Hydraulic tools for troubleshooting any hydraulic system. Locate source of contamination that caused scoring. Basic hydraulic troubleshooting training system amatrol. We will introduce many aspects of troubleshooting hydraulic systems and will share information that will help you to better understand and enhance the operation of your hydraulic equipment. Parkers motion and control training department offers a full range of training equipment and curriculum to support the teaching of hydraulic and electromechanical motion and control technologies. Valve sticks or works hard tie bolts too tight on valve stacks. The following troubleshooting guides cover five categories of hydraulic problems.
It follows our 2day course, practical hydraulics, and prepares students for our advanced fluid power courses. Relief valve protects the hydraulic pump and in turn the prime mover from overload quickly in case the system is exposed to overpressure. Always refer to the technical manuals for your system before performing repairs. Troubleshooting tips for hydraulic systems womack machine. Troubleshooting hydraulic systems and components workshop for. Systems with relief valves the purposes of a relief valve in a pressure compensating pump system are. Normal operating temperature for the majority of hydraulic systems is between 100120 degrees f. Hydraulic system troubleshooting pellerin milnor corporation. System design there is, of course, little point in discussing the design of a system which has been operating satisfactorily for a period of time. For any problems encountered that are not addressed in this manual, contact hwh corporation for assistance. Troubleshooting hydraulics systems for industrial employees. Whatever your hydraulic applications, practical hydraulic systems. Advanced mobile with load sense troubleshooting, hydrostatic drive troubleshooting boot camp, and advanced hydraulic troubleshooting. 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.
Review hydraulic principles and misconceptions that affect troubleshooters activity. Common conditions requiring pump troubleshooting expertise are cavitation, hydraulic imbalance, undersized shafts, and mechanical seal failure. Try to isolate the hydraulic system from the rest of the system by blocking the pressure source. 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. This hydraulic repair and troubleshooting seminar provides the basic building blocks and knowledge needed to be proficient working with industrial hydraulics and fluid power. It is important to ensure that the correct brake fluid is used in the vehicle brake system and incompatible fluids are not mixed. Remember also that truck mounted hydraulic systems differ from. The following guide may help you locate and resolve problems quickly.
This will all be discussed in this study along with the value of using schematics to understand and diagnose hydraulic systems. The maintenance requirements are small in comparison to the work the system performs. 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. Understanding what contamination is, why its harmful, how it gets in, and how to control it can go a long way in particulate contaminants particulate contaminants are the most common, measurable. This is the next generation of training with fantastic content. Avoiding these costly mistakes requires the correct equipment and a logical approach. Do not use teflon tape on pipe thread fittings pump is hot. When a hydraulic system has problems, it is common practice to first look at the pump. In the minds of maintenance personnel, production managers, and plant managers, the word troubleshooting conjures up images of hours of downtime and lost production.
General hydraulic hints good assembly practices most important cleanliness. Most system failures can be pinpointed to one of these components. All equipment problems and failures no matter how mystical always make complete sense after you find them. 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. Check for air leaks in the air pump inlet line and fittings if there is low systempump oil flow.
Preventing hydraulic system problems begins by addressing fluid contamination. Troubleshooting procedures are followed and documented to isolate and correct hydraulic system problems. Hydraulic systems dissipate heat through the reservoir. Symptoms of common hydraulic problems and their root causes. Periodically check the running time of the compressor under various operating conditions. Understanding the basic hydraulic systems and components can be of great value when troubleshooting and testing hydraulic equipment. Introduction a pneumatic control system is more sophisticated and complex than many electrical control systems. Nov 18, 2014 this is the first of a special set of videos we have created on hydraulic systems and troubleshooting. Lacking flow the flow is taking the path of least resistance. Pneumatic controls preventive maintenance and troubleshooting johnson controls, inc. The upper illustration would be a circuit used to raise a cutting unit with a hydraulic cylinder. Fluid power system maintenance and troubleshooting.
In any troubleshooting situation, no matter how simple or complex the hydraulic system, always start with the basics. Yet, most of the problems encountered in all of these systems are often traced down to a few basic issues. The three types of pressures used in a pneumatic system. Force is figured in pounds, pressure is figured in psi pounds per square inch and area is the square inches of the movable rod or piston in the cylinder. The purpose, location and operation of a moisture separator. Advanced fluid systems features hydraulic system tools and resources for troubleshooting. Hydraulic brakes and airoverhydraulic brake systems.
