Hints on maintenance of hydraulic fluid in the system. In order for the obvious to be obvious, the fundamental laws. Condensed table causes of trouble and their effects in hydraulic installations. Basic hydraulic troubleshooting learning system aidex. The hydraulic system is only one of several interrelated slide out room system components. Portable hydrauliccircuit testers figure 220 are lightweight units you can use to check or troubleshoot a hydraulicpowered system on the job or in a. Target hydraulic troubleshooting,troubleshooting hydraulic. Plant engineering 12 steps to troubleshooting pneumatic systems. Troubleshooting and preventive maintenance of hydraulic. Hydraulic pump troubleshooting guide no oil flow from pump. Knowing the system probably the greatest aid to troubleshooting is the confidence of knowing the system. The power unite drives the cylinder rod in a forward and backward motion to drive the slide room in and out. Do not use teflon tape on pipe thread fittings pump is hot. Many problems with hydraulic systems occur on start up of a new system, after a repair or overhaul, after a new component is added, or when a component is adjusted or some other form of change occurs.
How to troubleshoot hydraulic cylinder drift hydraulics. Gradual or sudden loss of pressure or flow resulting in a loss of power is common in hydraulic system failure. The benefits of this approach are clearly illustrated by a recent troubleshooting situation. All equipment problems and failures no matter how mystical always make complete sense after you find them. Chapter 7 hydraulic system troubleshooting general the following troubleshooting information is provided as a general guide to identify, locate and correct problems that may be experienced with the hydraulic system of this crane. It is a device used to convert fluid power into mechanical power to do useful. Close a ball valve, disconnect a line and plug, etc. Items referenced in the explanations are those shown on the schematic. The chapter carries out preliminary troubleshooting activities for determining the causes of malfunctioning in a hydraulic system.
The process of troubleshooting should always begin with checking and eliminating the easy things first. The basic function of a hydraulic pump is to take fluid that is provided at the inlet and discharge it through the outlet into a hydraulic system. Hydraulic troubleshooting guide in different hydraulic applications such as hydraulic pump troubleshooting guide, simple hydraulic system and hydraulic cylinder troubleshooting, hydraulic pump problems and so much more other hydraulic products problems, like hydraulic valve troubleshooting, hydraulic manifold block problems and hydraulic dump valve failed. Check mechanical, electrical andor hydraulic limits and sequence devices. In the minds of maintenance personnel, production managers, and plant managers, the word troubleshooting conjures up images of hours of downtime and lost production. The lippert hydraulic through frame slideout system is a rack and pinion guide system utilizing a hydraulic cylinder to move the room assembly. Troubleshooting tips for hydraulic systems download data sheet this data sheet describes a stepbystep checkout procedure for hydraulic systems which have previously been working satisfactorily but which have developed trouble, usually over a 24hour working period, which renders them inoperative. Oil that is too hot will degrade rapidly, drop in viscosity and can lead to accelerated component wear and poor systemcan lead to accelerated component wear and poor system performance. Hydraulic troubleshooting guide in different hydraulic applications such as hydraulic pump troubleshooting guide, simple hydraulic system and hydraulic cylinder troubleshooting, hydraulic pump problems and so much more other hydraulic products problems, like hydraulic valve troubleshooting, hydraulic manifold block problems and hydraulic. Preface this is a discussion of basic hydraulics which can help with the diagnostics and repair of hwh hydraulic leveling and room extension systems.
In order for the obvious to be obvious, the fundamental laws of hydraulics must be kept in mind. Fluid contamination is the leading cause of hydraulic system failures. Understanding the basic hydraulic systems and components can be of great value when troubleshooting and testing hydraulic equipment. The increase in p c increases the hydraulic force produced by the actuating piston, and eventually it rotates the yoke until it is perpendicular to the shaft and pump displacement is zero. Hydraulic system troubleshooting advanced fluid systems. Cylinders are energized by a 12 volt dc high pressure hydraulic pump through electrically. A popular misconception about hydraulic cylinders is that if the piston seal is leaking, the cylinder will drift down. The guide also includes a troubleshooting section on ac motors used with variable speed drives and brake motors. In fact, the cylinders may stall under light loads or may not move at all. Pdf study of failure in hydraulic systems researchgate. As leakage in the system increases, the amp draw will increase.
