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Troubleshooting Guide – The 90/10 rule    

Troubleshooting Guide – The 90/10 rule

It would be a virtually impossible task to try to document the cause and remedy of every possible fault that could occur on even the simplest hydraulic system. For this reason it is necessary to adopt a logical approach to troubleshooting, in order to locate a fault as quickly and accurately as possible.

Downtime on modern production machinery is very expensive, so time saved in locating a problem may reduce lost production. Inevitably, hydraulic systems are becoming more complex as methods of controlling machines become increasingly sophisticated.

The objective of this guide is to provide a logical approach to troubleshooting. When troubleshooting is applied logically, not all hydraulic problems are equally as difficult to solve, the split between ‘easy’ and ‘hard’ hydraulic problems is around 90/10. In other words, at least 90% of the hydraulic problems you’re ever likely to encounter are easily rectifiable if the correct procedures are followed.

Problem – Excessive Noise

A.) NOISY PUMP

Cavitation

Remedy – Replace dirty filters, wash strainers in solvent, clean clogged inlet line or replace reservoir breather vent, change system fluid, change to proper pump motor speed, overhaul or replace supercharge pump, fluid is too cold.

Air in fluid

Remedy – Tighten leaking connections, fill reservoir to proper level, bleed air from the system, replace pump shaft seal and or shaft if worn at seal.

Coupling misaligned

Remedy – Align unit and check condition of seals, bearing and couplings.

Pump worn or damaged

Remedy – Overhaul or replace.

B.) NOISY MOTOR

Coupling misaligned

Remedy – Align unit and check condition of seals, bearing and couplings

Motor or coupling worn or damaged

Remedy – Tighten leaking connections, fill reservoir to proper level, bleed air from the system, replace pump shaft seal and or shaft if worn at seal.

C.) NOISY RELIEF VALVE

Setting too low or too close to another valve setting

Remedy – Install pressure gauge and adjust to correct pressure

Worn poppet and seal

Remedy – Overhaul or replace

 

Problem – Excessive Heat

A.) PUMP HEATED

Cavitation

Remedy – Replace dirty filters, clean clogged inlet line, clean or replace reservoir breather vent, change system fluid, change to proper pump drive motor speed overhaul or replace supercharge pump.

Air in fluid

Remedy – Tighten leaking connections, fill reservoir to proper level, bleed air from system, replace pump shaft seal.

Relief or unloading valves set too high

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Excessive load

Remedy – Align unit and check condition of seals and bearings, locate and correct mechanical binding, check for work load in excess of circuit design.

Worn or damaged pump

Remedy – Overhaul or replace.

B.) MOTOR HEATED

Fluid heated

Remedy – Overhaul or replace.

Worn or damaged motor

Remedy – Align unit and check condition of seals and bearings, locate and correct mechanical binding, check for work load in excess of circuit design.

Excessive load

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Relief or unloading valve set too high

See below D.) Fluid Heated

C.)  RELIEF VALVE HEATED

Fluid heated

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Valve setting incorrect

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Worn or damaged valve

Remedy – Overhaul or replace.

D.) FLUID HEATED

System pressure too high

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Unloading valve set too high

Remedy – Install pressure gauge and adjust to correct pressure (keep at least 125 psi difference between valve settings).

Fluid dirty or low supply

Remedy – Change filters and also system fluid if improper viscosity, fill reservoir to proper level.

Incorrect fluid viscosity

Remedy – Change filters and also system fluid if improper viscosity, fill reservoir to proper level.

Faulty fluid cooling system

Remedy – Clean cooler and or cooler strainer, replace cooler control valve, repair or replace cooler.

Worn pump, valve, motor, cylinder or other component

Remedy – Overhaul or replace.

This trouble shooting guide is just a few easy steps to follow which can help you diagnose the problem causing a tool to fault on site.When hiring equipment from HTL you don’t have to be concerned with fixing problems onsite or sourcing the correct solution yourself; HTL’s industry knowledge and expertise is available 24/7 to assist you. With express delivery available and our Fast Track Calibration Service, replacement equipment is sent direct to site reducing your downtime whilst your equipment is being repaired or calibrated by our fully qualified Service Engineers.

For more information or for an instant quote contact us today: call +44(0)1670 700 003 or email info@hiretorque.com / info@htl-australasia.com.

Related Links: https://www.linkedin.com/pulse/advantages-hiring-equipment-htl-georgie-arnold?trk=mp-author-card

https://www.linkedin.com/pulse/why-choose-htl-georgie-arnold?trk=mp-author-card


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