CHAPTER 8

Hydraulic System troubleshooting

8.0 Introduction

It is of prime importance that the trouble shooter is competently acquainted

with the design and the method of operation of the individual control
elements, sub assemblies as well as installation as a whole. Trouble shooting
becomes simple if the person concerned is competent in reading and
understanding circuit diagrams and operational sequences. Logically thinking
is another important point. The Hydraulic circuit, operational sequence
diagrams and other relevant documents must be obtained before attempting
to take any step. Trouble shooter should also have good understanding of
electrical / electronic drawings.

The table given below could be used as a guideline for a majority of

troubleshooting jobs.

Leaks are one of the most common problems in hydraulic installations. Origin
of leak should be identified first. If leakage occurs at pipe fittings, they can
often be dealt simply by tightening. If leakage originates from (inside) valves,
then it requires replacement of O-ring or oil seal.

8.1 Some Important Troubleshooting Tips

• Hydraulic systems do not normally fail overnight. There are usually

symptoms of an approaching problem. If the “Suggested Remedies” do
not correct the trouble and you need to refer to Oiltech’s hydraulic
specialists, always give as much background to the trouble as possible.
• Get to know the operation of the equipment you’re maintaining. Read
manufacturers’ instructions and study circuit diagrams carefully,
particularly recommended start-up procedures.
• Use the right tools – some hydraulic components are delicate and it
can take just the right touch to make them tick.
• Don’t take shortcuts – it rarely works Play it safe. Most modern
hydraulic equipment works in the range of 1 Mpa to over 100 Mpa (150
– 15000 psi) and high pressures can be dangerous. The safest way to
work on any machine is to shut it down first.
• Analyse the system and develop a logical sequence for setting valves,
mechanical stops, interlocks and electrical controls.
• Don’t experiment unless it’s your last resort. Manufacturers spend
experienced time designing, building and testing equipment. Take it
easy when making any improvements.
 Troubleshooting Table 1

8.1.1 EXCESSIVE NOISE

Symptoms Remedy
Be sure the fluid reservoir is filled to normal level and that fluid
intake is below surface of the fluid. (With rare exception, all return
lines should be below fluid level in the reservoir.) Check pump
packing, pipe and tubing connections, and all other points where
Air in fluid
air might leak into system. One way to check a point on the intake
side
suspected of leakage is to pour hydraulic fluid over it. If the pump
noise stops, you’ve found the leak.
Check for clogged or restricted intake line, plugged air vent in
reservoir. Check and wash strainers in a fluid compatible with
system fluid and check that the fluid viscosity is not too high.
Cavitation
Check for undersized suction line. check proper pump drive motor
speed plus pulley and gear sizes, particularly if a replacement
motor has been installed.
Pump Misaligned Align unit and check condition of seals, bearings and coupling.
with motor Misalignment may be caused by temperature distortion.
Check manufacturer’s maintenance instructions first. Tightening
Loose or Worn; every nut in sight may not be the way to stop noise or leakage.
Pump, Motor, Look for worn gaskets and packings; there is usually no way to
Poppet and Seat compensate for wear in a part and it is almost always better to
replace it. Check the fluid specification and quality.
Parts may be stuck by metallic chips, bits of lint, etc which need to
be cleaned out thoroughly. Avoid the use of emery cloth or
steel hammers etc on machined surfaces. Products of fluid
Stuck Vanes, deterioration such as gums, sludges, varnished, and lacquers
Valves, Pistons etc. need to be cleaned from parts with a solvent then dried thoroughly
before reassembling. Be sure new replacement fluid in system
provides adequate protection against corrosion and has sufficient
resistance to deterioration.
Filter and strainers must be kept clean enough to permit adequate
Filter or Strainer flow. Ensure that original filter has not been replaced by one of
dirty smaller capacity or inferior quality. Refill with fluid of quality high
enough to prevent rapid sludge formation.
Valve Setting too
If the relief valve sounds noisy, check the pressure setting by
Low or too Close to
installing a pressure gauge and adjust to the correct pressure if
another Valve
necessary.
Setting

