E:TN | Vickers Logical Troubleshooting in Hydraulic Systems WICKERSIndex Introduction 3 Shutting Down Machines 3 Line Service 3 Checking Faults 4 Instrumentation Principles and Measuring Instruments 5 Measuring instruments 6 Pressure Gauges 6 Prossure Gauge Installation 6 Flow Meters 7 Flow Meter Installation Machine maltunction procedure 9 Machine faults 10 System faults 10 ‘System malfunction 10 ‘System faults 1 Unit Fault Preliminary Check 2 Excessive Temperature 13 Excessive Noise 14 Excessive Vibration cy Excessive Leakage 16 System test for gear and vane pumps 7 System test for piston pumps 8 System test for pressure relief valves 20 System test for sequence valves 21 System test for pressure reducing valves 22 System test for flow contro! valves 23 System test for directional contol valves 28 System test for pilot operated check valves 2 Systarn test for eylingors ‘System test for hyd ic motors System test for accumulators 28 System test for coolers 28 System test for air leaks 30 System test for fluid contamination 31 Pump cavitation ae Aeration of Huie 3 Restart procedure 34 Bar trimming machine - Troubleshoot 25 Bar trimming machine layou 36 Circuit diagram for bar rimming machine Warning ‘Logical Troubleshooting in Hydraulic Systems" is intended as a guide to systematic fault fincings in a hydraulic system. Vickers systems (to the extent permitted by law) accept na liability for loss or damage suffered as a result of the use of this guide. If in doubt, always refer to the original equipment manufacturer. Refer at all times to the “safety procedure” on pages 3 and 34Introduction would be a vitually impossible task to tty t0 document the cause and remedy of every possible fault that could occur (on even the simplest hysraulic system. For this reasoa itis necessary to adopt logical approach to troubleshooting, in order to locate a fault as quickly ane accurately as possible. Down time on modern production machinery 's very expensive, so an hour saved in locating a problem may make hundreds, or sometimes thousands, of pounds worth of saving in lost production Ineviabyy, hydraulic systems are becoming more and more complex as methods of controling machines become increasingly sophisticated. The last ter years has seen rapid technological advances in the components used in many hycraulic systems, and itis vital hat equipment, or machine manufacturer's ervice information or ‘sofware’ keeps pace with the actual hardware being sed. Ibis probably true to say that there is stil a ‘general lack of understarcing of hydraulics in some areas of industry, and in roaly, the job of a hydraulic maintenance ong: oer is now a specialized occupation with many simiartes to that of an irstument o electrical engineer. “The object ofthis book is to provide pro- cedure for a logical approach to trouble shooting, which can be extended when necessary to cover specific machines in all areas of ndusty. The fundamentals ch this procedure is devel (oped, that is, the control of flow, pressure and direction of fow, applies equally as well toa rolling mil ina steel works or a winch drive on a teawier around wi The Hit and Miss Approach The only alternative to a logical rouble shooting method isthe hit and miss approach, where units are changed at random until the faled component is located. Eventually the problem may be found, but on all but the simplest of systems this method proves to be expensive in terms of time and money. is usually the case that a large number of perfectly servicable units are changed before the right one is found, {As with all troubleshooting techniques, knowledge of components and their function in a system is vitaly important. It's probably fair to say that when all the components of a hydraule system nave been identtied, their function deter mined and the operation of the system as a whole understood, the trouble shooter has gore 51% of the way towards finding the problem. tis impor- tanl therefore, that 10 make use of this book effectively, a good understanding of the basic principles of hydraulics together with a knowledge of the opera tion and application of hydraulic compo- nents shoul first be obtained Shutting Down Machines Whenever servicing work is cariad out on a hydraulic system, te overriding consideration should be one o safety: to the maintenance engineer himself, his, colleagues and the machine operators, Although safe working practices rely largely on common sense, it's very easy to overlook a