Converting Vacuum Hydraulic Systems to Air Hydraulic Systems on Trail King Trailers

[MikePhua]

Introduction: Understanding Hydraulic Systems on Trailers
Hydraulic systems play a crucial role in the operation of heavy equipment trailers, such as those used by Trail King. These systems are responsible for powering a variety of functions, including braking, lifting, and dumping. Depending on the trailer's design and application, different types of hydraulic systems can be used—two common types being vacuum hydraulic and air hydraulic systems.
In this article, we’ll focus on the process of converting a vacuum hydraulic system to an air hydraulic system, with a particular focus on how this conversion affects performance, safety, and operational efficiency. We will also explore why an operator might opt for such a conversion and provide practical advice on the conversion process.
What is a Vacuum Hydraulic System?
A vacuum hydraulic system is commonly used in older trailer models or in specific applications where space or weight is limited. In these systems, hydraulic pressure is created by a vacuum pump that draws fluid into the hydraulic lines. The vacuum system works by pulling hydraulic fluid from the reservoir into the lines, creating pressure and activating various components like brakes or lift gates.

• Components of a Vacuum Hydraulic System: This system typically includes a vacuum pump, a reservoir, hydraulic lines, and actuators. It operates by creating a vacuum that allows fluid to move through the system, enabling the hydraulic functions.
  
• Applications: Vacuum hydraulic systems are typically used in trailers that require lower pressure but still need to maintain sufficient force for certain functions. These systems are lighter and can be simpler in design, but they may lack the power and efficiency of higher-pressure systems like air hydraulic systems.
  

What is an Air Hydraulic System?
An air hydraulic system uses compressed air to generate hydraulic pressure, typically through an air compressor or air-powered hydraulic pump. Air hydraulics are often preferred in modern equipment due to their higher power output and efficiency, especially when dealing with large loads or high-intensity operations.

• Components of an Air Hydraulic System: The air hydraulic system includes a compressor, a hydraulic pump, air lines, and hydraulic actuators. Compressed air is used to drive the hydraulic pump, which in turn creates high pressure in the hydraulic system to operate various components.
  
• Advantages: The main advantage of air hydraulic systems is their ability to generate higher pressures, making them ideal for trailers that need to handle larger loads or perform heavy-duty functions. These systems are also known for their reliability and efficiency, particularly in cold weather conditions where vacuum systems may struggle.
  

Reasons for Converting to Air Hydraulic Systems
There are several reasons why an operator or fleet manager may choose to convert a vacuum hydraulic system to an air hydraulic system on a Trail King trailer. Let’s explore these reasons in detail:

1. Increased Power and Efficiency
   

Air hydraulic systems offer much higher pressure capabilities than vacuum systems. This can translate to increased lifting capacities, faster response times, and more reliable operation, particularly when dealing with heavy loads or demanding tasks.

• Heavy Duty Operations: Air hydraulics are better suited for heavy-duty operations that require greater force, such as lifting heavy cargo or operating hydraulic brakes under high load conditions.
  

1. Improved Safety and Control
   

With higher hydraulic pressure, an air hydraulic system can provide more consistent and predictable performance, which can improve safety, especially when performing braking or load-lifting operations. It ensures that the trailer can handle even the most challenging terrain or operational conditions.

• Braking Performance: Air hydraulic systems are often used in modern braking systems because they allow for greater control and quicker response times, reducing the risk of accidents.
  

1. Cold Weather Performance
   

Vacuum hydraulic systems are often less efficient in cold weather conditions, as the fluid can become thicker and harder to move through the lines. Air hydraulic systems, however, are less affected by temperature changes and tend to perform better in freezing conditions.

• Winter Operation: Trailers operating in colder climates benefit from the conversion to air hydraulics, as these systems are less prone to freezing or fluid thickening, ensuring reliable operation year-round.
  

1. Better Maintenance and Durability
   

Air hydraulic systems tend to be more durable and easier to maintain in the long term. Unlike vacuum systems, which may require frequent checks for fluid leaks, air hydraulic systems have fewer components that need regular attention. Moreover, compressed air is generally less prone to contamination than hydraulic fluid, which reduces wear on internal components.