The cylinders may not move at all, or if they do they may move too slowly or may stall under light loads. Use amp meters or ampere transducers for measurements. We will introduce many aspects of troubleshooting hydraulic systems and will. Many problems with hydraulic systems occur on start up of a new system, after a repair or overhaul, after a new component is added, or when a component is. Hydraulic system troubleshooting oil foaming low oil level. Through the handson hydraulic troubleshooting training program and hydraulic safety training, participants will construct, operate, and troubleshoot systems using common hydraulic. Hydraulic system troubleshooting hydraulic power packs. Hydraulic systems may be very complex, but every system, no matter how basic, must contain a reservoir, a pump, various valves to control oil flow, direction and. Many of the failures in a hydraulic system show similar symptoms. Includes hydraulic basics, hydraulic systems, pumps, hydraulic actuators, valves, circuit diagrams, electrical devices, troubleshooting and safety mechanics and hydraulics kindle edition by tsd training, training, tsd. Use flow meters to measure flow or low pressure gage or pressure transducer in the. Troubleshooting tips for hydraulic systems womack machine. And besides, there are no books devoted entirely to hydraulic troubleshooting in a meaningful way. Hydraulic system troubleshooting pellerin milnor corporation.
Basic hydraulic troubleshooting training system handson. In any troubleshooting situation, no matter how simple or complex the hydraulic system, always start with the basics. Its a training program which combines printed materials, computer simulation and screencapture videos. The following troubleshooting guides cover five categories of hydraulic problems. Troubleshooting and preventive maintenance of hydraulic systems. The hydraulic troubleshooting system features a large array of industrialgrade components on a mobile workstation, including a siemens s71200 plc with hmi, a hydraulic power supply, supply and return lines, motor with flywheel, proximity switches, magnetic reed sensors, and a wide variety of valves. Lacking flow the flow is taking the path of least resistance. Early classifications of pipe wall thicknesses were. The first section of this school, introduction to hydraulics is a more indepth study of general hydraulics and should be studied before continuing in this section. When pc pump are compensated, the electric motor amp draw is low.
Following the schematic are descriptions of the various parts of the operating cycle and what the hydraulic system does during each part. Review hydraulic principles and misconceptions that affect troubleshooters activity. Each piston has a spherical end that mounts in a shoe fig. The lippert hydraulic slideout system is designed to operate as a negative ground system.
This chapter explains the various causes for failure in a hydraulic system, the preventive maintenance of system, and the functions and importance of sealing devices in a hydraulic system. This course is designed specifically for millwrights, electricians, reliability technicians, supervisors and engineers who are responsible for maintaining and controlling pneumatic systems. Often an electrical issue will affect the hydraulic operation. It is expected that all troubleshooting and testing will be performed by a qualified hydraulic. Basic hydraulic troubleshooting training system amatrol. If you dont know normal, you cant identify abnormal. Troubleshooting for relief valves used in hydraulic systems prof. Logical troubleshooting in hydraulic systems is intended as a guide to systematic fault findings in a hydraulic system. The upper illustration would be a circuit used to raise a cutting unit with a hydraulic cylinder. Troubleshooting hydraulic system problems troubleshooting.
We have a hydraulic system that operates two cylinders. Hydraulic system troubleshooting guide follow these steps to make an initial diagnosis of what may be causing a low or no pressure situation with a hydratech hydraulic power unit system. The hydraulic slideout system is a fixed displacement system, using double acting hydraulic cylinders to open and close a room assembly built into the travel trailer or motor home. Compensate pump or load up motor and measure case drains. In any machine, particularly in hydraulics, any change in one part of the system will affect all the other parts of the total system. The construction and operating characteristics of each one should be understood. Protects hydraulic system from contamination closes off hydraulic system to protect from evaporation waterglycol standard capacities from 2. A pump, which is the heart of a hydraulic system, converts mechanical energy, which is primarily rotational power from an electric motor or engine, into hydraulic energy. This study relates to the description of a relief valve briefly and troubleshooting due to pressure rise in hydraulic system.