potential hazard in the stress of a breakdown situation Maintenance personnel should therefore discipline themselves to go through a set procedure before corimencing any work on a hydraulic system. Because hydraulic uid is only sighty compressible when compared with gas, only a relatively small amount of expansion has to take place to lease the static pressure. However, where compressed gas can be presentin a hydraulic system, ether through inetfective dleading, or where an ‘accumulator is fited, extra care must be taken to release the pressure gradually. Safety procedure for shutting down machines Lower or mechanically secure alll suspended loads ee Exhaust any pressute locked in the system —— Drain down all accumulators ——s————— Discharge both ends of intensifier Ld Isolate the electrical contral system Isolate the electrical power supply Line Service When adopting service ar rouble: shooting procedures, itis usetul ta Geline three distinc areas similar to those used in the armed forces, that's, list, second and thed line servica, First Line Service or troubleshooting carried out fon the machine itself and resuling in the failed component being idensitied and repaired whist stil in situs, or replaced. Second Line Investigation and repair of a failed or Suspect component away from the machine, possibly ina user’s own workshop Third Line Investigation, overhaul ard retest of a ‘component carried out at the maker's {actory or service depot It should be the responsibilty of the maintenance manager to decde where the dividing line is cravn between each area for his particular equipment.This book is confined to the fist ine area ie. working from a fault to the falled component. Second line service information ean be found in ether ‘Vickers publications together with dotails of specialist test equipment First Line Service Checking Faults The troubleshooting procedure inthis book will endeavor to answer the follow ing questions: What do I check? Second Line Service Repair in workshop, Third Line Service Manutacturers repair service What do | check with? nf en t\ (ee NN LO? wal We me Lo For example, ita pump fails on a system it may be possible to repair the unt whilst stil on the machine ie. frst ine vice. In ancther case t may be necessary to replace the unit with a new tone sending the failed pumo to a work stop or second ine area where a Pressure gauge Temperature gauge Flow meter in one unit Flow Meter Installation Flow meters may be installed in a hycraulic system to check while the machine is operating normally {on-line} ‘oF while the machine is shut down for maintenance purposes (aff tine} Ondine Figure (A) illustrates a flow meter instaled in the mar tow ine trom the pump. By incorporating two 3-way valves inthe lin, allow meter can be connected tothe system and the 3-way valves selected to iver flow through the meter, The meter used must obvously be capabie ot vwithstanging the ful system pressure and flow The meter reading wil indicate the iow avaiable fo te system, but the reading is less than specticaton itis not immediately apparent whether the pump is guing less flow than required or the relict valve is leaking a proportion of the ump flow fo tank, if problem is found however, the lis of possible causes has been narrowed down to two units, and a ‘check on the tank retum line rom the relet valve should then conti which of the two units is al fault a Measures pump outout at normal system a pressure - Does not alow for , relief valve or leakage 8) Montors puma performance by measuring cease leaKageIn the case ofa variable pump, the pump output flow will only be that actually required by the system at any time. A {good indication of pump performance however, can be obtained by measuring the internal leakage in the pump, ie. measuring the case drain flow as indicated in Figure (8). A certain amount of case leakage is inherent on brand new pumps (caused by de: lubrication ling et.) so t will be necessary to compare tne leakage actually measured wit that for a pump within full specifcation. When measuring case leakage it's important that itis done under steady state conditions, i. with the pump delivering a constant volume. The flow meter required will only have to withstand pump case pressure {normally around 0:3 bar) and very low Nlows so in fact a measuring jar and stopwatch may be used. ts important however thatthe drain ine is NEVER allowed to be blocked of Figure (C)ilustrates atypical ofl arrangement, The