Accidentally Mixed Diesel with Hydraulic Fluid? Learn How to Get Diesel Out of Hydraulic Fluid and Save Your Equipment

Diesel fuel contamination in hydraulic fluid is a common problem that can lead to serious issues with your equipment. Whether you’ve accidentally mixed the fluids or suspect a leak, understanding how to get diesel out of hydraulic fluid is essential for maintaining the health and performance of your hydraulic system. This guide provides a comprehensive overview of the problem, the dangers, and effective solutions for removing diesel contamination.

Understanding the Problem

Hydraulic fluid and diesel fuel are incompatible. Diesel fuel is a lighter, less viscous liquid designed for combustion, while hydraulic fluid is designed to transmit force and lubricate hydraulic components. When diesel fuel enters the hydraulic system, it can cause a range of problems, including:

• Reduced Lubrication: Diesel fuel dilutes the hydraulic fluid, reducing its lubricating properties and increasing wear on hydraulic components.
• Fluid Degradation: The presence of diesel can accelerate the breakdown of hydraulic fluid, leading to sludge and varnish formation.
• Air Entrapment: Diesel fuel can introduce air into the hydraulic system, leading to cavitation and reduced hydraulic efficiency.
• System Failure: Severe contamination can lead to component failures, such as pumps, motors, and valves, resulting in costly repairs and downtime.

Identifying Diesel Contamination

Recognizing the signs of diesel contamination is crucial for prompt action. Here are some telltale indicators:

• Fluid Color Change: Hydraulic fluid typically has a reddish or amber color. Diesel contamination can cause the fluid to become darker, even black in severe cases.
• Fuel Odor: A strong diesel odor emanating from the hydraulic system is a clear indication of contamination.
• Performance Issues: Reduced hydraulic power, erratic movements, or noisy operation can point to diesel contamination.
• Fluid Viscosity: Diesel contamination reduces the viscosity of the hydraulic fluid, making it thinner and less effective.

The Dangers of Ignoring Diesel Contamination

Leaving diesel contamination untreated can have severe consequences for your hydraulic system and equipment. Here are some potential risks:

• Increased Wear and Tear: Reduced lubrication leads to increased wear on hydraulic components, shortening their lifespan.
• System Damage: Severe contamination can damage pumps, motors, valves, and other hydraulic components, leading to costly repairs.
• Safety Hazards: A compromised hydraulic system can lead to unexpected equipment failures, posing a safety risk to operators and bystanders.
• Environmental Concerns: Leaking contaminated hydraulic fluid can pollute the environment, potentially harming soil and water sources.

Methods for Removing Diesel Contamination

There are several strategies for removing diesel contamination from hydraulic fluid. The most effective method depends on the severity of the contamination and the type of hydraulic system.

1. Fluid Replacement

For minor contamination, a complete fluid replacement is often the simplest and most effective solution. This involves draining the contaminated fluid and replacing it with fresh, high-quality hydraulic fluid.

2. Filtration and Vacuum Dehydration

This method removes both diesel fuel and water from the hydraulic fluid. Specialized filters and vacuum dehydrators are used to separate the contaminants from the fluid.

3. Chemical Treatment

Certain chemicals can be added to the hydraulic fluid to neutralize diesel contamination and restore the fluid’s properties. These treatments are typically used for moderate to severe contamination.

4. Flushing and Cleaning

For extensive contamination, a thorough flushing and cleaning of the hydraulic system is necessary. This involves circulating a cleaning solution through the system to remove contaminants and debris.

Choosing the Right Method

The choice of method depends on the severity of the contamination and the type of hydraulic system:

• Minor Contamination: Fluid replacement or filtration may suffice.
• Moderate Contamination: Chemical treatment, flushing, or a combination of methods may be necessary.
• Severe Contamination: Thorough flushing and cleaning are essential, followed by a complete fluid replacement.

Preventing Diesel Contamination

Preventing contamination is the best way to protect your hydraulic system. Here are some preventative measures:

• Proper Handling: Store diesel fuel and hydraulic fluid separately, using clearly labeled containers.
• Regular Inspections: Inspect your hydraulic system regularly for leaks and signs of contamination.
• Cleanliness: Keep your work area clean and free of contaminants.
• Operator Training: Train operators on proper handling procedures and the importance of preventing contamination.

Final Thoughts: Maintaining Hydraulic System Health

Contamination is a serious threat to the health and performance of your hydraulic system. By understanding the dangers of diesel contamination, recognizing the signs, and employing effective removal methods, you can ensure your equipment operates efficiently and safely. Remember, prevention is key. By following proper handling procedures and implementing preventative measures, you can minimize the risk of contamination and extend the life of your hydraulic system.

Answers to Your Questions

1. Can I use a diesel fuel filter to remove diesel from hydraulic fluid?

While diesel fuel filters can remove some diesel particles, they are not designed for removing diesel fuel from hydraulic fluid. They may not effectively remove all contaminants and can even damage the filter.

2. How long can I run my hydraulic system with diesel contamination?

Running a hydraulic system with diesel contamination for an extended period can lead to accelerated wear and tear, component failures, and ultimately, system failure. It’s best to address the contamination as soon as possible.

3. What if I accidentally mixed diesel fuel and hydraulic fluid?

If you accidentally mixed diesel fuel and hydraulic fluid, it’s crucial to drain the contaminated fluid immediately and replace it with fresh hydraulic fluid. You may also need to flush and clean the system depending on the severity of the contamination.

4. Can I use a fuel additive to remove diesel from hydraulic fluid?

Some fuel additives claim to remove diesel contamination, but their effectiveness is often questionable. It’s best to consult with a hydraulic expert for the most effective solution.

5. How often should I change my hydraulic fluid?

The frequency of hydraulic fluid changes depends on factors such as usage, operating conditions, and fluid type. Consult your equipment manual or a hydraulic expert for recommended change intervals.