8.1.2 OVERHEATING

Symptoms Remedy
Fluid Overheating Make sure the fluid supply is up to the correct level so that sufficient
fluid is available to disperse heat in the system. Make sure the fluid
in the system is not contaminated. Check fluid recommendations
 and viscosity requirements; if in doubt it may be worth your while
to drain the system, change the filter and refill with the correct
fluid. Unusually high temperature conditions may cause fluid of
correct viscosity for “working temperature” to thicken too much
because of oxidation. A possible cure would be to use a fluid of a
higher viscosity index.
Check for wear and loose packing. Fluid viscosity may be too low.
Internal Leakage
Check recommendations. Proceed with caution if you a tempted to
too high
try a high viscosity fluid.
Install pressure gauge and adjust to correct pressure. At least 860
Relief or Kpa (125psi) difference between valve settings should be kept on
Unloading Valve most systems, check with manufacturer’s recommendation.
Set too High Check that the relief valve is not stuck open. This indicates the
system contains dirty or deteriorated fluid.
Poorly Fitted or Poorly fitted parts may cause undue friction. Look for signs of
Worn Parts excessive friction; be sure all parts are aligned correctly.
On any machine equipped with an oil cooler, it is probable that high
temperatures are anticipated. If temperatures run high normally,
Oil Cooler they’ll go even higher if oil cooler passages are clogged. If you find
Clogged a clogged cooler, try blowing it out with compressed air. If this does
not work, try solvent or Oiltech Transclean 801. It may be
necessary to replace cooler control valve and/or cooler.

8.1.3 INCORRECT FLOW

Symptom Remedy

Shut down immediately. Some types of pumps can turn in either

direction without causing damage; others are designed to turn
Pump Shaft Turning in one direction only. Check belts, pulleys, gears and motor
in Wrong Direction connections. Reversed leads on 3-phase motors are a common
cause of wrong rotation. It may be necessary to replace pilot
pressure pump.

Replace dirty filters, clean clogged inlet line, clean reservoir

Pump Not Receiving breather vent and fill the reservoir to the correct level. Overhaul
Fluid or Replace supercharge pump. Check the yoke activating
device is Operative (variable displacement pumps).
Mechanical Trouble Mechanical trouble is often accompanied by a noise that you
(broken shaft, drive can locate very easily. If you find it necessary to disassemble,
motor not operating, follow the manufacturer’s recommendations to the letter.
loose coupling etc.) Improperly assembled pumps are often the cause of no flow.

Some pumps will deliver hydraulic fluid over a wide range of

speeds, others must turn at recommended speed to give
Pump Shaft Speed appreciable flow. Find out the speed recommended by the
Too Low manufacturer, then check the speed of pump with a flow
counter if possible. If the speed is too low, look for trouble with
driving motor and check relief or unloading valve.
Check that the Yoke actuating device is operative (variable
displacement pumps). The flow control may be set too high or
Excessive Flow
an
improper size replacement pump has been used.
If any air at all id going through the pump, it will probably be
Air Leak in System
quite noisy.

8.1.4 INCORRECT PRESSURE

Symptom Remedy
If valve settings are too low, fluid may flow from pump through
valves and back to the fluid reservoir without reaching point of
Pressure Reducing
use. If valves are set too high, refer to OVERHEATING advice.
Unloading, or Relief
Check that valves are not damaged, worn or dirty. To check
Valve Setting
relief valve setting, block discharge line beyond relief valve and
Incorrect
check
line pressure with pressure gauge.
If open – centre directional control valves are unintentionally set
Incorrect Control
at neutral, fluid will return to reservoir without meeting any
Valve Setting, Fluid
appreciable resistance and very little pressure will be developed.
“Short Circuit” to
Scored control valve pistons and cylinders can cause this trouble
Reservoir
Replace worn parts.
Check whole system for leaks. Serious leaks in the open are
easy
to detect, but leaks often occur in concealed piping. One routine
Leak in System in leak testing is to install pressure gauge in discharge line near
pump and then block off circuit progressively. When gauge
pressure drops with gauge installed at a given point, leak is
between this point and check point just before it.
Install pressure gauge and block system just beyond relief valve.
Broken, Worn or
If no appreciable pressure is developed and relief valve is OK,
Stuck Pump Parts
look for mechanical trouble in pump.
Accumulator
Check gas valve for leaks. Charge to correct pressure. Overhaul
Defective or Lost
if defective.
Charge
8.1.5 ERRATIC ACTION

Symptom Remedy
First check suspected part for mechanical deficiencies such as
misalignment of a shaft, worn bearings etc. Then look for signs
of dirt, sludge, varnished and lacquers caused by fluid
Valve Pistons etc.
deterioration. You can make up for mechanical deficiencies by
Sticking
replacing worn parts, but remember deficiencies are often
caused by the fluid level being too low or the use of the wrong
fluid.
This can cause noisy as well as erratic movement. To avoid
Lack of Mechanical
wear ensure linkages and machine ways are correctly
Lubrication
lubricated.
Malfunctioning Servo
Amplifier, Servo Valve Clean and adjust or replace. Check the condition of system
or Feedback fluid and filters.
Transducer
Sluggishness is often caused by fluid that is too thick at
starting temperatures. If you can accept this for a few minutes,
fluid may thin out enough to give satisfactory operation. If fluid
does not
Sluggishness when a
thin out, or if ambient temperature remains relatively low, you
Machine is first Started
may have to change to fluid of lower pour point, lighter
viscosity
and/or higher VI. Under severe conditions immersion heaters
are sometimes used to pre-heat oil.

