E:T-N | Vickers Logical Troubleshooting in Hydraulic SystemsIndex Introduction 3 ‘Shutting Down Machines 3 Line Service 3 Checking Faults wee coe 4 Instrumentation Principles and Measuring Instruments 5 Measuring instruments 6 Pressure Gauges 6 Pressure Gauge Installation 6 Flow Meters 7 Flow Meter Installation 7 Machine maifunction procedure 9 Machine faults 10 System faults 10 ‘System maifunction 10 System faults " Unit Fault Preliminary Check 12 Excessive Temperature ) Excessive Noise 4 Excessive Vibration 8 Excessive Leakage 16 ‘System test for gear and vane pumps 7 ‘System test for piston pumps 18 ‘System test for pressure relief valves 20 ‘System test for sequence valves at ‘System test for pressure reducing valves 22 ‘System test for flow control valves 23 ‘System test for directional control valves 28 ‘System test for pilot operated check valves 25 ‘System test for cylinders 26 ‘System test for hydraulic motors. ar ‘System test for accumulators 28 ‘System test for coolers 29 ‘System test for air leaks 30 ‘System test for fluid contamination 31 Pump cavitation 32 Aeration of fluid 3 Re-start procedure 34 Bar trimming machine ~ Troubleshooting exercise 35 Bar trimming machine layout 36 Circuit diagram for bar trimming machine 37 Warning “Logical Troubleshooting in Hydraulic Systems" is intended as a guide to systematic fault findings in a hydraulic system. Vickers systems (to the extent permitted by law) accept no liabilty for loss or damage suffered as a result of the use of this guide. Ifin doubt, always, refer to the original equipment manufacturer. Refer at all times to the “safety procedure” on pages 3 and 34.Introduction It would be a virtually impossible task to tty to document the cause and remedy of every possible fault that could occur ‘on even the simplest hydraulic system. For this reason itis necessary to adopt logical approach to troubleshooting, in order to locate a fault as quickly and accurately as possible. Down time on ‘modern production machinery is very expensive, so an hour saved in locating a problem may make hundreds, or sometimes thousands, of pounds worth of saving in lost production, Inevitably, hydraulic systems are ‘becoming more and more complex as ‘methods of controling machines become increasingly sophisticated, The last ten years has seen rapid technological ‘advances in the components used in ‘many hydraulic systems, and itis vital that equipment, or machine manufacturer's service information or ‘software’ keeps pace with the actual hardware being Used. Itis probably true to say that thoro is stil a (goneral lack of understanding of hydraulics in some areas of industry, and in realty, the job of a hydraulic maintenance eng) ner is now a specialized occupation with ‘many similarities to that ofan instrument or 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 industry. The fundamentals ‘around which this procedure is devel ‘oped, that is, the control of flow, pressure and direction of flow, applies equally as well o a rolling mil in a stee!- works or a winch drive on a trawler The Hit and Miss Approach The only alternative to a logical trouble- shooting method is the ‘hit and miss’ ‘approach, where units are changed at random until the failed 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. It is usually the case that a large number of perfectly servicable units are changed before the right one is found, ‘accumulator is fitted, extra care must be taken to release the pressure gradually Safety procedure for shutting down machines Tower or mechanically secure all suspended loads ‘As with all troubleshooting techniques, knowledge of components and their function in a system is vitally important. Itis probably fairto say that when all the ‘components of a hydraulic system have ‘been identified, their function deter- mined and the operation of the system ‘as a whole understood, the trouble- shooter has