Logical troubleshooting in hydraulic systems is intended as a guide to systematic fault findings in a hydraulic system. Assessing poor cylinder performance in a hydraulic system. If in doubt, always refer to the original equipment manufacturer. This system consists of a master cylinder or cylinders and two or more slave cylinders. Condensed table causes of trouble and their effects in hydraulic installations. Htcs carry local inventory of parker products, ensuring customers fast delivery and reduced downtime. Provide fluid filters in locations that assure the required protection. The pump is arguably the heart of almost every hydraulic system and, as such, has traditionally been blamed for almost every operating problem. It is also important to understand how the different components in the systems work. Check all components, particularly the relief valve for proper settings. Pressure pump and related control components components on top of press dbet card in control box legend 1. The seminar delivers an interactive training experience designed to help participants understand the various components found in a typical hydraulic system and how these. The ideal steadystate flow conditions through an offline filter make this a must for most applications.
Hydraulic line from proportional valve to pump control port 4. Integrating hydraulics with the capabilities and limitations of the truck engine, transmission, and power takeoff is paramount. This subcourse is to be completed on a selfstudy basis. 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. 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. Possible causes and remedies are listed for each type of trouble. Troubleshooting is nothing more than knowing what normal operation is. Troubleshooting hydraulic systems can be a complex exercise. Hydraulic pump troubleshooting guide no oil flow from pump.
Troubleshooting and preventive maintenance of hydraulic systems. Oct 04, 2017 examples of troubleshooting a hydraulic system for mr. High fluid temperature can be caused by anything that either reduces the system s capacity to dissipate heat or increases its heat load. Dec 17, 2011 an effective pump troubleshooting tool will always begin with the question when did this start. The temperature at which this occurs is dependent on the viscosity grade of the fluid in the system and can be well below 180f. The hydraulic systems used in army aircraft are dependable and relatively troublefree. Troubleshooting hydraulic system problems troubleshooting. All cylinder, valve, pump and hose connections should be sealed andor capped until just prior. Hydraulic system troubleshooting advanced fluid systems. Stickslip effect due to the friction of the cylinder packings being too high. Principles, operation and maintenance training seminar provides participants with a greater working expertise and understanding of hydraulic power systems. This unit describes the performance outcomes required to diagnose and repair faults in hydraulic systems.
Basic hydraulic troubleshooting learning system aidex. Troubleshooting for relief valves used in hydraulic systems prof. Troubleshooting hydraulic systems, and operating and maintaining your own hydraulic equipment starts with simply understanding how and why all the various components work. Plant engineering 12 steps to troubleshooting pneumatic systems. Troubleshooting and preventive maintenance of hydraulic. This comprehensive service manual features photos and illustrations along with stepbystep instructions that will guide you through the entire repair process. The seminar delivers an interactive training experience designed to help participants understand the various components found in a typical hydraulic system and how these components function and interact with. This is your last resort before delving into the machine itself. Mar 10, 2004 12 steps to troubleshooting pneumatic systems troubleshooting a pneumatic system has been considered an art, a science, or just hitormiss luck. Our hydraulic products have a wide range applications, they include scissor lift,tipping trailer, electric straddle stacker, hydraulic power unit and custom bespoke hydraulic systems. 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. 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.
Hydraulic system troubleshooting hydraulic power packs. Sevil1 faculty of mechanical engineering eskisehir osmangazi university, eskisehir1, turkey. Target hydraulics is a manufacturer of hydraulic cartridge valves, hydraulic valve manifold blocks and mini hydraulic power pack units. Please note that many systems operate in environments or contain components that have other maintenance andor startup.
Introduction to pneumatics and pneumatic circuit problems. It is equipped with a pressure relief valve to maintain the operation pressure of the system at a predetermined level. The lower illustration would be a circuit that uses a hydraulic motor to drive a cutting unit reel. The hydraulic system and how it functions during operation the single stage press hydraulic schematic is shown in figure 36. If there is no hydraulic system pressure, the hydraulic pump could be worn.
The infrared camera has many uses in the hydraulic field and should be used when troubleshooting any hydraulic problem. Infrared cameras are the most effective tool to use when trying to locate where the heat is being generated. Do not operate the filter skid with system pressure exceeding 150 psi. Hydraulic system troubleshooting check for and remove any obstruction in return line. And so now ive built the hydraulic troubleshooting app. Industrial hydraulics at the heart of every industrial hydraulic solution is parkers 85year reputation for innovation and quality manufacturing. 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. Typical metaltometal clearances in cat hydraulic systems are 35 microns one micron is one millionth of a meter. Session 1 will include components of a hydraulic system, and the fundamental elements that. As you may already be aware, when it comes to hydraulic troubleshooting, i wrote the book on the subject. Pdf introduction to hydraulics for industry professionals.
