Hydraulic Systems

The hydraulic system of Aircraft is an important power organization and plays an

important role in the process of airplane operation. The failures of the airplane have
the character of concealment, complexity and uncertainty. So if the hydraulic system
ran out of order it not only cause huge casualties and economic losses, but also has a
long and low efficiency maintenance cycle. This text analyzes the common causes of
the failures and the failures that newly appeared of the aircraft hydraulic systems in
detailed. Some of effective solutions have been proposed which quicken accelerate
the speed of fault diagnosis and improve the efficiency of aircraft maintenance.

 Anticipated Impact on Crew

The crew that experiences problems with hydraulics might face the

following:

 Downgraded flight characteristics - the crew could have difficulties

controlling the aircraft that might vary from light to severe if all

hydraulic systems are not present;

 Increased stress in the cockpit - the crew would need to perform

some preliminary checks to estimate the extent of reduction of the

normal characteristics of the aircraft.

 Increased time allowance - additional time might be needed in order to

check the status of the problem and to initiate the required mitigations.

It should be noted that some of the situations are present in SOPs or

 other documents with proper check-lists, but others may necessitate

an ad hoc solution.

 Manual flying - major damage of hydraulics would usually affect the

auto-pilot functions.

 Immediate landing - after assessing the situation, the crew could

decide to carry out an immediate landing at the nearest (suitable)

airport.

 Effects

Depending on the extent of damage to the hydraulic system(s), the

following effects might appear:

 Difficulties with extending/retracting of landing gear;

 Lack of autopilot;
 Partial control over different control surfaces;
 Reduced braking capability upon landing;
 Lack of control over thrust reversers;
 Loss of nose wheel steering making it difficult or impossible
to clear the runway after landing;
 Partial/total loss of control while flying.

(*)As the hydraulic systems are of paramount importance for

the safe flight, many design steps are taken to ensure
reliability, redundancy and control. Often three independent
hydraulic systems are in presence. They are fitted with
different sources of power/pressurization, run in different lines
and exchange pressure/liquid only under controlled conditions.
  Common Causes of Hydraulic Failure

1. Air and Water Contamination

Air and water contamination are the leading causes of hydraulic failure,

accounting for 80 to 90% of hydraulic failures. Faulty pumps, system

breaches or temperature issues often cause both types of contamination.

Air contamination is the entrance of air into a hydraulic system and

consists of two types — aeration and cavitation. Both can cause severe

damage to the hydraulic system over time by wearing down the pump and

surrounding components, contaminating hydraulic fluids and even

overheating the system. Although we are not pump manufacturers, we

know it is essential to be aware of these types of contamination and how

to identify them.

 Cavitation: Hydraulic oil consists of about 9% dissolved air,

which the pump can pull out and implode, causing damage to
the pump and to other components in a hydraulic system over
time. You can identify this problem if your hydraulic pump is
making a whining noise.
 Aeration: Aeration occurs when air enters the pump cavity
from an outside source. Usually, loose connections or leaks in
the system cause this issue. Aeration also creates a sound
when the pump is running, which sounds like knocking.
 2. Temperature Problems

Hydraulic systems that run too hot or too cold can cause severe

problems over time. Some of these challenges include the following.

 Fluid thinning: Heat can cause hydraulic fluids to thin,

preventing lubrication and making the fluid more likely to
leak.
 Fluid oxidization: Extreme heat can cause hydraulic fluid to
oxidize and thicken. This fluid thickening can cause buildups
in the system that restrict flow, but can also further reduce the
ability of the system to dissipate heat.
 Fluid thickening: Low temperatures increase the viscosity of
hydraulic oil, making it harder for the oil to reach the pump.
Putting systems under load before the oil reaches 70 degrees or
more can damage the system through cavitation.

3. Fluid Levels and Quality

Fluid levels and quality can affect hydraulic system performance. Low

fluid levels and inappropriate filtration can result in air contamination,

while fluid contamination can cause temperature problems. Leaks can

further exacerbate both issues.Using the correct type of fluid is also

essential, as certain hydraulic oils are compatible with specific

applications. There are even oil options that offer higher resistance to

temperature-related problems. Some oils even offer anti-wear and

anti-foam additives to help prevent against wear and air contamination,

respectively.

