TROUBLE SHOOTING
AND APPLICATIONS
INTRODUCTION
THE DIFFERENT STEPS INVOLVED
• INSTALLATION AND SELECTION OF HYDRAULIC SYSTEM
AND ITS COMPONETS
• MAINTENANCE
• TROUBLE SHOOTING AND ITS REMEDIES
I) INSTALLATION AND SELECTION OF
HYDRAULIC SYSTEMS
• IN ORDER TO MAKE SURE THAT THE HYDRAULIC SYSTEM
WORKS EFFICIENTLY, CAREFUL PLANNING AS WELL AS
PROPER INSTALLATION AND START UP IS REQUIRED.
REGULAR MAINTENACE OF HYDRAULIC COMPONENTS IS
A MUST.
• THE HYDRAULIC SYSTEM IS TO BE PLANNED AND
EXECTUED SO THAT PERSONNEL CANNOT BE
ENDANGERED DURING POSSIBLE MALFUNCTIONS AND
THE INSTALLATION STEPS SHOULD BE STRICLY ADHERED.
• THE FOLLOWING ARE SOME STEPS TO BE FOLLOWED WHILE INSTALLING HYDRAULIC
SYSTEM:
• HYDRAULIC ACCUMULATOR – HYDRAULIC ACCUMULATORS MUST BE PRE FILLED WITH
NITROGEN AND THE FILLING UP OF THIS SHOULD BE DONE ACCORDING TO THE INTRUCTIONS OF ITS
PRODUCER USING SPECIAL TOOLS
• TRANSPORT AND STORAGE - THE POWER UNIT OF THE HYDRAULIC SYSTEM SHOULD BE
PROPERLY PACKED AND HANDED OVER TO THE TRANSPORT COMPANY. THE POWER UNIT, MANIFOLDS
AND ALL THE OTHER HYDRAULIC COMPONENTS SHOULD BE PROTECTED FROM CONTAMINATION AND
WEATHER DAMAGE. SUITABLE MEASURES SHOULD ALSO BE TAKEN TO MAKE SURE THE COMPONENTS
DON’T GET CORRODED.
• HYDRAULIC HOSES – IN ORDER FOR YOUR HYDRAULIC MACHINE TO DRIVE
SMOOTHLY, HIGH QUALITY HYDRAULIC HOSES AND CONNECTORS ARE REQUIRED AND
ITS MAIN TASK IS TO TRANSFER OIL FROM ONE HYDRAULIC COMPONENT TO ANOTHER .
• SOME PRECAUTIONS THAT ARE TO BE TAKEN BEFORE USAGE OF THE PIPE
a. OBSERVE THE CROSS- SECTIONS’ OF THE PIPE AND ALSO ITS PERMISSIBLE WORKING
PRESSURE
b. ASSEMBLE THE PIPE BENDS USING BENDING DEVICES
c. THE PIPES AFTER BEING CUT TO THEIR LENGTHS SHOULD BE DEBURRED AND CLEANED
THOROUGHLY
d. HEAT TREATED PIPES ARE TO BE MECHANICALLY CLEANED AND DESCALED
e. THE PIPES SHOULD BE SUFFICIENTLY MOUNTED WITH PIPE BRACKETS IN ORDER TO
OVERCOME THE VIBRATIONS
AFTER ALL THE PRECAUTIONS ARE TAKEN, WE SHOULD MAKE SURE THAT THE PIPES
CONNECTIONS JOINTS OF THE UNIT MUST BE CONNECTED WITH THE EXTERNALLY
MOUNTED DEVICES OR MANIFOLDS AS PER THE HYDRAULIC SCHEME(SCHEMATIC
DIAGRAM)
• FLUIDS - THE HYDRAULIC UNIT IS TO BE FILLED WITH A HIGH
QUALITY HYDRAULIC FLUID SINCE IT PLAYS A KEY ROLE IN THE
TRANSFER OF POWER FROM THE PUMP TO VARIOUS OTHER PARTS AND
HELPS IN TRANSFERRING OF HEAT.
• THE MOST IMPORTANT FACTOR WHILE SELECTING HYDRAULIC FLUID
IS THE RIGHT VISCOSITY GRADE. IF ITS NOT SELECTED ACCORDINGLY,
THEN THE COMPONENTS WOULD DEGRADE AT A FASTER RATE.
• HERE THE VALUE OF VISOCITY GRADE DIFFERES ACCORDING TO THE
TYPE OFCOMPONENTS
COMPONENT USED MINIMUM
PERMISSIBLE
MINIMUM OPTIMUM
VISCOSITY(cst)
VISCOSITY(cst)
INTERNAL GEAR 10 25
EXTERNAL GEAR 20 25
RADIAL PISTON 18 30
AXIAL PISTON 10 16
HYDRAULIC FLUIDS
MINERAL OILS
WATER GLYCOL
EMULSIONS
FIRE RESISTANT FLUIDS
STARTING-UP SAFTEY INSTRUCTIONS
• THE COMPONETS ARE TO BE INSPECTED BY THE SPECALISTS BEFORE
USE
a. ACCURATE CONNECTIONS OF PRESSURE AND RETURN PIPES
b. ACCURATE CONNECTIONS OF PILOT PRESSURE PIPES
c. ACCURATE CONNECTIONS OF OTHER HYDRAULIC COMPONENTS
d. HYDRAULIC SYSTEM SHOULD BE MOUNTED SAFELY FOR THE
OPERATION
e. THE HYDRAULIC POWER UNIT SHOULD BE PLACED IN A LOCATION
WHERE ITS ACCESSBILITY IS EASY AND ALSO THAT IT DOES GET
BUMPED OR DAMAGED
THIS IS DONE SO THAT THE COMPONETS AND OTHER PARTS OF THE
SYSTEM ARE PROTECTED FROM DAMAGE
• FILLING - Before the hydraulic oil is filed in the reservoir, its
interior must be checked for cleanliness and if not should cleaned
properly(ISO 4406)
The hydraulic fluid is filled into the tank by using a fine filter.
• FLUSHING- here we circulate the fluid throughout the hydraulic
system and we repeat this process for a couple of times
• The flushing operation is done with the help of a flushing rig.
Before flushing is done, we need to make sure that the the DCVs
and the check valves are to be removed and replaced by flushing
plates to avoid damage of these valves
• ELECTRICAL CONNECTIONS :
• WE HAVE TO CHECK THE MOTOR CONNECTIONS AND THE VALUE OF THE
AVALIABLE CURRENT WITH THE E-MOTOR TYPE PLATE
• TO CHECK THE TYPE OF CURRENT AND THE VOLTAGE LEVELS FOR SOLENOID
VALVES
• THE ELECTRICAL CONNECTIONS ARE DONE ACCORDING TO THE TECHNICAL
RULES BY USING APPRORIATE PLUGS
• PUMP :
• THE PUMP CASE MUST BE FILLED WITH A CLEAN OPERATING HYDRAULIC FLUID
BEFORE START-UP IN ORDER TO LUBRIACTE THE BEARINGS
• IT IS ALSO ADVISED TO KEEP THE PRESSURE SETTING LOW AT FIRST WHEN
STARTING THE PUMP FOR THE FIRST TIME.
• THE PRESSURE COMPENSATOR IN A VARIABLE DISPLACMENT PUMP AND THE
PRESSURE LIMITING VALVES IN A FIXED DISPLACEMENT PUMP ARE SET TO
APPROX 15-20 BAR