addtion of two shutott valves inthe system allows the system ise to be isolates arc the pump fow ign clearances, Oftine © + Measures pump J ut aiow pressure Does not allow for relia valve leakage I I || Measures ° flow available at actuator verted through the Pow meter Again a low pressure meter can be used since the pump ‘low is measured at low pres athough this may not give a tue indication fof the pump outer at nermal working pressure. As mentioned previously, afow ficiency could be caused by law pum output or rai valve leakage so a further creck will be toque if this is the case. i is possible to ncorperate a restctor in the ‘low metor ine in order to develop pressure, in which case of course, a high pressure meter wll be requited, It the output from the pump unit proves to be satisfactory, it may be necessary rect low meter into ather areas ot the system. Again the adcttion of isolating valves as ilustrated in Figure (0) considerably simpties the operation. ‘CAUTION Whenever a flow metaris connected into a system, itis ViaTTS eneure that the pump always has direct access to the relief valve, and the reliot valve tank line is naver allowed to be blocked off or unduly restricted Where do I check and what do | expect to read? When considering falures in a hycraulic system there can be two alternative starting points namoly || Erratic we ae ‘movement Movemem fo where there shouldn't be ‘+ Machine Malfunction — where a fault occurs ina hydraulic system causing a malfunction on the machine itself ie. an actuator fails to operate correctly, + System Malfunction ~ where a fault occurs inthe hydraulic system without necessarily affecting the machine performance in the short tarm, ag. excassive leakage, tompera ture ete. The two can of course occur together. For example, a pump failure would result in the machine failing to operate correctly and would mast Ikely be accompanied by an increase in noise ‘evel. Experience has shown that itis, usually Detter to start atthe fundamental problem and work through the checking procedure, using symptoms such as heat, noise, leakage ete, as clues. ‘Again, common sense must prevail when working through this procedure, as some symptoms may point straight 10 the problem area. A fountain of oi gushing from a valve points immediately tothe probiem area, but some symptoms may not be s0 obvious. When a unit leaks flow from high to low, pressure heat is usually generated ‘cally in that part ol the systom which may not be immediately obvious, 1} movement | —Firong directionWhichever the staring point, certain questions should oe answered betore proceeding. When a problem is reported, 's important to gather as mary facts together as posse. It coud be that the same problem accured six montis ago and is recorded somewhere on a log sheet Cr record card in which case a good deal (of ime can be saved. I snould &e asoertaned whether any recert maintenance work or adjustments have bboen made tothe system. The exact nature ofthe failure shoud be determined, was i @ sudden or gradual breakdown, which parts of the machine have been atfoctod and which have not? I may be itfout always to get the complete story, but an effort should be made to gather as "uct information as possible. ‘The philosopty ofthe trouble shootng procedure isto staat the fundamental prcblem and determine which aspects of the hycraulc system is at taut: ow, pressure or direction, By consulting the Ccreut dagram, alist of possible causes can be drawn up. The next stage isto then look forthe obvious this perhaps human eiture when faced wih & chalenging problem to search too deeply 100 quicky, in the process overlooking what in hindsight appears a very obvious solution. There are oertan checks that can bo cared out on a hydraulic systom using the human senses of sight, touc are hearing and whict can be carried out very cuicky. I rigid procedure is adopted feach tme it wil ensure that no odious oF apparenty ‘iva problem s overlooked. In practice very many problems willbe solved at this siaga without having to casort to additonal Instumentaton, COniy # is stage fas to reveal the prcblem is t necessary to resort to extra pressure gauges, tow meters etc. and again a logical approach sould be adopted using the algortim chars in this book Machine malfunction procedure MACHINE MALFUNCTION Step 1 1 “An actuator Gan Tail To Operate correcly in the following ways: Incorrect Space Incorect Trrust No Movement Movement inthe Wrong rection Erratic