8.1.6 LEAKAGE AROUND PUMP

Symptom Remedy
Tighten packing gland or replace packing. Trouble may be caused
Worn Packing by abrasives in fluid. A check of points where abrasives might
enter should be made.
Usually it is better to have slight pressure on the suction side of
the pump, although it may not be necessary. With more than slight
Head of Fluid on
head, leakage may result. If head is not required and components
Suction Line
can be re-arranged, do so. Leakages should always be fixed
because they are points which allow suction of air.

Troubleshooting Table 2

Sources of Mechanical Suction line Pump Pressure Return line pressure

trouble / drive line valve
effect

A excessive Coupling Suction line Pump rpm line line Valve chatter
noises wrongly resistance higher than mountings mountings due to dirt on
aligned. excessive rated. are are valve seat,
because missing or missing or valve worn.
Load loose. loose.
(1) Suction pressure Insufficient
 Coupling filter exceeds lines have lines have damping.
loose. clogged or rated value been been
too small. of pump. wrongly wrongly Flow noises
coupling laid. laid. when
defective. (2) Suction Shaft seals operating.
line blocked defective ID of pipe id of pipe
Loose or leaking. too small. too small. Unsuitable
mounting on Seals of characteristic
pump & mp; (3) Suction suction line Installation Installation curve.
mp; mp; / line has defective. not bled not bled
motor. wrong completely completely. Wrong
dimensions- pump design
Other ID. or too defective. Return
transmission many terminates
elements bends above oil
Pressure &
loose. mp; mp ;mp; level.
(4) Oil level return line
Pump / too low. connected Return
motor wrongly. filter
defective. blocked.
Control
Direction of system
rotation oscillating.
wrong.
Noise
Noise damping not
damping not incorporated
incorporated in design.-
in design.- rubber
rubber metal metal
mountings. mountings

B Insufficient Power AS 2AInternal leakage due Leakage. Excessive Operating

power & mp transmission to wear. line pressure set
;mp; mp; defective. Excessive resistance. too low.
torque at Unsuitable type. line
the power Coupling resistance. Filter Internal
take offs. element blocked. leakage due
Pump defective.
defective. Pressure to wear.
( pressure filter
Control element
too low) Direction of blocked. Dirty or
defective.
rotation damaged
wrong. valve seat.

Motor Broken
defective. spring

Key sheared
off at pump
or motor
shaft.
C Jerky AS 1 A AS 2A.Pump defective. Installation AS 5B AS 6A1...2
cylinder & 1.....7. not bled
mp; mp completely. Excessive
;mp; motor length of
movements.
- Variations undamped
in pressure remote
& mp; mp; control line.
mp; flow.
Unsuitable
remote
control valve.
 Sources of 1 2 3 4 5 6
trouble /
effect mechanical Suction pump pressure return PRESSURE
drive line line line VALVE
D no oil flow or as 1A as 2A internal as 4b as 5b AS 6B.
insufficient 1.....7. leakage
flow. due to With
wear. sequential
control:
pump
defective. Sequence
valve
inlet ∓ setting is
mp; return too high, or
lines valve is
connected defective.
wrongly.
E excessive reduction internal as 4e
operating in diameter
temperature. efficiency too low,
due to causes
wear. frictional
resistance.
rpm is
high or pressure
flow rate filter
is blocked.
excessive.

Sources of 7 8 9 10 11
trouble / effect
Flow Directional Oil Hydro Others
control control motor /
valve valve. cylinder
E excessive through- leakage as 9 b. losses in cooling
operating flow set too losses too efficiency performance
temperature. low.- high. due to of assembly is
excessive wear. insufficient in
pump pressure relation to
delivery circulation internal installed
through fails to friction too power or
pressure switch on. high. operating
relief valve. time.
spool internal
valve sticking. leakage pressure less
defective. losses. circulation not
provided.

insufficient oil
in the system.
 coolant valve
fails to switch.

thermostat set
too high.

coolant not
switched on
or no coolant,
or fan
defective.

coolant
temperature
too high.

surrounding
temperature
too high.

deposits in
coolers.

insufficient
heat
dissipation.
F foaming in oil unsuitable
grade.
G cylinder run- switching internal pilot
0n. time set too leakage. controlled
low. check valve
faulty fails to close
defective bleeding. immediately
solenoid because
causes
leakage in
valve.

valve dirty.