness Class	Indicates the amount of particles in the oil. Ex: 18/16/13
Viscosity	It refers to the fluidity of the oil. Extreme low/temperature is a problem.
Water Content (%)	Water deteriorates the film thickness of the oil; causes rust and cavitation.
TAN (Total Acid Number)	It indicates the level of oxidation in the oil. The increase indicates chemical aging.
Ferrometric Wear Analysis	Metal wear particles from parts such as valves, pumps and cylinders are measured.

Example:

An oil with an ISO 4406 value of 21/19/16 is outside the acceptable cleanliness limits. This indicates abnormal wear, inadequate filtration, or a lack of flushing in the system.

How Often Should Oil Analysis Be Done?

System Density	Recommended Oil Analysis Frequency
Heavy-duty / 24/7 operating systems	Monthly
Standard industrial applications	Every 3 months
Mobile hydraulic systems	At the beginning and middle of the season
Systems to be recommissioned	Before commissioning

Hidroman recommendation: The frequency of analysis should be customized according to the criticality of the system, environmental conditions and past failure history.

What to do with the oil analysis data?

Results from oil analysis:

Updating the filtration system
Premature change of oil
Checking components such as valves, pumps, cylinders in the system
Planning the flushing process
Achieving ISO 4406 cleaning targets

Provides.

In this way, not only does it prevent breakdowns, but also reduces energy consumption, increases production quality and increases system efficiency.

Hidroman's Predictive Maintenance Approach

The services we provide as Hidroman are as follows:

✅ On-site oil
✅ sampling ISO 4406 particle analysis (on-site or in laboratory)
✅ Determination of metal wear (ferrographic analysis)
✅ Viscosity, water ratio and TAN analysis
✅ Technical evaluation report and maintenance recommendations
✅ Filter solutions✅of
3 microns and below Supply of flushing unit and mobile analysis sets

"The system that speaks with data is understood before it breaks down, not after it is silenced."

Real Case: Pump Failure Is Prevented by Oil Analysis

The hydraulic pump in the rotary table system of one of our customers started to experience a low flow problem before the end of 1 year. In the oil analysis:

ISO 4406 value: 22/20/18 (heavily dirty)
Water rate: 0.23% (above limit)
TAN: 2.8 (2 times normal)

These data pointed to both the filtration problem and oxidation caused by high temperatures. Filter systems were updated, flushing was done and the oil was changed. The system has been running smoothly for 6 months.

Predictive maintenance in hydraulic systems is not a luxury, but a necessary investment. Early detection, especially with oil analysis, can extend system life by up to 30% and reduce maintenance costs by 40%.

Hidroman is ready to be your solution partner in predictive maintenance with its technical knowledge and field experience.

All hydraulic components required for your machine are offered to you from a single address. With 20 years of experience in hydraulic system engineering, strong collaborations with the world's distinguished brands and following new technologies in the sector, we offer you perfect and competitive solutions.

We produce special solutions for you.

Our Hydraulic System Engineers produce package solutions for you. Hydraulic Components such as Hydraulic Hose, Bent Pipe with Union, Connection Element, Pipe Clamps, Hydraulic Filters, Line Type Valves that your machine needs are determined on-site by our Engineers and all equipment suitable for your needs are listed after the necessary system calculations and offered to you as a package solution.

Our customers choose Hidroman companies due to the creativity and efficiency of our employees. We are committed to diversity, innovations, technology, and we invest in skills through training and development.

We understand you very well with our machine manufacturing experience dating back to 1950.

OUR BRANDS

We manufacture in many areas under the roof of Hidroman. We manage each product group and production groups separately to increase our service quality. For more information: www.hidroman.com.tr

As Seide Makina A.Ş., we establish Hydraulic Hose Production Lines with Fittings and Twisted Steel Drawn Pipe Production Lines with Fittings. For more information:

www.seidehydraulics.com

www.seidemachine.com

As Heben Makina, we produce mobile construction equipment with hydraulic systems.

As Hydraulic Market, we offer hydraulic equipment and services to our customers via the internet with our online sales platform in Türkiye. For more information: www.hidrolikmarket.com.tr

As Hydraulic Store, we offer hydraulic equipment and services to our customers via the internet with our online sales platform abroad.

As Pneumatic Market, we offer our customers pneumatic equipment and services over the internet with our online sales platform in Türkiye. For more information: www.pnomatikmarket.com

As Ata Hydraulic Cylinder, we manufacture hydraulic cylinders and perform hydraulic cylinder revisions.

As Hydraulic Service, we are not only there for you in case of Hydraulic System Failures and Sudden Stops, but also ensure that your hydraulic system machines operate with more efficiency with our predictive maintenance work. For more information: www.hidrolikservis.com.tr

Customer - Supplier - Employee Collaboration on Sustainability
Great marketing is a powerful tool for change. We work with the world's leading expert brands on social and environmental issues, creating work that addresses stereotypes, changes minds and encourages healthier and more sustainable consumer choices.