gone 51% of the way towards finding the problem. itis impor- tant therefore, that to make use of this ‘book etfectvely, a good understanding of the basic principles of hydraulics together with a knowledge of the opera tion and application of hydraulic compo- nents should frst be obtained ‘Shutting Down Machines Whenever servicing work is carried out (on a hydraulic system, the overriding consideration should be one of safety; 0 the maintenance engineer himself his colleagues and the machine operators, ‘Although safe working practices rely largely on common sense, itis very ‘easy 10 overlook a potential hazard in the stress of a breakdown situation. Maintenance personnel should therefore relief valve 2 leakage Monitors pump performance by measuring case leakagein the case of a variable pump, the pump ‘output flow will only be that actually required by the system at any time. A {900d indication of pump performance however, can be obtained by measuring the internal leakage in the pump, Le. ‘measuring the case drain flow as ingicated in Figure (B). A certain amount of case leakage is inherent on brand new pumps (caused by design clearances, lubrication ailing ete.) so it willbe necessary to compare the leakage actually measured with that for a pump within full specification. When measuring ‘case leakage itis important that itis done under steady state conditions, ie 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 flows so in fact a measuring jar and stopwatch may be used. Itis important however that the drain line is NEVER, allowed to be blocked of Figure (0) ilusirates a typical oftine arrangement. The addition of two shutoft valves in the system allows the system ‘verted through the flow meter. Again a low pressure meter can be used since the pump fow is measured at low pressure although this may not give a true indication (ofthe purmp outlet at normal working pressure. As mentioned previous, a flow ] when moton |CE={ motion taking) | _meterin pace has stopped i pump outet a a] ves/"istherea veine \\ves| Correct a eee flow trom tow rom Check next rotation cree Systm ay vave neue cn or it y "y wy isthe para Reassemble | NO ‘Check the YES assembled re NES heck he pune corrector vacuum atine | ( Pereigivaag >] toll vae cored me mp il rele va ves{y TS Pumpis | YES/vacuum mon Prime Is the pump i Check he : cawatng KEY “ans - pump consult FCR1 (-0.21 bar) bump SFinores eck tne Check the rele vave are ‘onkine 7System test for piston pumps. ourtet INLET & INLET ff p--4 ourtet ourlet 6g 0 INLET i pves Pye 10815 Pres PrB 108 15, START ing at pump cutet Check drive Is the pump (eading norma == ‘to pump shatt rotating system pressure no isthe pum ‘othe Load Is the system Readust | No/ [sme pure Bi NO! check next system oftoased”) | compensator >mpensator) system prble unto ist eting Tackot tow comecty YES vest [check pressure] YES/ Is there Re-adust | YES/ Is the reliet insert fow iron Preten’ KE=X motion taking) | elo valve ‘ave adusiea) | "mete has stopped sting conedty 7 | pumpcutet ye Tethe Isthe dive \ [Check pressure] YES/ le there ves| Comet raison) | nhon motor KX mation aking) (fom heck next tat conrect? has stopped piace he pump unit om it wy Adjust 's the pure) Check for | YES/is there tlow\ {Shere fow\ ves conpersatr Lege ™uponen) | catanen remany valve) (Reveigivag)=O] reel ve seting rin the system return ine ral! val ves] wy Presa] Prime Is the pump. Check the Is the pump\ NO |” stop andior Um pamed case drain on maximum compensator pump primed flow delivery setting wey ¥ ieee ton ves Check the [EY passing down\NO| Check the «Si, rine (OF roe” ae Noy Continued on next page 18System test for piston pumps (cont'd) ‘Algo A2 ‘ouTLeT INLET & INLET & INLET & ouTLeT ‘OUTLET ‘OUTLET Pes Pye 108 15 PFBS PFB 108 15 PVB 20829 Continued from previous page + (Check the vacuum at the ‘pump inlet Pump is cavitating consult FCRt 19System test for pressure