Movement Incorrect Sequence Creep Whichever fault or faults have occurred, the fundamental problem area snould be defined where possible as one of FLOW, PRESSURE or DIRECTION siz Fram the areut dlagram each ccomoonert in the system can be identified ard its tunction in the system determined coos ‘Ast of units that can possibly afect the problem area can now be draw up. 29, A slow actuator speed can be Celine as a problem of FLOW (even ‘though this may in tum be due to lack of PRESSURE, the fundamental pro lem area s FLOW). A Ist of units chat can possibly affect flow to the actuator including the acuator sof) drawn Up bearing in mind tat, fo example a leaking or wrongly adjusted relief valve lie. @ PRESSURE contol valve) could efoct flaw to the actuator. Step 4 The lat of unis car be arranged in rough order of priotiy based on past experience and also ease of checkng step 5 'A preliminary check can now ba cared fut on each unit on te Ist in turn to ‘eck such tings as instalation, adustrent, signals ete. ard also to dlermine i any unit exhists abnormal symptoms such as excessive temperature, noise, viraton ete Step 6 Tihe prolminary check does not reveal the unit at faul, a more exnaustve test fon cach unt can be caring out using additonal instumentaton but wthout any unit tom the system, Step 7 The nsbumant shacks should now reveal he failed unt and a decsion can be made wheather "0 repair or replace the unit t fault Step 8 Belore restarting the machine, thought shous be given fa both the cause and fhe consequence of the fare. Itthe falure was caused by contaminated or overheated hid, then further fares can be expected and remecal action shoulé be taker. Ita pump has broken up on a system, there is a possbilty of pump debrs having entered the system which should be thoroughly cleaned out before a new oump i fited THINK ABOUT WHAT CAUSED THE FAILURE AND ANY CONSEQUENCES OF IT. aMachine faults System faults step 1 | aw Direction 2 Grcuit agram i Lato 3 Unis to be checked i 4 Order of checking i 5 Noise [Prim | Vibration & crocs | & Heat Leaks * i 6 ‘ALGO test” 7 i 8 Think" + Algo’s 0.1 10.0.5, “Algo’s Ato L ‘System malfunction ‘SYSTEM MALFUNCTION ‘A hydraulic system may exhibit | erlonance in the short term problem elsewnere in the system eg, cavitation or Performance in the short ter aeration on a pump inlet line. In this case the Whichever the problem, a preliminary check can be carriad out lo try and identity the problem area by using the human senses ct sight, touch and hearing Ifthe problem is not idensfiag by the preliminary check, then @ more exhaustive check must be ‘carried aut ch suscect uns and a similar procedure tothe Machine Fault exercise can be carried outSystem faults HEA’ NOISE VIBRATION LEAKS Protim. Prelim. Prelim. Check Check FoR, je Check Algo 0.2 Algo 0.3 Algo 0.5 Continue on Continue on Continue on system Machine Fault acting Machine Fault! Inspection diagram step 3 iagram st diagram step 3 Li Problem AreaUnit Fault Preliminary Check model uo mbes oct? YES Isthe unt \_ No talled YES change. unt Remedy installation isthe unt YES. adjustable? ]:; Re-adust unit Does the unit ves is the signal an external rect? signal? Does the unit exhibit abnor ympioms' {ncise, neat Continue ‘on next chat Check the unt Check the unt ‘Algo 0.1Excessive Temperature ‘Algo 0.2 E tomperatur cnart Aigo 2) Too up the Drain ang refill with correct uid List al units rn drain returns,Excessive Noise Is the noise id with yes /'s the reservoir YES ‘lui level too dep up NO " aon at and repair or screaming he system cR2 lr ves / cane a chock aoe rset vacua re pump let \° I Check setings Pumps and agjustme YES. cavitating ohalvalves corel fon ine \no alignment [= pump ansExcessive Vibration 'sthe vioration\ YES Is the flexible \ YES. sociated with ‘coupling Replace cours ,° ," ighten oF NO__/s the pipework Is the align- (NO Realign ing caps saestely mentor ive “es ‘supported? shafts | YES YES wore Check setting YES vibration pump \NO Tighten or enocavstront associed sieratn \" ves Check setng Capea and adjustments Is there air in \WES. FCRe of al the system? \" Remove pump ang Algo 0.4Excessive Leakage Clean down the system Can the jeaxage be traced to one uni? YES Repair or repla unit J” (Can the leak age be traced \ YES to one area of pinework? replace pipework I!" sawater \ veg cooler fitted to the system? tT Isolate each par cf the system in tum and check tor leaks ‘Algo 0.5 16System test for gear and vane pumps. Aigo A INLET 