It does not matter how small an orifice connects two parts of the system if the system is static, the pressure is the same. The power unit drives the cylinder rod in a forward and backward motion to move the slide room in and out. Use features like bookmarks, note taking and highlighting while reading the. Isolating portions of the system isolating portions of the circuit is a good way to identify the area of concern. Advanced fluid systems features hydraulic system tools and resources for troubleshooting. Industrial hydraulics at the heart of every industrial hydraulic solution is parkers 85year reputation for innovation and quality manufacturing. These stepbystep procedures should help you locate and remedy the problem quickly. Seamless steel pipe is recommended for use in hydraulic systems with the pipe interior free of rust, scale and dirt. Mar 10, 2004 12 steps to troubleshooting pneumatic systems troubleshooting a pneumatic system has been considered an art, a science, or just hitormiss luck. Any one of the system s components may be at fault. Most system failures can be pinpointed to one of these components. Try to isolate the hydraulic system from the rest of the system by blocking the pressure source.
While mechanical rotational power is the product of torque and speed, hydraulic power is pressure times flow. Basic hydraulic troubleshooting learning system 950htb1 fo. When a system is static, the pressure in the system to all parts that are hydraulically connected is the same. Troubleshooting hydraulic systems and components workshop course syllabus upon completion of the troubleshooting hydraulics training workshop a person will be able to explain, describe, andor perform the following. The maintenance staff recently reported that the pump pistontype had failed for reasons unknown at. Download it once and read it on your kindle device, pc, phones or tablets.
In any hydraulic system, it is essential to limit the maximum pressure generated by the constant displacement pump. For this purpose, usually pressure relief valve is used and pressure across the relief valve. Sevil1 faculty of mechanical engineering eskisehir osmangazi university, eskisehir1, turkey. With more than 200,000 hydraulic models numbers in inventory, parkers breadth of product is unmatched whether designing new applications or retrofitting older ones, parker is. The machine in question had a complex hydraulic system, the heart of which comprised two engines driving 10 pumps. The axial piston pump has a series of cylinders typically 7 or 9 mounted parallel to the axis of rotation. Refer to the electrical schematic manualparticularly the schematics on microprocessor. Hydraulic pumps convert the mechanical energy transmitted by its prime mover electric motor or gas engine into hydraulic working energy.
Install pressure gauge and adjust to correct valve setting pressure. The hydraulic system and how it functions during operation the single stage press hydraulic schematic is shown in figure 36. The arrangement is similar to shell chambers in a revolver. Amatrols basic hydraulic troubleshooting learning system 950htb1 teaches learners how to troubleshoot hydraulic systems and their components, such as hydraulic motors, directional control valves, and cylinders. You will be glad to know that right now the hydraulic troubleshooting handbook book pdf is available on our online library. Troubleshooting is nothing more than knowing what normal operation is. The person maintaining air systems in todays modern plant must know the following. The pump will hold this pressure and deliver no flow until something is done to lower the pump outlet pressure. Absorb pressure spikes operate as an extreme safety device the only time the relief valve should open is when the pressure rises above the compensator setting.
Systems with relief valves the purposes of a relief valve in a pressure compensating pump system are. Basic diagram for a typical hydraulic system symptoms many of the failures in a hydraulic system show similar symptoms. The focus of this document is single stage press hydraulic circuitry and how the hydraulic components function during the various parts of the operating cycle. Basic components and its functions of a hydraulic system. The lower illustration would be a circuit that uses a hydraulic. Possible causes and remedies are listed for each type of trouble. At present, pipe is the least expensive way to go when assembling a system. Troubleshooting hydraulic systems and components workshop for. Most problems of hydraulic failure in gold mining machines on field site. For example, knowing that a solenoid controlled directional valve can be manually actuated will save considerable time in isolating a defective. This system includes industrygrade components for both greater learner comprehension and durability to stand up to frequent use.
Hydraulic system consists of a prime mover engine or electrical motor. No or low voltage at a solenoid valve due to a defective limit switch, misadjusted limit switch, plc output, power supply, transformer or no control power. There is no magical way to troubleshoot a hydraulic system. When something restricts from travel on front, rear, or both, system performance will be unpredictable. The definitive guide to hydraulic troubleshooting is not a book. By learning to control contamination, you can help maintain system efficiency, extend.
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