Hints on maintenance of hydraulic fluid in the system. Using schematics to troubleshoot hydraulics systems. Use manufacturers recommendation to adjust tie bolt torque. Hydraulic systems are used in so many automatic machines. If you dont know normal, you cant identify abnormal. Following the schematic are descriptions of the various parts of the operating cycle and what the hydraulic system does during each part. All openings in the reservoir should be sealed after cleaning. It involves a lot of science and sometimes, a bit of art. Hydraulic trouble shooting hydraulic systems can be very simple, such as a hand pump pumping up a small hydraulic jack, or very complex, with several pumps, complex valving, accumulators, and many cylinders and other actuators.
It involves preparing for the task, selecting the correct diagnostic procedure, carrying out the diagnosis and the repair, performing post repair testing, and completing workplace processes and documentation. Close a ball valve, disconnect a line and plug, etc. Install pressure gauge and adjust to correct valve setting pressure. Gradual or sudden loss of pressure or flow resulting in a loss of power is common in hydraulic system failure. How do i troubleshoot john deere hydraulic systems. Cylinders are energized by a 12 volt dc high pressure hydraulic pump through electrically. Tillage hydraulic systems lift system the lift system used on all great plains tillage equipment is a rephasing system. The relationship of air pressure, volume and temperature. Introduction to hydraulics for industry professionals hydraulic systems volume 1. However, a seemingly uncomplicated procedure such as relocating a system or changing a component part can cause problems. In a pneumatic system, energy that will be used by the system and transmitted through the system is stored as potential energy in an air receiver tank in the form of compressed air.
The size of the air compressor station has been selected to provide the necessary supply of compressed air for each control system. Items referenced in the explanations are those shown on the schematic. Hydraulic system troubleshooting pellerin milnor corporation figure 35. Troubleshooting a pneumatic system has been considered an art, a science, or just hitormiss luck. A pressure regulator is positioned after a receiver tank and is used to portion out this stored energy to each leg of the circuit. Contaminated oil is the primary threat to todays hydraulic systems. Because of this, the following points should be considered. Refer to the electrical schematic manualparticularly the schematics on microprocessor. All equipment problems and failures no matter how mystical always make. Make sure all hydraulic connections are made and shut off valves opened prior to operating unit. Any one of the system s components may be at fault. These stepbystep procedures should help you locate and remedy the problem quickly.
The most common problem in pneumatic systems is insufficient airflow caused by leaks from worn, disconnected, or. Reubas practical exam for fluid power circuits at sc4. Check to see if the reservoir air vent cap is plugged. Hydraulic system troubleshooting system operates slowly cold oil. Chapter 14 fluid power system maintenance and troubleshooting. In order for the obvious to be obvious, the fundamental laws of hydraulics must be kept in mind.
No grinding or welding operations should be done in the area where hydraulic components are being installed. This study relates to the description of a relief valve briefly and troubleshooting due to pressure rise in hydraulic system. Other hydraulic systems use petroleumbased brake fluids mineral oil. The schematic worksheet shows the routing of hydraulics and their interplay within the machine via motors, valves, pumps, and other assorted parts. In many cases this will save time and mistakes when trouble shooting a system. To properly maintain and service a pneumatic control, it is important for the service technician to be familiar. For problems with the boom arms not rising or lowering correctly, it could mean that the gear pump is damaged. Vickers systems to the extent permitted by law accept no liability for loss or damage suffered as a result of the use of this guide.
Hydraulic farm and ranch equipment troubleshooting guide hydraulic system failure can arise from many points within the system. Incorrect diagnosis prolongs downtime and can result in the unnecessary repair or replacement of serviceable components. It is impossible to anticipate every problem or combination of problems. Target hydraulic troubleshooting,troubleshooting hydraulic. Aug 28, 2014 hydraulic system troubleshooting on august 28, 2014 in hydraulic systems by ben lee cavitation was first discovered in 1917 when lord rayleigh a british physicist decided to investigate why fastrotating ship propellers were eroding at such an incredibly rapid pace. These cylinders operate evenly to raise and lower the machine to the desired working depth. Hydraulics trouble shooting guide advanced fluid systems. Bobcat service 763, 763h skid steer service shop manual. Hydraulic systems 9 toro university technical training understanding the basic hydraulic systems and components can be of great value when troubleshooting and testing hydraulic equipment. 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. Replace the oil and the filter if the oil viscosity is not correct.
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