8 ourer INLET INET OUTLET ounet ouruet ~A INveT Gear Pump Vane Pump Inva-Vane Pump START is there a NO pressure read WES. ing at pump outel No is pressur Check dv heading norma vopump system press NO, Load so [ ist ie system Check next system relief valve valve aduusted) (SYS itonlist corecly ack sniton ESI YES Check re isthe Insert tow has stooped place pump outlet caxter | ves/Isthere a ihe \ve oveet (Check or won \ CZ towton VSS] creck neat rotation sakes any val the pump, unit on list yst return line correct Reassemole Sscorbied Cheokthe ] / Settee to VEST Oe mp correctly for vacuum al i the reliet valv relat valve corr rotation ammo Kis rank line Tite Prime pump “han so of mercury Check the reliet valve ey Check the pumpSystem test for piston pumps ourter INLET & INLET & 4 ourer ourtet ~~ - 3 1 f 3 ie INLET . B ‘Aigo A2 INLETS oumet START Cheek ative Is the pump) /-: pressure \ ves “tooump aft rotating casing re ete roy Continued on next page , is te pry isthe yet ‘sues | compensator compensator) Cystem pctenhuy Oreck next ostem ooate sting ae to uniton Is nop Ye rac prosana) YES/" tethers Fons] YES/‘ re ee motion‘aiing) | rele vawve valve asjstto has stopped pace seh ores 7 | poe te ves o heck pressure] YES/ Is there isthe \ ves! wenn Cher motor KX moton taking) (fos tom Check nex ‘oration has stopped place he puro Unton lst wy 5 ves /, compete neck fr (ls ere How \ Check he setting the system retum line of valve my Prine One the LYES/ Ie the pum stopandor mp case drain on maximum compensator are ‘low delivery setting wey ves/'sihero to ves Check the q passing down NO] Check the reiehvalve revel vay puma rain to tak ne ercessiveSystem test for piston pumps (cont'd) i rts out a ' A . i] 4 ty wer i ‘ Continued trom previous page ¥ Check the vacuum at the pump inlet v he than s" Hg 21 bar YES | Punpis cavitating consult FCRT NO pumpSystem test for pressure relief valves Aigo 8.1 No rr oG-08 66-10 Insen pressure gauge n TP1 the pres No sure maxi Load tt mum system, system Is thee ation taking place YES, has stopped fs there tele vave tank line next chart Ro adjust relia valve ayes ‘Check istnere flo, yeg [Check ‘o the relist from any leakage in valve alve tank the system clu ine the relict valve 20System test for sequence valves Algo B2 mile = @ Tee Tee pe 1p2 ci 4 1p Fre 7 Stet g ‘e = ° RCT-06 & G06 & 1 isthe Ace te valve Re-achust Prassures adjusted the valve Check No tsthopiot \ NOL! check tn next uit sonal pilot sgna ‘ot con ves Wyves is here or ve Check YES Istnediain\ ESA) Check the the valve ine bocka drain line NO su the syste down in a sale eondtion & remove va end cane sme LES. Check spa) re rex unt ? on list ve Chock th aSystem test for pressure reducing valves ‘Aigo BS Ter gre Ee fowl 2F8 > y £1 i { rer SIO) ae } 2 4 2. P2. 4 TP2 ; Tre 3 E ba 1 x7-06 8 10 XG.06810 XCG-058 10 xeL03 Insor prossure gauges IPT Tee is the NO systom on Toad Bre no ‘sthee \ NO ‘Check tor reading equa wroton sking leakage i oul syser making akg pressure Pla he system ayes yes These motion has ‘oaped No. is tho valve adjusted Readust correcty Ge NO. | check nex ate, LESS] cnoce ne orcdiem ick ist rer ine Gran ine ottow © ves ve Is the Cheok next Cheek 1 drain tow “Sion Nave Check theSystem test for flow control valves Algo C4 , 10 ayes vu No_/ isthe vaive fora) \ NO ayes yyes wo /See\ wo [SESO\ veg [Src 7 stalled. Chec YES/' readings at (NO. WES [ead the \pO, next unit 23System test for directional control valves Aigo 0. ox Ae 68x tre Ts T 7 0G17S406 7 oA Pio ‘on TP’ oad syst on TP2 system, YES res ‘YES Is reading Istrere \NO 's reading \NO Isthere \NO YES Uves Uyyes 24System test for pilot operated check valves ‘Algo E.1 e«aP TP: TP: 1 x TP2 ox 12 TP2 | « y i i \ / 4CT-06 & 10 Insert gauges PIE TP2 Check pr sures with flow passing thru the valve (Check the valve Insert gauge in pilot pressure i Is plot pres: Cheek sure sutfcient pilot {0 open valv supply a ‘Does piel pres Is the systen sure decay wen probiem vave i requed ° ¥ ves [Check the valve Check nex Unit on list restriction in pilot ineSystem test for cylinders ‘Aigo G1 1? 