rel Pt IT Insert pressure ‘gauge in TP is the pres TP TP 8-08 S10 arenes tate Me gy tozate system on poo load a ws tsthae \ ves, [check pressure problem ack rreton ‘ten ton of flow taking piace has stopped NO fairaro ton) No passing down v0 | continua on |s the relief Re-adjust ascing dow ee valve acjsteg) ralot valve tank line, comectly aes Te Cheek isihoretod\ veg [check tor co mere wes] est valve valve tank the system ron check srovelt valve 20 Algo BaSystem test for sequence valves ‘Algo B.2 RT-06 & 10 ACT-06 8 10 RG-06 & 10 ROG-06 & 10 Check the pressures at FP and 1P2 isthe ones valve Ro-adiust adjusted thevalve correctly YES Check No/ eine Is the pit \_ NO Check the ext unit problem signal pilot signal on list lack of flow, correct Wes Wes is there ox\ Check ES / Sco tow Isthe drain\ YES,.| Check the the valve ‘down valve line blocked rain ine rain ine NO Shut the system oun in a sale concion & remove ae ond caps isthe \ YE! Cheek spool ee next unit a on list ve Check the valve atSystem test for pressure reducing valves Algo B.3 fe 9 1 wal] [ rr X70 810 XCTOBAI0 —-—-XG-058 10 KCGO6A 10 xeL-03 Insert pressure gauges in TP! Tee meres \No. Isthe \ NO) toad ne eee system on ada at sl pumps yes Se J No. Is there \_NO Check for tec cael mon ang leakegein sien ace the system ayes YES Creek he Check tho presuure wren onus mation has stopped Tetho No pressure tsthevahe Re-adust reading ache valve corey Ss ithe isthe system \,NO. Check next draining \ESS,| Check the orc aly unto st wet rain ine hes ee anbthe,, \Wp | checknext Check the Qacesve unit on list valve Wes Check the valve 22System test for flow control valves Algo Ca TP1 1P3 TP2 FCG-02-1000 system problem flow Site Insert Cone ove ns isan inte - Sweaty VES \s the valve eI a NO ‘Check for Readust cose am lessin vai aoe J ion aes ayes Tet woot anges one's “a “85 ester |quo/‘Srroma\wo (Srra\ ves [Gos rooin onan Sym wong x — pressure pressure ene Tes eo Taso Check he ongest rk ‘System is. Are the stalled, Check NES) readings at NO Insert gauge seater an Pe abs isracua ihosame ‘anonra | ves /Ovecga\ no. [cmm cxeporsaing wosdne aay erect ae fee ae et 23System test for directional control valves Da3se ‘igo bt me Dgsse-t0e wee na rer Ad 48 tre ots Pus ty p61784-06 7% zl JL Tr Tee el tr fer Ie SLL Eu Te Tre Tepe Troon gauges ee tbe Opewaisvave Operate vave mal realy Pion Pie Tstherea ‘ote Tetheroa = reading ‘system on, road ae) reading ‘the on TP1 load system on TP2 system Check pit Check it supply supply Isthere \NO Is reading \NO Is there \NO- ‘motion taking Check the full system ‘motion taking coneck place valve pressure place 0 ve eS Walt on Walt on mation nas Ghecknent | | motor nas finished unit on list finished 24System test for pilot operated check valves TP2 Algo E.4 406-06 810 4oT.06 8 10 = gauses ite. Tek ee sure wih ow poritiey ‘ee Ts the \ ves [— Check pressure hes Gteronco oe v Taso gauge bist eseare tne Is pilot pres- NO Check sue saison) mt = var steely oss fina ston 8S /Does it mee YES [Check problem valve is required a ‘wee ‘oat vr iO eck or Check next Check for ‘unit on list in pilot line. 25System test for cylinders P C pe Double acting Algo G1 << Double acting double rod Bleed air from cylinder bleed points Fully extend cylinder to end of stroke ¥ Offload or release system Pressure at eylinder ports ¥ Disconnect annulus connection of cylinder ¥ Apply pressure| to full bore end| ¥ Check next Unit on list is ol leakin ‘rom annulus oylinder ‘Check the cylinder 26System test for hydraulic motors [check pressure} ‘at motor inlet port 25M, 35M 45M, 50M heck ors rena Teen pce Uyes Grea res otter Isback \ YES ‘Check for pets secon ieee vara re Grek ot pet Disconnect] NO YES moe cna ges ton chest ma urs Lem "sors wemotr ‘aed Is shaft be Check ee wena Tpves Chek vent on 27System test for accumulators e | Algo Jt Tnsert test gauge in {928 side of accumu- lator as manufactur ers instructions