ME 453 Hydraulics & Pneumatics

Dr.Yesuenyeagbe A.K. Fiagbe

2
 General Requirement

Good equipment properly install

Properly trained personnel

Thorough knowledge of equipment’s operations

Ability to inspect, Trouble-shoot and remedy problem

Good maintenance programme

Keeping good record

Continues inspection

System cleanliness

Making minor repairs

3
 Tools

Equipment manuals, blueprints, data sheet, part lists, others

Adequate testing facility to bench test pumps, controls and
actuators

Adequate tools such as pressure gauge, flow meter, hand
tools

Good inventory of spare parts like seals, bearings, repair kits,
extra hydraulic fluid, filter cartridges.

4
 Records

Equipment record: model number; rating; manufacturer;
provided on a card

Repair card: provide repair history; running cost

Inspection check list: listing of points or things to be checked
and when to check

A maintenance schedule of inspection

An inventory control (may be combined with repair history
and cost)

5
 Optimum Service Life of Fluid

Control the Temperature

Excessive temperature will oxidize the oil

Typical systems Range 43 – 65oC (Some fluid may go upto 120oC)

Oil cooler should properly function

Air cool radiator should be free of dirt

Keep System Clean

Prevent contamination from diet, water, metal particles

Keep the Fluid Clean

Good storage and handling

Inspect fluid filters regularly and change or clean them before they go
into bypass mode

Keep an oil Analysis Programme

Regular draining of oil

6
 System Care

Check fluid level. Add using same oil brand and viscosity
grade. DO NOT MIX

Inspect breather caps, breather filters and fill screen

Check filter indicators and/or pressure differential gauges

Visually inspect all system hoses, pipes, pipe connections for
leaks.

Check system temperatures via built in thermometers or
otherwise.

Visually inspect for signs of aeration in the reservoir (use
flash light via fill hole).

7
 System Care

Listen to the pump for signs of cavitation (high-pitched
whine or scream)

Inspect small sample of fluid for colour, signs of
contamination and odor.

Scan electrically controlled servo valves for high
temperatures (High valve and solenoid temperatures > 65oC
usually indicate the valve is sticking).

8
 SAFETY RULES

Understand the basic principle and be familiar with
components of the system.

The pressure in the system should never exceed the rated
pressure of the lowest rated component.

Be certain all interfaces to the fluid power system are
adequate in strength.

Never work on or service a system under pressure or
while the pump is running (unless bleeding the system)

Test all circuitry with low pressure before the load is
attached.

Use only the pressure required to achieve the effect.
9

Use common sense!!!
 Hydraulic Systems Safety

Always wear eye protection and appropriate clothing.

Do not remove cylinders until the working units are resting
on the floor or ground, on safety stands or on blocks.

Before disconnecting oil lines, relieve all hydraulic pressure
and discharge the accumulator.

Ensure that all line connections are tight and the lines are not
damaged. Escaping oil under pressure is a fire hazard and can
penetrate the skin causing serious injury.

10
 Trouble Shooting

Measurements:

Pressure

Flow

Temperature

Operating Pressure: good indication if leakage problem occur

Less load can be accomplished

Actuator may stall under loaded condition

11
 About Pumps

The hydraulic pump contained within the power pack
provides the fluid flow from the power pack. An efficient
pump will provide the required flow at system pressure.

A pump that has excessive internal wear will not provide
the required flow at pressure due to internal bypass
leakage.

To keep the power pack operating at it’s top efficiency it
is necessary to keep the pump in top operating condition.

12
 MOTOR RUNS BUT HYDRAULIC SYSTEM
DOES NOT FUNCTION

Check drive connection between motor and pump,
the connecting parts may be broken. Repair or replace if
necessary.

Check for internal failure of pump, deep scoring of
pump body, broken pump shaft or gear may be the cause
of the problem.

Repair or replace if necessary.

13
 SLOW OPERATION OF HYDRAULIC
SYSTEM

Check for worn pump, pump with excessive internal wear will not
deliver proper system flow at pressure. Inspect pump for wear, repair
or replace if necessary.

Check for too small pump displacement, System should be designed
with proper sized pump to match motor size. It may be necessary to
increase motor and pump size to increase speed of hydraulic system
operation.

Check for proper line sizes, too small hydraulic lines will restrict pump
flow to working cylinders or motors. Flow will be greatly affected by
cold weather and small lines. Increase line size if necessary.

Check for excessive line length, too long lines will affect pump flow due
to line flow restriction. Correct if necessary.

Check for proper relief valve setting, relief valve may be set too close to
required system operating pressure. Reset relief valve to correct
pressure.

14
 HYDRAULIC SYSTEM RUNS HOT

Check for worn pump – internal wear will cause excessive
internal fluid leakage at pressure, resulting in excessive heat
generation.

Inspect pump, repair or replace if necessary.

Check for correct pump inlet line size as cavitation can cause
noise and heat.

15
 SHORT PUMP LIFE

Check for contaminated oil in system, dirty oil will wear
out a pump prematurely.

To help prevent premature pump failure, change system oil
frequently and change system filters on a routine schedule.

Check oil type, use a quality oil specified for use in
hydraulic systems, with the proper viscosity and anti wear
properties.

Check for water in system, water will quickly destroy a
pump. Drain system and change to proper oil.

16
TROUBLESHOOTING GUIDELINES
Remedies (Chart 1)

a. Any or all of the following: Replace dirty filters; wash strainers
in solvent compatible with system fluid; 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; fluid may be too cold.

b. Any or all of the following: Tighten leaking connections; fill
reservoir to proper level (with rare exception all return lines
should be below fluid level in reservoir); bleed air from system;
replace pump shaft seal (and shaft if worn at seal journal).

c. Align unit and check condition of seals, bearings and coupling.

d. Install pressure gauge and adjust to correct pressure.

e. Overhaul or replace.
Remedies (Chart 2)

a. Any or all of the following: 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.

b. Any or all of the following: Tighten leaking connections; fill reservoir to
proper level (with rare exception all return lines should be below fluid level in
reservoir); bleed air from system; replace pump shaft seal (and shaft if worn at
seal journal).

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

d. Install pressure gauge and adjust to correct pressure (keep at least 125 PSI
difference between valve settings).

e. Overhaul or replace.

f. Change filters and also system fluid if improper viscosity; fill reservoir to
proper level.

g. Clean cooler and/or cooler strainer; replace cooler control valve; repair or
replace cooler.
Remedies (Chart 3)

a. Any or all of the following: Replace dirty filters; clean clogged
inlet line; clean or replace reservoir breather vent; fill reservoir to
proper level; overhaul or replace supercharge pump.

b. Tighten leaking connections.

c. Check for damaged pump or pump drive; replace and align
coupling.

d. Adjust.

e. Overhaul or replace.

f. Check position of manually operated controls; check electrical
circuit on solenoid operated controls; repair or replace pilot
pressure pump.

g. Reverse rotation.

h. Replace with correct unit.
Remedies (Chart 4)

a. Replace dirty filters and system fluid.

b. Tighten leaking connections (fill reservoir to proper level
and bleed air from system).
Remedies (Chart 5)

a. Fluid may be too cold or should be changed to clean fluid
of correct viscosity.

b. Locate bind and repair.

c. Adjust, repair or replace.

d. Clean and adjust or replace; check condition of system
fluid and filters.

e. Overhaul or replace.

f. Repair command console or interconnecting wires.

g. Lubricate.

h. Adjust, repair or replace counterbalance valve.