7? Double acting ing double 10 ihe system \\ YES Bleed air probiem from eylinde motion bleed points " Fully extenc cylinger to end stroke GF release system eylinder p us connection of cylinder + ‘Apply pressure to tul bore end ¥ Check next {sol leakin fom anaulus cyinder he oylinger 26System test for hydraulic motors bee TP cS 1 a 2.200 25M, 35M 425M, 5M Algo G.2 TP, FB and rotate by Check pressure ‘at motor inlet port working pressure Check for loss in tha system wes neck pressure| ‘at motor outlet port Isback \YES [Check tor pressure restriction in YES hack the motor ext unit oniist aSystem test for accumulators Tsar test gauge in tas side of accumu: lator as manufactur ersiinst v farge flu from sumulator an wok gas pressure v Ismepe \ no [hago mth pressure correct correct pressure Us Stop pumps and discharge accumulator v Insert pressure ‘gauge in fad Tine v Charge accumu lator fo fd sys-| ‘Algo Jt No/'ls te pres\\ VES sure switch Check the acon mulator according ‘Ghack next unit pressure ‘an lst ‘switch compensator 28System test for coolers Algo 32 Check the al temo fal the outiat port of the cooler v Is the tome \AB ‘0 high fs there a citer ‘ence batweon cl inlet and outle temps. Yes Coole’ is working Check next unit on lst ares " no /'sihe water Check when i Oper water suey has reach valve suoned on orang comp oS Beadust 1QE/ ermosta shexmostat dusted the water oud let temp hight nan water inet No tem Wes Is the water YES vet temp Check water tong supply ve istheol \ NO [Gra flow thru id the cooler loss sysiom 29System test for air leaks ‘Algo 1 ‘iting Tighten o aro stings S| reptee wom wight itings wes smear each joint wit grease| one at atime v Has the Continue Hastne \NO[ Check the ‘Smear with pump noise pump noise pump shat EES} OTe changes changed seal grease yes YES Check tha eta last joint NO| pump and strainers are aeration below fluid ves lava Famove pump and replace shaft and seal i needed No / Ave they below fud Fill tank to 30System test for fluid contamination Draw ofa sample and compare with ‘eesh fluid v Does te Algo L.2 ‘system sarm-\\NO ple appear 19 be ark Do ftuis apoes milky white cae eee. re \ nol Alowtia a samples to hhour together with @ shall Sel up an LJ incined sare ba ‘pis onto ne Pour both sam inline at the Wes wves This of has oxisized Pour a quantity into a test ‘ana heal tube a v Can @.pap\\ NO} Nol The fuidis Darey papscee | Alw tid sah ow be heard at to sland the same. Pe a ey Na ayes u apes he fluid is Do air wate lagen vubbies ST Tasiuicd Fuld vscoaty rerfagen 7 (appear athe pelt ‘Scone Ty ves Te Nia seaiy Ea? atPump cavitation FAULT Pump Cavitation CAUSE FORT REMEDY Suction strainer clogged 1 or too smal Clean or renew Lf Beet suster ine Fitlargor bore pas t—+ Teo many bends in Mosity ppe layout | cron ine nora guerre |_J ict a Fepace wih covet |__.J—~“Arreaterboores ‘9 too smal Clean oF replace element ‘ocal restriction in suction line €.9, partly closed valve or hose collapse (Open or modify valves, renew houses, [| __ Failure of boost pump. — ‘ump running too fas Fieduce to Pump running too fast ‘ecommended speed LJ Pump mounted too high Moaily pump installation above 0) 32Aeration of fluid FAULT Aeration of 4 fluid CAUSE FOR 2 REMEDY v0 fhid level low Fillo correct level Poor reservoir design Mosity design Return line in reservoir above “ui level Extend return pips bbeiow tuid level Unsuttable tid Replace with correct fluid Pump shalt seal wor or damaged Renew seals ‘Suction ine joints allowing entry of air Renew or tighten joints Porous suction hose Renew ne improper bleeding Re-bleed system 33Re-start procedure Start the sysiem ° ne. Carry ou failure been ‘urher remedied investigation with Remesy nections, instalation correct Aro all electrical connections adjusted to safe tcandition fo startup Is the unit Fill up case Have all beer removed ety fave al person re-staring ‘Sound alarm for inform all personnel Aigo 06 No Adjust to rdtion 34Bar trimming machine — Troubleshooting exercise Introduction To illustrate the procedure deseribad in ‘nis book, an example will be worked through in cefail for 2 typical machine as shown on page 36. The Bar Trimming Mactine consists of a cariage which s drven backwards and forwards by a hydraulic motor. Mounted on the cariage is 2 averse cyinder which ‘aves a euting forch across a meta bat Two ciame cyindors hols the barn place and a semioiary actuator pushes the bar ‘orto a ral lable at the end o! the cyale. ‘Assume that the operator has reported three problems which oceurred simultaneously ang prior to which the machine was operating sat stactorly. ‘Symptoms + The cariage drive motor is slow in both directions, + The traverse cylinder is slow when extending, «+ The system is running holler than usual Starting Point Start al the fundamental problem, Le. the Slow movement of tie cariage motor and traverse cylinder, using the