4. Human Error

Human error is the base cause of many hydraulic system problems. Some

of the most common errors that may result in your hydraulic pump not

building pressure include the following.

 Faulty installations: Improper installation of any component in a

hydraulic system can result in severe errors. For example, the pump

shaft may be rotating in the wrong direction, negatively affecting

pressure buildup, or pipes may be incorrectly fitted, resulting in leaks.

 Incompatible parts: An inexperienced installer may put mismatched

components together, resulting in functional failures. For example, a

pump may have a motor that runs beyond its maximum drive speed.

 Improper maintenance or usage: Using systems outside their

operational capabilities or failing to perform regular maintenance are

some of the most common causes of hydraulic system damage, but

are easy to rectify through updated maintenance policies and training.

 How to Prevent Hydraulic System Failure

 Follow specifications: We can trace the most common hydraulic

system issues back to fundamental system problems like
incompatible or improperly installed parts. For this reason, it's
essential to always double-check specifications to ensure your
purchased parts can work together seamlessly.
 Consult with professionals: When purchasing new equipment,
consult with industry peers and professionals to discover what
they recommend. While manufacturers can tell you how a
product should work, industry professionals can provide
concrete examples of how well the equipment works for their
industry.
 Perform maintenance: It is essential to focus your operations
on equipment longevity. Review your daily, monthly and
annual maintenance procedures to ensure you are covering
every aspect of your system according to best maintenance
practices.

Hydraulic System Maintenance.

 Daily tasks: Take care of a few simple daily checks to avoid

issues. For example, personnel should check the oil levels,
hoses and connections and listen to the pump for abnormal
sounds.
 Routine tasks: Plan and execute a weekly and monthly
maintenance routine, checking for the most common failure
sources given your system's working conditions. These should
include components, filters and the condition of the oil.
 Complete system checks: Depending on the conditions of your
system, you and your team should perform complete systems
checks monthly, quarterly or annually. Tasks should include
running a comprehensive report on the system, cleaning
devices, draining the system and replacing damaged parts.
 How to Work Safely With Hydraulics

 Wear safety equipment: Always wear appropriate safety gear when

working close to a system, including a helmet, glasses, gloves and

protective clothing and shoes.

 Power down systems: Never service a running hydraulic system

unless it is strictly necessary.

 Be mindful of location: Do not stand at end points while working on

hydraulic systems. This safety measure can help prevent loss of limb

and life, as there is a lot of pressure built up in these areas that can

release and result in life-threatening situations.

 Use safety locks: Hydraulic safety locks save lives. Always use these

when transporting or lifting equipment for service.

 Use caution around running systems: Always keep an eye out on

pressure taps, couplings and hoses when they are under pressure. If

something does not look right, power down the system before

checking it. Loose or faulty parts can easily become deadly

projectiles.
The best safety measures, however, are to perform excellent

maintenance and use high-quality parts. If you're looking for a quality

hydraulic component manufacturer, York Precision Machining &

Hydraulics can help.

 Hydraulic System Troubleshooting

The sources of hydraulic system failures can be tricky to identify, but

some troubleshooting steps can help narrow down the options. So how do

you troubleshoot a hydraulic system? Here are some of the fundamentals.

1. Check the motor: Ensure the motor has the correct wiring and can

turn on and off.

2. Check the pump: Take the pump assembly apart and assess all parts

to ensure that they are functional and installed correctly. The most

common problem areas include the pump shaft, coupling and filter.

3. Check the fluids: Check the level, color and viscosity of the hydraulic

oil to ensure it meets specifications and has not become contaminated.

When in doubt, drain and replace the fluids.

4. Check valves and lines: Observe all lines for potential leaks, and

tighten every connection point. Also, check the relief valve for any

signs of damage.

5. Run the system: When you have completed all these essential checks,

turn on the system and monitor it for pressure and temperature

fluctuations, as well as abnormal sounds. If all seems well, check your

pressure sensor for potential failure.