Maintenance and Troubleshooting of Hydraulic System

Maintenance of Hydraulic System:

All actions necessary for retaining an item, or restoring to

it, a serviceable condition, include servicing, repair, modification, overhaul, inspection and condition verification. Types of maintenance: Preventive maintenance Breakdown maintenance

1. Preventive Maintenance
Check and replace it before breaks down Regular check-ups, replacements and servicing Checking condition of various operating

members of the system, lubrication Replacement of worn out seals, packings, clogged strainers and filters Use of preventive maintenance sheets

2. Breakdown Maintenance:
Repair of failed or damaged parts of system Requires understanding of working and construction of the system and practical experience Inspection and Servicing: Inspection: Checking and testing by means of observations and measurements

Servicing: cleaning and replacement of consumables

( oil, seals and packings, filtering elements)

Troubleshooting of Hydraulic System

Cluster of no. of elements in hydraulic system Malfunctioning of one element affects the performance of another one Most common causes of hydraulic system breakdown: Clogged or dirty oil filters Inadequate supply of oil in the reservoir Leaking seals Loose inlet lines that causes the pump to take air Incorrect type of oil Excessive oil temperature and pressure

1. Noisy Pump:
Air entering pump inlet Misalignment of pump and drive shaft / unit

Excessive oil viscosity

Dirty inlet strainer Damaged pump Excessive pump speed Loose or damaged inlet line

2. Low or erratic pressure:

Air in the fluid PRV set too low PRV not properly seated Leak in the line Defective or worn out pump Defective or worn out actuator

3. No pressure:
Pump turning in wrong direction Ruptured hydraulic line Low oil level in the reservoir PRV open Broken pump shaft Full pump flow bypassed to tank due to faulty valve or actuator

4. Actuator fails to move:

Faulty pump DCV fails to shift System pressure too low Defective actuator PRV open Excessive actuator load Check valve in backwards

5. Slow or erratic motion of actuator:

Air in the system Too high fluid viscosity

Worn or damaged pump

Pump speed too low

Excessive leakage through actuators or control

valves Faulty flow control valve Low oil level in the tank Defective PRV

6. Overheating of hydraulic fluid:

Heat exchanger turned off or faulty incorrect fluid Continuous operation of PRV Overloaded system Dirty fluid Excessive pump speed Clogged filtering elements

General safety measures for fluid power

Examine the machine, inspect the parts, starting and stopping switches, protective devices, etc. Ensure safe pressure of the hudraulic system and pneumatic decices. Ensure safe clamping and declamping procedures for automatic systems. Adjust the control levers and switches against malfunctioning. Use protective guards Use proper oil and have regular inspection of oil Use face shields for self protection against pressure actuated system and machine tools. Never work the machine with higher designed pressure. Equipment for protection against fire should be kept ready Should kept in clean atmosphere Use correct tool for dismantling parts Disconnect power source while checking for mechanical faults Hoses and pipes should not be twisted.