When faced with a hydraulic system failure, pinpointing the root cause can be quite a challenge. Hydraulic systems are composed of various components, including a sump, motor, pump, valves, actuators, and hydraulic fluid. Any of these parts could potentially be the source of failure. On top of that, human error and improper maintenance practices can also contribute to system failures. It is crucial to not only understand why your system failed but also how to identify the failure and ensure smooth operation in the future while prioritizing the safety of personnel.
1. Air and Water Contamination:
The leading culprits behind hydraulic failures are air and water contamination, accounting for approximately 80 to 90% of all issues. These types of contamination can arise from faulty pumps, system breaches, or temperature-related problems.
Cavitation: Cavitation occurs when the hydraulic oil contains approximately 9% dissolved air, which can be drawn out by the pump and implode. This process leads to pump damage and wear on surrounding components over time. Identifying cavitation can be done by listening for a distinct whining noise emitted by the hydraulic pump.
Aeration: Aeration happens when air enters the pump cavity from an external source. Loose connections or leaks within the system are often responsible for this issue. Aeration manifests as a knocking sound while the pump is in operation.
Water contamination is another prevalent problem in hydraulic systems and is typically caused by system leaks or condensation resulting from temperature fluctuations. Over time, water can degrade hydraulic components through oxidation and freeze damage. A milky appearance in the hydraulic fluid is a telltale sign of water contamination.
2. Temperature Problems
Maintaining the optimal temperature in hydraulic systems is crucial to prevent long-term issues. When the temperature is too high or too low, various challenges can arise, leading to detrimental consequences. Let's take a closer look at some of these symptoms:
Fluid thinning
Excessive heat can cause hydraulic fluids to thin out, which hampers their lubricating properties and increases the likelihood of leakage. This can compromise the overall efficiency and performance of the system.
Fluid oxidization:
When hydraulic fluid is exposed to extreme heat, it can undergo oxidization and thicken. This thickening can lead to the formation of buildups within the system, restricting the flow of fluid and hindering its ability to dissipate heat effectively.
Fluid thickening:
On the other hand, low temperatures can cause hydraulic oil to become more viscous, making it harder for the oil to reach the pump. If the system is subjected to heavy loads before the oil reaches a temperature of 70 degrees or higher, it can result in cavitation and potential damage to the system.
The primary culprit behind heat buildup is often poor heat dissipation, while excessively cool temperatures are typically caused by environmental factors.
3. Fluid Levels and Quality
The level and quality of hydraulic fluid play a significant role in the performance of the hydraulic system. Insufficient fluid levels and inadequate filtration can lead to air contamination, while contaminated fluid can contribute to temperature-related problems. Additionally, leaks can further exacerbate both issues.
Using the correct type of hydraulic fluid is essential, as different applications require compatible fluids. There are even specialized oil options available that offer enhanced resistance to temperature-related problems. Some oils are formulated with anti-wear and anti-foam additives, providing additional protection against wear and air contamination, respectively.
4. Human Error
Human error is often the root cause of many hydraulic system problems. Several common errors can result in the hydraulic pump failing to build pressure. It is important to be aware of these potential pitfalls to avoid them:
- Faulty installations: Improper installation of any component within a hydraulic system can lead to significant errors. For example, if the pump shaft is rotating in the wrong direction, it can adversely affect pressure buildup. Similarly, incorrectly fitted pipes can result in leaks, compromising the system's overall performance.
- Incompatible parts: Inexperienced installers may unintentionally combine mismatched components, resulting in functional failures. For instance, a pump may have a motor that operates beyond its maximum drive speed, leading to inefficiencies and potential damage.
- Improper maintenance or usage: Using hydraulic systems beyond their operational capabilities or neglecting regular maintenance are among the most common causes of hydraulic system damage. However, these issues can be easily rectified through the implementation of updated maintenance policies and comprehensive training programs.
By addressing temperature problems, ensuring proper fluid levels and quality, and mitigating human errors, you can significantly enhance the reliability and longevity of your hydraulic system.
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