• Longevity: Air hydraulic systems are less prone to wear and tear, meaning they can offer greater longevity and reliability compared to vacuum hydraulic systems, which often require more frequent maintenance.
  

Steps to Convert from Vacuum Hydraulic to Air Hydraulic System
The conversion from vacuum hydraulic to air hydraulic is a relatively complex process that involves several steps. Here is a high-level breakdown of the conversion procedure:

1. Assess the Current System and Requirements
   

Before beginning the conversion, it’s important to assess the existing vacuum hydraulic system and determine the exact requirements for the new air hydraulic setup. This includes understanding the load capacities, operational needs, and whether the current equipment (such as the brake or lifting systems) can be retrofitted to work with air hydraulics.

• Check Compatibility: Ensure that the trailer components are compatible with air hydraulic systems, including the air compressor, hydraulic pumps, and actuators.
  

1. Remove Existing Vacuum Hydraulic Components
   

The first step in the conversion is to remove the vacuum pump, reservoir, and other components of the vacuum hydraulic system. Take care to drain any remaining hydraulic fluid and clean the system to prevent contamination when installing the new components.

• Clean the System: Properly clean and flush the hydraulic lines to remove any residual fluid or debris that could cause problems with the air hydraulic system.
  

1. Install the Air Compressor and Hydraulic Pump
   

The next step is to install the air compressor and hydraulic pump. The air compressor will supply the necessary pressure to drive the hydraulic pump, which in turn powers the hydraulic system.

• Sizing the Compressor: Choose an air compressor that meets the requirements of the trailer and the load capacities you need to handle. Ensure that the compressor is properly sized for the trailer’s operational needs.
  

1. Install Air Lines and Hydraulic Lines
   

Next, install the necessary air lines and hydraulic lines that will connect the air compressor, hydraulic pump, and actuators. Ensure that all connections are secure and leak-free to maintain pressure and efficiency.

• Check for Leaks: After installation, perform a thorough check to ensure there are no air or hydraulic fluid leaks, as even a small leak can reduce performance and efficiency.
  

1. Replace or Retrofit Hydraulic Components
   

If necessary, replace or retrofit any hydraulic components such as valves, cylinders, or actuators that are designed for use with vacuum hydraulics. These components need to be compatible with the higher pressure generated by air hydraulics.

• Adjust Hydraulic Valves: Some valves may need to be adjusted or replaced to handle the increased pressure. Ensure that the new components can handle the pressure range provided by the air hydraulic system.
  

1. Test the System
   

Once the installation is complete, it’s crucial to test the air hydraulic system under load. Check for proper function, including braking and lifting capabilities, and ensure that all components are operating smoothly.

• Load Testing: Perform a series of test operations to ensure that the system works effectively, particularly during heavy-duty tasks.
  

Challenges and Considerations
While converting to an air hydraulic system has its benefits, there are also challenges to be aware of:

• Cost of Conversion: The conversion can be costly, especially if the system requires custom parts or retrofitting. Ensure that the benefits outweigh the initial investment.
  
• Training and Familiarization: Operators may need additional training to operate air hydraulic systems effectively, as they differ significantly from vacuum hydraulic systems in terms of pressure handling and operation.
  
• Compatibility: Not all trailers are suitable for conversion, so it’s important to consult with a professional to determine whether your specific model can be upgraded.
  

Conclusion: The Benefits of Converting to Air Hydraulics
Converting a vacuum hydraulic system to an air hydraulic system can significantly improve the performance, safety, and reliability of a Trail King trailer. While the conversion process may require investment and time, the long-term benefits—including increased lifting capacities, enhanced braking performance, better cold weather operation, and lower maintenance costs—make it a worthwhile upgrade for many operators.
By understanding the steps involved and the benefits that air hydraulic systems offer, trailer operators can make informed decisions to improve their fleet’s efficiency and safety. With the right equipment and professional guidance, transitioning to air hydraulics can enhance both day-to-day operations and the overall longevity of the trailer.