Standard Maintenance practices

Periodic checking of oil level in the reservoir

Periodic cleaning of suction strainer Return line filter element to be changed after initial 100 hrs

and at 500 hrs there after. Periodic analysis of oil sample for contamination Flushing of the system after major breakdown and restart Mounting of magnets in reservoir to prevent entry of ferrous particles Dont return to the system any fluid that has leaked out Dont mix two different grades / makes of oil

Standard Maintenance practices

Use clean containers, hoses and funnels for filling the oil

into the reservoir. Use of portable filtration unit is recommended Use only cloth for cleaning or wiping of hydraulic components Ensure proper type and quantity of spare items and proper storage

Sequence of shutting down the machine for service

Lower or mechanically secure all suspended loads Exhaust any pressure locked in the system Drain down all accumulators

Isolate the electrical power supply

Isolate the electrical control supply

Discharge both ends of the intensifier

What is to be checked?
The Pressure
The Flow The Direction of flow

- For Force of the actuator

- For Speed of the actuator - For the direction of the actuator

Ask questions in terms of pressure, flow and control to identify the problems

Trouble shooting
Required pressure not developed:
Probable Cause Remedy Preset pressure of relief valve Reset the relief valve pressure with the help of is too low pressure gauge Relief valve is not opened Open the relief valve, check for smoothness in movement of piston Check for seating area is proper (Poppet and seat) Clean the orifice hole in the piston if it is blocked Check the actuator / Valves for excess internal leakage Check the valves for malfunction (All valves) Incorrect spool function of Dir. Valve, change to correct spool function Make setting again or eliminate the malfunction

Excessive internal leakage System oil flows back to the reservoir Incorrect adjustment or malfunctioning of slow regulator valve

Trouble shooting
No Flow from the pump:
Probable Cause Wrong direction of pump rotation Pump shaft not rotating Large air entry form the suction port Insufficient revolution Failure of vanes to come out of slots in a vane pump Delivery rate set at set at 0 with a variable displacement pump High mounting position Excessive oil viscosity Worn out or damaged parts Remedy Run in specified direction of rotation Key not fitted or coupling is loose Tighten all suction fittings, fill with hydraulic oil or cover with grease Run at least minimum specified RPM Disassemble, clean and remove dust in slots Re adjust the delivery rate Height of pump inlet port to be within one meter from the oil level in reservoir Choose oil with suitable viscosity grade Repair or replace the parts

Trouble shooting
Excessive Temperature:
Probable Cause Reservoir fluid level low Reduced efficiency of oil cooler Remedy Top up the Reservoir Check the temp. of cooling media (Air/ Water) Check for choking of cooling area (Tubes / Fins) Check for quantity of supply of cooling media (Fan angle damage / Water supply) Drain and refill with correct fluid

Correct fluid is not used

The pump output pressure is Readjust the set pressure of the relief valve to meet too high with required system load Increased internal drain in pump (Wear out) Reservoir surrounding not clear Measure the drain amount Piston pump Measure flow at set pressure Vane pump & Gear pump (volumetric efficiency) Clear the area for natural cooling

Trouble shooting
Excessive Noise:
Probable Cause Pump noisy Air in the system Air entry through pump shaft seal Remedy Tighten all suction fittings, fill with hydraulic oil or cover with grease Replace the shaft seal if worn out

Air bubbles in the reservoir

Return line pipe should terminate below oil surface in reservoir at any time Location of return pipe with respect to suction pipe to be proper and also flow path
Change to larger size suction strainer Clean or replace the strainer / Filter element Reduce the pump speed to the rated speed Realign motor and pump accurately Adjust to correct pressure

Small size of the suction strainer (Increased suction flow resistance) Clogged strainer / Filter (Increased suction flow resistance) Pump speed is too high Coupling misalignment Relief valve noisy Setting too low or too close to another valve setting

Trouble shooting
Oil leakage:
Probable Cause The line pressure is out of the rated pressure range of the seals Seal is not compatible with oil Remedy Check the seal if it meets with the use for the line pressure. If not replace it Either swelling or shrinkage can occur due to the chemical reaction. Change the seals to the particular type of oil used

Deformation due to self life of seals

The finish of the surface which interferes with the seal is improper

Flatness or hardness may change or degradation can occur since the seals have a specific self life
Check the surface area for roughness, burrs and contaminant particles on the area Refurnish the surface, Get rid of burrs, clean the surface area

Trouble shooting
Oil leakage:
Probable Cause Misalignment of pipes and fittings Improper tightening torque for bite type fitting Improper usage of thread combination Damaged sealing material Remedy Open the nut, correct the eccentricity between the pipe ferrule and fitting Check for the ferrule movement Deformation inside the pipe Use correct thread combination Parallel to Parallel Parallel to Taper Damaged Dowty seal Damaged O-ring