Common Faults and Solutions of Hydraulic System

At the heart of the system is the hydraulic pump itself, which must be properly lubricated to work properly. In fact, recent industry analysis shows that contamination of the lubricating fluid is responsible for 80-90% of hydraulic problems. Regular inspections of hydraulic equipment and hydraulic testing should be part of basic plant maintenance for all companies. Knowledge of the warning signs of common hydraulic problems can save expensive plant machine repairs by resolving the problem as quickly as possible.

I. Hydraulic system failure warnings:

1) Excessive temperature:

The optimal temperature for a hydraulic system operating at peak efficiency is eighty-two degrees Celsius. If your system frequently exceeds this temperature, it may be a sign of ventilation, a damaged heat exchanger, or dust accumulation in the filter. Increased heat in the system causes the viscosity of the hydraulic oil to decrease, which reduces lubrication of moving parts and causes them to grind against each other. This causes wear on parts and introduces metal fragments into the system, causing internal damage, and seal wear due to the abrasive nature of the fragments. Further increases in temperature cause the fluid to oxidize and thicken, forming varnish-like deposits on components that will reduce flow in the future. Higher viscosity also reduces the ability of the lubrication and fluid cooling system.

2) Excessive Noise:

While hydraulic systems are inherently noisy, any persistent knocking or rapping coming from the system could be a sign that air has entered the system (called aeration) and contaminated the hydraulic fluid, which can lead to a number of problems. The movement of the pump causes air bubbles to compress and decompress as they move through the system, creating a knocking or rapping noise. When placed under pressure, the bubbles can burst, which can cause wear on parts and dislodge debris, further contaminating the fluid and raising the temperature within the pump. Abnormal rapping or rapping can also indicate a condition called cavitation, where air or fluid vapor takes over a portion of the hydraulic pump instead of just the hydraulic fluid. Again,

3) Physical Identification of Hydraulic Fluid:

If the hydraulic fluid is drained and replaced regularly, some signs of internal problems can also be discovered simply by observing the physical condition of the hydraulic fluid itself. Temperature can be easily measured to ensure it is not above eighty-two degrees, turbidity due to contamination from foreign particles or larger particles in the air or fluid can be easily observed, and viscosity can be measured, as an overly thick fluid can be measured as a significant factor in cavitation. It is also possible to measure the volume of fluid in the system, and lower volumes than usual are a potential indication of cavitation. If the fluid has a milky appearance, this is a sign of water contamination, which can lead to reduced lubrication and corrosion due to rust, which can cause parts to wear or seize, leading to broken parts or additional stress on the entire system. In extremely cold conditions, any water in the system may freeze, reducing performance and causing further damage. Foam in the fluid is another symptom of aeration.

4) Erratic Performance:

Any erratic or slow performance can be a sign of a leak inside or outside the system. This can cause slower cycle times due to the falling pressure, and increased heat in the system, which will reduce the viscosity of the hydraulic fluid, leading to increased leakage, which in turn leads to further temperature increases in a vicious cycle. Irregular movement of the actuator may also indicate aeration.

Second, Solution:

The easiest way to solve all of these problems is to have your hydraulic system regularly checked by a professional and ensure that it is regularly cleaned and properly maintained. Prevention is always better than cure, especially when your business depends on it. However, problems can still arise unexpectedly, in which case immediate action should be taken.

Heat buildup can be monitored externally with an infrared thermometer, but this is not always a good indicator of abnormal internal temperatures. The simplest solution is to ensure that the system is equipped with a fluid temperature alarm, which will immediately show if the temperature is rising. If an internal leak is suspected, it may be necessary to use a hydraulic flow tester to determine the exact location, saving time and effort without having to dismantle the entire system to find the source of the leak. External leaks such as burst pipes or loose seals will usually be obvious even with a cursory external inspection of the equipment, but it is always worth double-checking that all clamps and fittings are secure and seals are not fragile or worn. This is also a way to ensure that no air can enter when fluid escapes,

Since the main method of heat dissipation in hydraulic systems is through the water tank, it is important to check that the water level is always correct and that there are no obstructions or debris that will restrict airflow. Heat exchangers should also be checked regularly to ensure that there are no obstructions in the core that may reduce the flow of hydraulic fluid or hydraulic oil through the core, causing heat buildup. Obviously, if any of these components are damaged, they should be replaced immediately.

The inlet of the pump should be checked regularly as this is one of the main reasons for air to enter the system. All intake pipe fittings should be checked and tightened if necessary. Flexible intake pipes can also become worn or porous over time as the material degrades, so these should be checked and replaced if necessary. Low water levels in the reservoir can also create vortices that allow air in, so the correct water level must be maintained. Air can get in any way, which is also an opportunity for moisture to get in, so it is vital to perform these checks. In some systems, there is also a risk of air getting in through the pump seals, so these must also be checked.

To ensure optimal performance, hydraulic oil must be drained and replaced regularly. As mentioned above, this is a great opportunity to check the fluid for any signs of contamination with air, water or other foreign matter and to detect any signs of heat damage or damage to the filtration system. This can warn of many problems before they cause physical problems in the system and provide an opportunity to drain out any water that has been trapped. A number of synthetic oils for hydraulic systems are available that have increased resistance to heat and cold, protecting the system from damage while reducing oil degradation caused by heat. Many products also have oxidation inhibitors, anti-wear additives and defoamers to help extract air from the oil, all of which can reduce the need for oil.