11 Simple Steps for Flushing a Hydraulic

System
Noria Corporation

I was recently asked about a procedure for flushing hydraulic systems in order to change
from one type of fluid to another. Among the ideas mentioned involved using brake cleaner,
diesel fuel or some type of acid cleaning.
However, brake cleaner includes a number of chemicals such as acetone and
tetrachloroethylene. These solvents are known to cause problems for nitrile, neoprene,
millable polyurethane and silicone seals. Ethylene-propylene (EPDM) seals have a very
poor petroleum oil and solvent resistance, and are not recommended for exposure to
aromatic hydrocarbons or diesel oil.
Therefore, depending on the types of O-rings and seals in your hydraulic system, the
solvents used in brake cleaner and diesel fuel can dry out or damage your system’s O-
rings. There is also the issue of compatibility with the new type of fluid that has been
chosen.
For these reasons, it's important to understand flushing properly or to use an experienced
oil flushing service provider who can help you get the job done right.
In his article for Machinery Lubrication titled “Cleaning and Flushing Basics for Hydraulic
Systems and Similar Machines,” Tom Odden outlines the procedure for thoroughly cleaning
a hydraulic system. This would be the only “one-size-fits-all” solution and an example of
best practices. It involves mechanical and chemical cleaning of both the components and
the system.

of lubrication professionals say mechanical

28% cleaning is the flushing method used most

Step 1
While the fluid is at operating temperature, completely drain the system, paying attention to
the reservoir, all lines, cylinders, accumulators, filter housings or any area of fluid
accumulation. Also, replace the filters.

Step 2
With a lint-free rag, clean the reservoir of all sludge and deposits. Make sure the entire
reservoir is free of any soft or loosened paint.

Step 3
Flush the system with a lower viscosity fluid that is similar to the fluid to be used. A
Reynolds number between 2,000 and 4,000 should be selected to achieve enough
turbulence to remove particles from the lines. Stroke valves frequently to ensure they are
thoroughly flushed. The fluid should be filtered and the flushing should continue until
reaching one level beyond the system’s target cleanliness levels. For example, if the target
is ISO 15/13/11, continue to flush the system until ISO 14/12/10 is reached.

Step 4
Drain the flushing fluid as hot and as quickly as possible. Replace the filters and
inspect/clean the reservoir again.

Step 5
Fill the system to approximately 75 percent with the fluid to be used. Bleed/vent the pump. If
the pump has a pressure relief or bypass, it should be wide open. Run the pump for 15
seconds, then stop and let it sit for 45 seconds. Repeat this procedure a few times to prime
the pump.

Step 6
Run the pump for a minute with the bypass or pressure relief open. Stop the pump and let it
sit for a minute. Close the bypass and permit the pump to operate loaded for no more than
five minutes. Allow the relief valve to lift to confirm that it is flushed as well. Do not operate
the actuators at this time. Stop the pump and let the system sit for about five minutes.

Step 7
Start the pump and operate the actuators one at a time, allowing fluid to return to the
reservoir before moving to the next actuator. After operating the final actuator, shut down
the system. Keep an eye on the fluid level in the reservoir. If the level drops below 25
percent, add fluid and fill to 50 percent.

Step 8
Refill the reservoir to 75 percent and run the system in five-minute intervals. At each
shutdown, bleed the air from the system. Pay close attention to the system sounds to
determine if the pump is cavitating.
Step 9
Run the system for 30 minutes to bring it to normal operating temperature. Shut down the
system and replace the filters. Inspect the reservoir for obvious signs of cross-
contamination. If any indication of cross-contamination is present, drain and flush the
system again.

Step 10
After six hours of operation, shut down the system, replace the filters and sample and test
the fluid.

Step 11
The sampling frequency should be increased until you are confident that the system fluid is
stable.

Flushing Tactics
There are a lot of different ways to flush out a machine. You want to match the flushing
method to the flushing condition. Following are common tactics for accomplishing this:
Drawdown Filtration/Separation — Contaminants or insoluble suspensions removed by
filtration or separation technologies at normal flow rates.
High Turbulence, High Fluid Velocity, Low Oil Viscosity — Flushing is enhanced by
high turbulence flushing conditions by lower flush oil viscosity and increasing oil flow rates.
This usually requires specialized equipment to achieve proper turbulent flow. Talk to
a service provider you trust who offers high-velocity oil flushing services.
High Flush Oil Temperature — This reduces viscosity, increases turbulence and
increases oil solvency. Temperatures in the range of 175 to 195 degrees F are generally
targeted.
Cycling Flush Oil Temperature — Using heat exchangers and coolers to change
temperature during flushing across a 100 degree F range helps dislodge crusty surface
deposits.
Pulsating Flush Oil Flow — Rapidly changing flow rates by pulsation help dislodge
contaminants from nooks and crannies.
Pneumatic Vibrators and Hammers — Used to break loose debris from pipe walls and
connectors.
Sparge Flush — Air or nitrogen is bubbled into the flush fluid to improve cleaning
effectiveness.
Reverse Flush Oil Flow — By changing fluid flow direction, some contaminants and
surface deposits can be dislodged and washed away.
Wand Flush Tool — Used for wet sumps, gearboxes and reservoirs with access hatches
and clean-out ports. A wand on the end of a flushing hose is used to direct high-velocity oil
flow to loosen deposits or for picking up bottom sediment.
Charged Particle (Electrostatic) Separators — Some suppliers have demonstrated
success at removing varnish from machine surfaces and stripping out submicron soft
contaminants that can contribute to varnish and sludge.
Solvent/Detergent Flush Fluid — Various solvents and detergents have been used with
different degrees of success, including mineral spirits, diesel fuel, motor oils and
detergent/dispersant packages.
Chemical Cleaning — These are chemically active compounds, typically caustics and
acids, used to aid in the removal of organic sludge and oxide deposits.
Mechanical Cleaning — This involves the use of scrapers, brushes and abrasives,
typically used with solvents and other chemicals, to remove hard adherent surface deposits.
Some adherent machine deposits require tactics that are more aggressive than a high-
velocity flush, so you must match the flushing tactic and strategy to the problem you are
trying to resolve with the flush. Once you understand the problem within the machine that
needs to be cleaned, you can then select the appropriate flushing tactic to remedy it. This
issue was described in Jim Fitch’s three-part series on flushing for Machinery Lubrication,
which can be read at www.machinerylubrication.com/Read/609/oil-
flush, www.machinerylubrication.com/Read/634/oil-flushing-tactics and www.machinerylubri
cation.com/Read/657/flushing-oil.
At this point, it should be obvious that a fluid changeout is not just a drain-and-fill operation.
Care must be taken to confirm that the system is as clean as possible prior to introducing
the new fluid. Most changeover procedures suggest that some of the old fluid will need to
be either drained off the bottom or skimmed off the top of the reservoir after a period of
time.
Just because the changeover has been completed does not mean that you are “out of the
woods.” Your system will need to be closely monitored for a while to make certain that the
flushing was thorough. Taking the time to verify that the system is fully flushed and purged
of the old fluid prior to introducing the new fluid will go a long way toward ensuring a
healthier hydraulic system.