Hydraulic system maintenance and troubleshooting

Standard maintenance procedure

Cleaning suction strainer periodically.
Filter element of return line should be changed after 100 hours and also 500 hours there after.
Taking oil sample and analysis it and checking the contamination level.
Keep spare parts for any emergency parts broken or failure.
Installing magnet inside the reservoir to collect ferrous particles.
Checking oil level periodically.
Should not reuse leakage oil that has leaked out.
Should use clean hoses, containers for refilling oil into the reservoir.

Hydraulic pressure problem and solutions

Problem causes: Relief valve pressure is too low.
Remedy: Adjust the pressure screw and set the required pressure.
Problem causes: If relief valve is open
Remedy: Check movement of piston by opening the relief valve. Also check the accurately poppet and seat. And check the orifice of piston due to blockage.
Problem causes: Oil is return to the tank.
Remedy: Check the directional valves and check valves properly working.
Problem causes: Internal leakage
Remedy: Inspect the Actuators leakage around it.
Problem causes: Wrong adjustment of regulator
Remedy: Check the setting and adjust by screwing adjusting screw.

No flow from pump

Problem causes: Pump rotating in reverse direction.
Remedy: Check the motor connection terminal or ensure the rotation direction.
Problem causes: Pump shaft not moving or rotating.
Remedy: Shaft key slot is damaged or coupling broken.
Problem causes: In a variable displacement pump set 0 delivery rate
Remedy: Again adjust the delivery rate.
Problem causes: Higher Oil viscosity.
Remedy: Select suitable viscosity oil grade.
Problem causes: Mounting position is too high.
Remedy: Keep 1 meter distance between pump inlet port and oil level of reservoir.
Problem causes: Revolution Per minute.
Remedy: Run pump at least minimum speed (RPM range).
Problem causes: Worn out.
Remedy: Replace the parts due to worn out.

Over temperature

Problem causes: Oil cooler efficiency is low
Remedy: Check air or water temperature. Clean strainer of heat exchanger connection area.
Problem causes: Low fluid level in reservoir.
Remedy: Fill the reservoir.
Problem causes: Wrong grade fluid is used
Remedy: Change the fluid and fill with correct grade fluid.
Problem causes: Pump pressure too high.
Remedy: Adjust the relief valve pressure and set the pressure as required to the system.

Excessive noise

Problem causes: Bubbles in the reservoir.
Remedy: Return oil line should be down and touch the ground of reservoir.
Problem causes: Pump creates noise
Remedy: Pump creates noise due to air in the system.Tightening the pipe fittings and inlet port of the pump.
Problem causes: Air leakage around the pump shaft seal
Remedy: Replace the pump shaft seal.
Problem causes: Suction strainer size is very low.
Remedy: It should set up the large size suction strainer.
Problem causes: Pump speed is very high
Remedy: Set the pump speed that is recommended by the manufacturers manual.
Problem causes: Misalignment coupling
Remedy: Correction the alignment of the coupling.
Problem causes: Noisy relief valve
Remedy: Readjust the pressure.

Oil leakages

Problem causes: Incompatible seal
Remedy: Seal should be change due to the chemical reactions.
Problem causes: Pressure ranges of seal is less than system pressure.
Remedy: Change the seal and set the good quality high pressure seal.
Problem causes: Pipe and fittings setup in misalignment's.
Remedy: Setup correctly pipe and fittings.
Problem causes: Seal is become hard due to long time use.
Remedy: Change the seal.
Problem causes: Incorrect thread.
Remedy: Use correct thread in the connection.

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