Katerina Swanson
Diesel fuel in hydraulic fluid is a common issue, often occurring by accident when refuelling a machine. Diesel fuel is an aromatic hydrocarbon, and as such, it can cause common EPDM (Ethylene-Propylene) O-rings and seals to become overly spongy, then dry out and fail. This can be prevented by draining the hydraulic tank and replacing the fluid. Some experts recommend diluting hydraulic oil with diesel to improve turning forces in hydraulic steering systems, but this is not recommended without consulting the manufacturer.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Impact on hydraulic system | Diesel fuel can thin the hydraulic oil, which may prevent proper lubrication and hinder performance. |
| Impact on "O" rings and seals | Diesel fuel, as an aromatic hydrocarbon, can cause EPDM and Neoprene "O" rings and seals to become overly spongy, then dry out and fail. |
| Safety | Diesel is more flammable than hydraulic fluid. |
| Lubrication | Diesel has some lubricating properties, but its effectiveness depends on the specific pump. |
| Durability | Using diesel in a hydraulic system can reduce the durability of the system. |
| Flushing | If diesel is accidentally added to a hydraulic system, flushing and replacing the hydraulic fluid may be necessary to prevent damage. |
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What You'll Learn
How to prevent diesel fuel contamination of hydraulic fluid
To prevent diesel fuel contamination of hydraulic fluid, it is important to be cautious and careful when refuelling. Here are some tips to prevent diesel fuel from contaminating hydraulic fluid:
Be Mindful During Refuelling: Pay close attention when refuelling machinery. Always verify that you are filling the correct tank with the appropriate fuel type. Take your time and ensure that the diesel cap and hydraulic fluid cap are clearly distinguished and accessible to avoid any mishaps.
Secure Fuel Caps: Keep fuel caps securely closed when not in use. Ensure that the diesel cap and hydraulic fluid cap are properly labelled and distinguishable to prevent accidental mix-ups.
Use Locking Mechanisms: If possible, utilise locking mechanisms on hydraulic fluid tanks. This adds an extra layer of protection by making it more deliberate to open the tank, reducing the chances of accidental refuelling with diesel.
Maintain Proper Storage and Handling: Store diesel fuel and hydraulic fluid separately and clearly labelled. Ensure that the handling procedures for both fluids are well understood by all operators to prevent accidental cross-contamination during transfer or storage.
Regular Inspection and Maintenance: Regularly inspect machinery for any signs of leakage or damage that could lead to fluid contamination. Maintain and service the equipment as recommended by the manufacturer, paying close attention to the hydraulic system.
By following these preventative measures, you can significantly reduce the risk of diesel fuel contaminating hydraulic fluid, thus avoiding potential damage and costly repairs.
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What to do if diesel is put in the hydraulic tank
If diesel is put in the hydraulic tank, the best course of action is to drain the hydraulic tank and replace it with new hydraulic oil. This is because diesel fuel can thin the hydraulic oil, which may prevent proper lubrication and hinder reaching the correct pressure.
If the machine has not been started after the diesel was added, simply draining and refilling the tank may be sufficient, and no further issues are expected. However, if the machine has been run with diesel in the hydraulic tank, it is recommended to take the machine to a mechanic for further inspection and servicing.
In some cases, it may be possible to add gear oil to the hydraulic tank to counteract the diesel fuel and thicken the hydraulic oil. However, this may not be suitable for all machines, and it is essential to consult a professional before attempting this solution.
It is important to act quickly and avoid starting the machine if diesel has been added to the hydraulic tank. Circulating the diesel throughout the system can cause it to contaminate other components, leading to more extensive repairs.
Additionally, it is worth noting that diesel fuel can weaken rubber seals in pumps, hoses, valves, and rams. Therefore, it is crucial to address the issue promptly and ensure that all contaminated hydraulic fluid is drained and replaced.
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Effects of diesel fuel contamination on hydraulic fluid
Diesel fuel contamination in hydraulic fluid can have several effects on the hydraulic system. Firstly, it is important to note that diesel fuel is not a suitable lubricant for hydraulic systems, and its presence can hinder the lubrication process. Diesel fuel can thin the hydraulic oil, preventing proper lubrication and affecting the system's ability to reach the correct pressure. This may lead to excessive wear and increased rates of corrosion within the system.
In addition to the lubrication issues, diesel fuel contamination can also impact the rubber seals within the hydraulic system. The diesel fuel can soften the rubber seals in pumps, hoses, valves, and rams, leading to potential leaks and reduced system efficiency.