Nect problem as a cue. Since wo machine ‘as have foccurrd itis not impossible that two faults have occurred in the hydraulic syslem smutaneously. tis more ikely howover, that one fault in the hydraulic systern ‘causing both machine lauts. The fog Procedure theetore is 10 look at machine faut in turn arg arrve at a ist of Units wien may be responsibie for that, particular symptom ther look for uns Common fo bath ists, Le. unts which could cause both symptoms. Machine Fault 1 Slow speed of carriage dive mot Step 1. The symptom is one of sp therefore, the proolem is Flow. Step 2. Corsult the cioult diagram and entity ie unts and therr function, Step 3. List the units that could affect the flow fo the carriage drive motor ep is fo narrow ‘of units fo be checked ‘a5 much as possible, Its important howover nat apply too much Judgement at this stage, since itis better fo have a fong list rather than a short ‘ane which misses out the vital unt. 1815 very easy to overtook a component when drawing up the jst, $0 for most systems iS safest fo go through the arts lst numerically and consider each boritin urn) Referring to the circuit diagram on page 37 the following Units may cause the problem: Tate [Commens Tate [Comments 3 [A partaly desea rat vahe 35 [Athough a faking olor valve atid stave tre pump and 37 |may affect he flow to tre hence the system of tid (Un 0 faults would have cer these crcumstances the (9 atest tne speed in ump would probably be cavi bth drections e. ether 36 & tating and hence nosy but as 37 bot leakrg or 36 8 38 mentoned above. Do not apply leaking or 37 & 38 leaking too much jwogement at this While this isnot impossible, t stage) is probably very much less 10 | biockaa iat Wier cous likely cause the same etc As for S0ano oT 77 [Cow output rary tre pump 22 [As above would attest he carriage dive —3g—[ Roar GaTAGOT motor sinee the How tothe having excessive drain motor is not throtled by any Igakago woud reduce the tow control vaves. etective low tothe motor 13 [A partally closed shut %SE_| From ihe solenoid eneraiza vaive may have the same 50 rion chart t can be seen that effect as a low pump output neither the traverse cyinder 16] parially closed check val far the eject rotary actuator wil also have the same eect are operating athe sare 17 —]Reakrg rele valve agar time as the carriage drive reduces the effective pump motor. Therefore, a leakage in So Bither of these two actuators 18] A blooked retum ine Wier may ‘uid rot attect flow to the resinict the exhaust fow from motor the motor (Atnough aby pass “ST | Because the camp ovinaors s fitted, the fiter may have are nele down under pressure been installed the wrong way when the carriage arive motor around) is operating (reer to solenoid [Toe maa aS energizaton char) leakage purpose of the accumulator in across the piston seals could this system isto suoplement ataat the How tothe carriage the pump flow, therefore an drive motor incorrect pre-charge pressure “52 _ | As abv may alec the llow rate from the accumulator. Machine Fault 2. 7 —|Apartally closed GORI Siow spead ot traverse cylinder when valve would tend to resinct extending the tow trom the aecuruigtor Step 4, Again the symptom is one of and hence tothe motor. speed, thertore the probleryis FM. ZE—[Rbiow dounvale e7 Spa — Sy : i diagram 1p 2. Consult the oreult dagram ana woulsteduce heetectve, amy he unts and ther funesons nat PeuMMI Step 3. Liste unts that coulé atfact ‘crane the ume he low fo the traverse cylinder when Go [Adirectonal vaweTeakngP— he panto ne singer whe to T could reduce the tow to the camage drive motor Tate [Comments Bi [As above x 34 —[Anexcessve leakage down — $__|See Machine Fault the drain ine of he pressure “T0_[ See Machine Fault reaueng valve could again ; a Fauk reduce the flow to ine carriage _!_[ See Machine Fault | ve motor 73_ [See Machine Fautt 35__[Aresiocion we avecton 76 —|See Machine FautT vave contoling the caiage = 22 Gove motor [caused by a arge “7__[See Machine FautT 08 of smart, incomplete spo movement or wrongy adjusted stroke adjusters for example} ‘could reduce the flow tothe fae Machine Fault ‘See Machine Fault} 2_ [See Machine 35Unit# [Commants Conta 22__ [See Machina Fault 30__| See Machine Fault “31 | See Machine Fault 7 34__ [Seo Machine Fault "35 _ [See Machine Fault T ‘See Machine Fault 1 Machine Fault] 4 @ of te by-pass ct valve, ie. jammed cosed, in the low control valve woula restrict the flow to the travers eylinger whan extencing [9 [Aleakage across the piston seals of the traverse cylinder Would recuce the ettective flow rate to the oylinder ‘See Machine Fault 1 See Machine Faull 'S common to both Isis le. unils which on their own could cause faults are as flows 7% 370, 30,31, 34, 35, Thorotore trom a total of 52 untts on tne system the search has been narrowed down to 78 by doing "0 more thaa look atthe circuit diagram, highighting the importance of being able to denti'y and Understand circuit dlagrams, Step 4. Arrange the list n order of checking The order in which urits are checked is purely arbivary and may be influences by such things 2s past experience, layout of components, position ot gauges etc., however, some unts will inev tably be easer 9 check than others. + Shutoff valves can be checked very easily to ensure they are in the correct position, so these may come first on the ist 9, 13, 21, 22, Assuming indicators are fitted 10 the fiters, these can also fe checked easly ~ 10, 18. + A pressure gauge is filed to the pump outlet port so the setting of the pump. compensator and relief valve can be checked quite readily 11, 17. + Apressure gauge isfited to reducing valve 34 50 the setting ofthis valve can be checked ~ 34, + The clamp cylinders can be quickly checked for abnorma symptoms - 51, 52. + The directional valves can naw be jecked for any aonormal sympioms — 30, 31, 35, 40, 42. + Finally check valve 16 can be checked for abnormal symptoms giving the complete Ist in orger as -9, 13, 21, 22, 10, 18, 11, 17, 34, 51, 52, 30, 31, 35, 40, 42, 16. Step 5. Preliminary check Before going to the trouble of fiting adcitional pressure gauges, fow meters, ec. oF of removing pipawork, there are Certain things that ean be checked wath the insrumerration already iastaled, or with the human senses of sight, touch, fang hearing. Uniess this slep is carried out, itis very easy to overlook what in hindsight appears a very obvious propio, i.e look for tha obvious Fist), For each of the units on the lst the folowing questions should be answered where applicable Is the Unit corect? (mode! number) Is the unttinstaled correctly? Is the unit adjusted correctly? Is the external signal correct? Does the unit respond fo the signal? ‘Avo thove any abnormal symatoms (heat, nose, etc}? ‘Assume thal the preliminary check is carried out for each unt up ‘a the clamp cylinder 52, which is unusually hot Step 6. Algotest Having d'scovered that one uril exhibits abnormal symptoms, 1. heat the unit ‘can now be cracked in mare detail by referring fo the system test sheet fo cylinders ie. Algo G.1. Assume that having -emoved the connection from the rod end of the cylinder and pressurized ne full Bore sda flu is found ta be leaking from the rod end connection, ite ine piston seals nave falea Step 7. The falec unt has now been ‘ocated and a decision can be made whether fo strp the unit in situ and make atepar or replace the complete unit, removing the faled unil fo te second ine service area for furtho’ examination Step 8. Think! Having made the epair or replaced the unit, theught should be given to Both the cause and the consequence ol the falure. Assuming the cylinder piston seals were damaged, the following Questions snoule be answered betore the machine is restarteo: What caused the seals fo become damaged? contamination? < heal? = wirong seals? = wrong installation? ete Will the failure have had ary elfect on the rest ol the syste” =I the seal has oroken up, have paticies of rubber entered the system? —Has the oll become overheated anc oxidized? Have any valves baen adjusted to ‘compensate for the leakage and will ow require re-adjusting, etc By thinking about the cause and the consequence ofthe failure, the same problem (or a consequential one) may be prevented at a later date, Carriage traverse cylinder Clamp cylindersCircuit diagram for bar trimming machine cramp a ie 2 Roa T39 4 Pressure Tank 2 Manifaldolock oa, Pre-charge ‘5 20) = Eaton ay = Eaton 1UBIS Lone Bak oad 5, 25) 20 Rossrond Rows Eden Paine, MN SH Footscray Usa OX Viton 311 To952 907 oo” Australia Fax 952 974-220 sw hydrauies eat, ot (1) 330193222 61) 360185718 ig) Accumiator E:-T-N Vickers ako 209 So apa e bla a8 8 obo ote O18 otto obs otpe 4 oi 8 ote 4 13 ote obs otto of 8 oo 10 f oe 8 oba NC ok , 2) a ALB, + + tpn oF £9 hh AR at ri CL Lt ahh» afte + L ont Dm, = , Manifold . tear 7 a Lys ® y £ Mae 18| f {8 Now Lan, vat sry Hanes FOBaN® Engin yn : ac a Ga aspinnerns|s a MW reba 5 : v0 = 5 wn ai Cope wa 37