Our ethical standards
We aim to create a consistent culture across Hidroman companies and locations, helping our employees apply high standards and make the right decisions. Respect for human rights is a fundamental principle for Hidroman and we apply rigorous privacy and data security standards.

Hydraulic Engineering Solutions That Suit Your Needs
Meet Hydraulic Component Kits that suit your needs!

We work to speed up your manufacturing with Good Engineering solutions.

With our ready-made kits, we undertake your stock costs and assembly costs, so your valuable time is yours. We think and implement everything so that you can produce better machines.

Perfect Solutions with Our Transparent Approach
With our transparent manufacturing approach, we open the doors of every stage of our production to you. Don't waste your valuable time on hydraulic components, we work to offer you good engineering solutions. Let us do all your work on hydraulic components, focus on your work without wasting time on your machine's hydraulic system improvements.

Value Added Service
· Independent application consultancy and engineering

· Active support with the selection of suitable components considering technical and economic criteria

· Analysis and optimization of the current design and development of the new system

· On-site assembly training and hydraulic seminars

Fast Supply
Meet our flexible customer-oriented solution methods; we produce special solutions for you so that you do not have problems with supply.

Our Strengths - Your Advantages
· We make the necessary machinery and equipment investments on your behalf to increase your efficiency and performance.

· We produce extra values by reducing the total cost.

We open branches for you, at your location, specifically for you and only to serve you.

Hidroman Makes a Difference with Its Customer-Focused After-Sales Service Approach!

Hidroman, which has a 20-year history in the Hydraulic System sector, offers an after-sales service approach focused on increasing customer satisfaction with maintenance contracts that aim to reduce the operating costs of its customers and increase efficiency.

Hidroman, the innovative brand of the Hydraulic Equipment sector, continues to make a difference with its after-sales services positioned in accordance with the needs of its customers as well as the services it offers before and after sales. Hidroman, which aims to provide uninterrupted and safe services to its customers with its operations throughout Turkey and Europe, defines a perfect customer experience as product reliability and after-sales service reliability.

Hidroman, which has made being with its customers throughout the life of the product in order to create brand loyalty a part of its corporate culture, organizes the services it offers within the scope of After-Sales Services under four main headings as supervision and assembly, commissioning, maintenance-repair and original spare parts supply. Supervision service; It covers consultancy and training services on issues such as efficient hydraulic equipment selection, rules to be considered for correct product installation and connection of the pump with other installation equipment. After the installation of the device, the commissioning service is also carried out by Hidroman’s expert technical staff.

In hydraulic equipment technologies used in many different areas, malfunctions may occur over time due to operating conditions. During the 10-year life of a piece of equipment, the initial investment cost and repair expenses constitute 10-15% of its total cost, while the remaining expenses are due to energy consumption. Hidroman examines all processes from the selection of the hydraulic system to all the equipment on which the hydraulic system will operate, and offers “efficient system solutions that aim to minimize energy consumption”.

In addition, with preventive and protective maintenance agreements, it aims to reduce the risk of failure of the device, extend its life and ensure that the device operates with high efficiency and low energy consumption.

Thanks to the advantages offered by Hidroman with preventive and protective maintenance services, the budget allocated by its customers for maintenance pays for itself in a short time.

In businesses where uninterrupted service is important, Hidroman intervenes in malfunctions in a short time and minimizes damages caused by labor losses. Offering its customers a 10-year original spare part guarantee in the hydraulic systems it sells, Hidroman delivers tested original spare parts from stock in case of malfunction, shortens malfunction periods and eliminates disruptions that may occur during this period.

Hidroman After-Sales Services department stated that they offer annual maintenance services in accordance with the needs of the business. It states that their aim with maintenance services is to increase hydraulic system efficiency, ensure continuous operation of the hydraulic system and to detect, monitor and prevent possible malfunctions in operating equipment and devices by using technological measurement, control, analysis and monitoring devices.

We aim to standardize the service provided by our authorized services by inspecting them at certain intervals. In addition, we follow the calibration processes of our technical equipment in line with quality certificates. We attach importance to communication channels to be established in order to increase customer satisfaction both in sales and service. We are at the service of our customers 24/7 with our competent services that can answer the questions of our customers who buy our products by trusting our brand. In order to measure the customer satisfaction rate, we organize surveys for our customers at certain intervals through our call center. As a result of the feedback we receive, we take action quickly to meet the expectations of our customers. The nature of the products and services in the market is changing rapidly with the effect of the digital transformation we are experiencing due to technological developments. For this reason, we see the development in our products and services as a constantly living process and we continue our improvement and development works without stopping.

The Power of Predictive Maintenance in Hydraulic Systems: Predicting Failures with Oil Analysis

The Power of Predictive Maintenance in Hydraulic Systems: Predicting Failures with Oil Analysis

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