v Discharge fluid from ‘accumulator and check gas pressure v Ts the pre: charge pressure correct Charge with ritrogen to correct pressure, wes ‘Stop pumps and discharge ‘accumulator v Insert pressure gauge in uid line v [charge accumu: lator to fluid sys- ‘tom pressure v Ts the No/istepes\ ves /Tstherelet \ yes [Check the accu pressure sure switch valve of com- mulator according reading setting ppensator ad- to manufacturers, correct correct lusted corecty instructions wes Vv NO Vv No Check Re-adjust Readjust next unit pressure if valve or on list ‘switch ‘compensator 28System test for coolers Algo J.2 Check the oil temp ‘atthe outlet port As the water out lsttems higher Checkthe fanmdortney Soler ‘eo wes Isthe water\ YES he wate Check water ‘too high: ‘supply isthe Chock or fom loses inthe ne ool yom dyes Check the cooler ol he cooler {sere a dite YES [cosas workin Is the tomp ce betwoon 0 “Check noe one ‘wo high inet and outet ares a is te water 4 when ol Open water supply has reached valve etched on vworang tome isthe Readust thermostat thermostat pee 29System test for air leaks ‘Algo Lt Check pipe fitings Tighten or Are fittings repace worn tight fittings ‘Smear each joint with grease ‘one ata time Has the Continue Has the \NO[ Check the — ump noise along the pump noise pump shaft >| “grease changed faints changed seal s ves YES vu heck that The last joint Has the pump and was causing] ] pump noise strainers are aeration changed below fd Ge level Famnove pump and replace shatt and seal it needed Fill tank to Are they correct level below fiuld level ay ves Chack Tor porous hoses and pipe fractures 30System test for fluid contamination Algol Draw otra sample and compare with ‘resh fuid aypemaam NO /Doesino \.NB] Satniesio Ln insnedoimne [a] serene te Bio appear ‘uid appear siandorone F>] witha staiow [> incine atthe \'o be darker, y hour together angle same time Tes wes Thisoiinas | | Poura guantiy oxidized tee ‘and heat an a Ne id they Can ape OF ow tie poe they \ Nol” The fuidis Bo Roard at to stand ihe samo Py ewer the test tube ‘speed y u YES u u YES The fluid is Do air NO] This fluid is water laden bubbles polluted ey pte pte polled is correct The tid badly ‘aerated consult FcR?Pump cavitation (F100 small Clean or replace element Local restriction in suction line €.g partly closed valve or hose collapse (Open or modify valves, renew houses, etc Failure of boost pump Repair or replace boost pump ron rawr cause neweoy Secon sae amed rane ok Cian osenen ‘suction line Modify pipe layout [| susiontnetoing fof Paiceram or | Fuld too cna a we caviafon fr beaher based ts Pump running oo fast Reduce 10 recommended speed LJ Pump mounted too high ‘above oil level | Modity pump installation 32Aeration of fluid FAULT ‘Aeration of a fluid CAUSE FOR REMEDY Reservoir fluid level low Fillo correct level Poor reservoir design Modity design Return line in reservoir Tid Extend retum pipe (or damaged above fluid level below fluid level — Unsuitable uid t——*| Replace with correct fluid |__[ Pump shart seal worn Renew seals ‘Suction line joints allowing entry of air Renew or tighten joints Porous suction hose Renew hose Improper bleeding Lil Re-bleed system 33Re-start procedure Start the system start-up re-stariing Have the ‘cases of pumps Filup case & motors coe been filled Will the systom\_YES. Bleed or require bleeding prime as ‘or priming necessary Have all safety Remove interlocks salety interlocks ‘Sound alarm aware the or inform all machine is personnel ‘Aigo 06 Has the cause of the aren failure been ere es investigation Clean or flush the system as failure or during required eplacement Modity or unit the replace wth correct one correct unit Ae all hydraulic Remedy connections installation correct Ave all electrical Remedy connections installation correct Is the unit No ‘Adjust to Is the unit adjusted to a sate) asafe adjustable condition for condition 34