Failures such as no pressure or insufficient pressure in a hydraulic system not only directly impact the normal operation of the equipment but can also lead to serious production delays and losses. Effectively resolving these issues requires rigorous troubleshooting procedures and professional judgment. During the troubleshooting process, systematic thinking and appropriate method selection can significantly improve troubleshooting efficiency while avoiding unnecessary component replacement and system damage.
1. Gather information
(1) When troubleshooting a hydraulic system, the first step is to gather as much information as possible. This step is often skipped to save time, but it is actually crucial. The most important tool is the system schematic, which can be used to trace the flow path of the system and identify the components that may be causing the problem.
(2) In addition, it is important to understand the specific circumstances when the fault occurred. For example, did the pressure drop suddenly or gradually? Was it accompanied by abnormal noise or temperature increase? This information can help us locate the root cause of the problem more effectively.
(3) By fully understanding the working status of the system, we can avoid premature component replacement and make more informed decisions by analyzing the symptoms. The system schematic is one of the most valuable reference tools for troubleshooting. It can help us comprehensively check possible fault points in the hydraulic circuit to ensure that no important clues are overlooked.
2. Troubleshooting steps for insufficient hydraulic system pressure
(1) Check the hydraulic oil level and quality.
The proper operation of the hydraulic system depends on sufficient oil volume and proper oil quality. Insufficient or contaminated oil will directly result in the system being unable to generate sufficient pressure. Therefore, you should first check whether the hydraulic oil level in the tank is within the appropriate range and confirm whether the oil is clean. If necessary, add or replace the hydraulic oil.
(2) Check the screens and filters in the system.
Clogged suction screens or other filters can hinder the flow of hydraulic oil, causing the pump to malfunction and leading to insufficient system pressure. Clean or replace clogged screens and filters to ensure smooth oil flow.
(3) Check the hydraulic pump and power source.
The hydraulic pump is the heart of the system. If the pump is worn or leaking internally, it will not generate sufficient pressure. In addition, check whether the power source driving the hydraulic pump is working properly, including whether the speed of the motor or internal combustion engine meets the standard. Ensure that the power source can provide sufficient power.
(4) Check the system for external or internal leaks.
External leaks are usually easy to detect by inspecting pipes and joints. Oil seepage or leakage is a common cause of insufficient pressure. If there is no external leakage, it may be an internal leak. In particular, internal damage to the pump, valve, or actuator may prevent the oil from effectively transmitting pressure. Use pressure testing equipment to detect leaks in these components.
(5) Check pressure regulating components, including overflow valves and safety valves.
Improper adjustment or failure of these valves may result in the system being unable to build up the required pressure. Check that the overflow valve and safety valve settings meet the requirements and ensure that the valves are not stuck or damaged. If necessary, readjust or repair them.
(6) Check hydraulic control valves and actuators.
Hydraulic control valves (such as directional valves or reversing valves) may fail to operate due to contamination or wear, affecting the flow of oil and thus reducing system pressure. In this case, check whether the valves are working properly and clean them. Damage to the seals of actuators (such as hydraulic cylinders or motors) can also cause pressure loss. Check their operation to ensure there are no abnormal leaks.
(7) Use a pressure gauge to fully test the system and measure the actual operating pressure of the system. Identify the specific source of pressure loss by gradually isolating each component of the hydraulic system. After confirming all inspections and adjustments, ensure that the system pressure returns to normal levels.
3. Summary
When a hydraulic system malfunctions, blindly replacing components is a common troubleshooting mistake. This not only wastes parts but also prolongs equipment downtime. Furthermore, each time a system component is removed, it is exposed to airborne contaminants, which can cause significant damage to the system’s long-term operation. Therefore, unless there is clear evidence of component failure, components should not be replaced haphazardly. The correct troubleshooting procedure involves gradually narrowing down the scope of the problem, logically analyzing each potential issue based on the system schematic and symptoms. This systematic diagnostic approach ensures that the equipment is restored to normal operation at the lowest cost.