Furthermore, diesel fuel contamination can cause issues with the fuel pump. Contaminated fuel can put extra stress on the fuel pump, leading to potential wear and tear on its internal components. This can result in costly repairs or replacements.
It is important to address diesel fuel contamination promptly to prevent further damage to the hydraulic system. Draining the contaminated hydraulic fluid and replacing it with fresh fluid is often recommended. However, it is crucial to consult a professional mechanic or seek specialized advice for the specific hydraulic system in question.
While diesel fuel contamination in hydraulic fluid can have negative effects, early detection and proper remedial actions can help mitigate potential issues. Regular sampling, testing, and maintenance of hydraulic systems can help identify any contamination issues before they cause significant harm.
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How to fix diesel-contaminated hydraulic fluid
If you've accidentally contaminated your hydraulic fluid with diesel, the best course of action is to drain the hydraulic oil and replace it with new oil. This is because diesel acts as a thinning agent, reducing the viscosity of the hydraulic fluid. This, in turn, may hinder lubrication and prevent the system from reaching the correct pressure.
If you are unable to drain and replace the hydraulic fluid, you can try adding gear oil to the mixture to counteract the thinning effects of the diesel. For example, adding 2 quarts of 90 weight gear oil to hydraulic fluid contaminated with diesel can help to restore the fluid to a thicker consistency.
It is important to act quickly if you discover that you have contaminated your hydraulic fluid with diesel. If the diesel is allowed to circulate through the system, it may cause damage to the seals, requiring a flush of the system and replacement of the filters.
In some cases, a small amount of diesel contamination may not cause significant harm if it is not circulated through the system. However, it is always best to err on the side of caution and consult with a professional mechanic if you are unsure about how to proceed.
Additionally, it is worth noting that some sources suggest that intentionally adding a small amount of diesel to hydraulic fluid can improve the performance of hydraulic steering systems by reducing viscosity and improving turning forces. However, this practice may not be suitable for all systems, and it is important to consult with a professional before attempting any modifications.
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Cost implications of diesel fuel contamination of hydraulic fluid
Diesel fuel contamination of hydraulic fluid can have significant cost implications for individuals and businesses. The financial impact can vary depending on the extent of the contamination, the type of equipment involved, and the remedial actions taken.
One of the immediate costs associated with diesel fuel contamination of hydraulic fluid is the need for specialised equipment and expertise to address the issue. In some cases, individuals may have to incur expenses for professional assistance, such as hiring mechanics or engineers, to properly diagnose and rectify the problem. This can include costs for labour, parts, and additional fluids required for flushing or replacement.
The extent of contamination plays a crucial role in determining the financial burden. Minor contaminations, if addressed promptly, may require only a simple fluid drain and refill. However, more severe cases, where diesel fuel has been circulated throughout the system, can necessitate multiple flushes, filter replacements, and even repairs or replacements of damaged components. The complexity and cost of remediation increase with the level of contamination.
Contamination of hydraulic fluid can lead to operational inefficiencies and potential downtime for equipment. This downtime can result in lost productivity and revenue for businesses, especially in industries that rely heavily on hydraulic machinery, such as construction or manufacturing. The financial impact of lost productivity can be substantial, depending on the nature of the business and the extent of the disruption.
In some cases, diesel fuel contamination may void equipment warranties, leading to unexpected financial burdens. Businesses or individuals may have to bear the full cost of repairs or replacements without the coverage provided by the manufacturer's warranty. This can be especially costly for high-value equipment with intricate hydraulic systems.
Furthermore, diesel fuel contamination can cause long-term damage to hydraulic systems, resulting in reduced equipment lifespan. This premature ageing of machinery can lead to additional capital expenditures for replacement or upgrades sooner than anticipated. The frequent need for repairs or replacements due to contamination issues can significantly impact a company's bottom line.
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Frequently asked questions
The first thing to do is not to start the machine. Then, drain the hydraulic tank. If you have EPDM (Ethylene-Propylene) O-rings, you may need to flush the system, as diesel can cause the O-rings to get overly spongy, then dry out and fail.
Circulating the diesel will require you to service the oil twice. While diesel won't cause significant harm, it can thin the oil, which may hinder lubrication.
Mixing diesel and hydraulic oil can cause foaming at the pump and seal failure.
Diesel can weaken the rubber seals in pumps, hoses, valves, and rams.
Pay attention to where the diesel tank and hydraulic tank are located and always check before filling.
