Hydraulic and pneumatic

systems maintenance and

troubleshooting
Objectives
After this part you will be able to:
• Understand and explain the various causes for failure in a
hydraulic system
• Carry out preventive maintenance of system
• Understand the functions and importance of sealing devices
in a hydraulic system
• Carry out preliminary troubleshooting activities for
determining the causes of malfunctioning in a hydraulic
system.
• Describe the minimum process for doing routine inspections.
• In the absence of the manufacturer’s recommendations,
build a maintenance plan for any Hydraulic system.
• Perform an inspection.
Cautions
• Inspecting a fluid power system requires an engineer and
technician to be very close to the components that are being
inspected.
• It is essential that safety glasses, or even a full face shield, be
worn during the inspection.
• It is advised to wear an oil-resistant apron, steel toe boots or
shoes, and gloves.
• Be sure to follow the manufacturer’s recommendations for
maintenance intervals.
• Perform the tasks suggested at a minimum.
DAILY MAINTENANCE CHECKS

• Begin daily inspections with a complete walk around the system.

• Check the condition of the hydraulic fluid and its level.
• Manually activate the systems and observe a complete cycle of
operation.
• Make sure that there are no hydraulic leaks and the operation of
equipment is smooth and its mechanical components operate smoothly
and within the required specifications .
• Manually test the warning devices to make sure the equipment and the
operators will be safe.
• While the equipment is cycling, make sure all of the gauges indicate the
correct operating pressures.
WEEKLY OR MONTHLY MAINTENANCE CHECKS
• Check the filters and clean or replace as necessary.
• Strainers or screens in the reservoir will be removed and cleaned.
• Restricted filters, strainers, and screens can reduce the ability of the pump to draw the
hydraulic oil from the reservoir.
• This can cause a pump to cavitate, reducing the efficiency of flow throughout the
system, and cause damage to the pump and possibly to other components in the
system.
• Also, pressure can build up behind filters due to the restriction of flow through the
filter.
• Eventually, the pressure can become great enough to tear the filter or screen, allowing
contaminants ordinarily filtered to be passed through the system, or worse, allowing
particles of the screen or filter to pass through the system.
• Check piping and hoses for broken lines, leaks, kinks, or blockages on a daily and a
weekly or monthly basis.
• The clean hoses and lines will make it easier to recognize new leaks during the daily
inspections.
• The cooler should be inspected for dirt and for air flow restrictions.
Quarterly or Annual Requirements
• Each fluid power system manufacturer has recommended
intervals for the replacement of the oil and the filters.
• Therefore, during the quarterly or annual inspections, a
sample of the oil should be sent to a lab for analysis.
• All electrical connections should be inspected for tightness.
Quarterly or Annual Requirements
•Pressure gauges, especially the old Bourdon tube
design, require occasional calibration.
•In more modern systems, pressure is
monitored by strain gauges and displayed on
digital panels. The design of strain gauges
cannot be calibrated.
• This of course does not mean that their
accuracy should not be checked on an annual
basis.
Check the Operation of warning and safety devices
• Larger fluid power systems will have safety devices and warning
devices that activate when the system behaves improperly
• In mobile equipment applications, these devices prevent excessive
weights from being lifted, prevent weights from being lifted at
dangerous angles, or warn system operators of potential pressure and
flow problems.
• Systems such as cranes and personnel lifts are usually equipped with
systems that prevent high-weight loads from being extended at an
angle that could cause tipping of the truck.
• Modern versions of these systems are based on digital controllers.
Proper operation of these systems can be verified with the use of
diagnostic software provided by the manufacturer.
Common causes for hydraulic system breakdown

The most common causes of hydraulic system failures are:

1. Clogged and dirty oil filters
2. An inadequate supply of oil in the reservoir Leaking seals
3. Loose inlet lines, which cause pump cavitations and eventual
pump damage
4. Incorrect type of oil.
5. Excessive oil temperature
6. Excessive oil pressure.
The three maintenance procedures that
have the greatest effect on system life,
performance and efficiency are:
1. Maintaining an adequate
quantity of clean and
proper hydraulic fluid with
the correct viscosity

2. Periodic cleaning and

changing of all filters and
strainers

3. Keeping air out of the

system by ensuring tight
connections.
 Safety
Hydraulic and pneumatics are no less
dangerous but tend to be approached in a
far more casual manner.
A hydraulic system can present the following dangers to an
operator:
1. High-pressure air or oil released suddenly can attain
explosive velocities and can easily cause an accident.
2. The unexpected movement or drift of components such as
cylinders can be harmful.
3. Spilt hydraulic oil is very slippery and can cause accidents.
A few guidelines to ensure safety in hydraulic systems are listed here:
• Anything that can move with change in pressure as a result of your actions should be mechanically secured or
guarded.
• Particular care should be taken with regard to suspended loads. It must be remembered that fail-open valves will
turn ON when the system is de-pressurized.
• Never disconnect pressurized lines or components. The whole system should be de-pressurized before
disconnecting any of the lines.
• Put up safety notices to prohibit operation by other people.
• Ensure that the accumulators in the hydraulic system are fully blown down.
• Make proper arrangements to prevent spillage of oil on the floor.
• Where there is an electrical interface to a hydraulic system (e.g., solenoids, pressure switches, limit switches) the
control circuit should be isolated, not only to reduce the risk of electric shock but also to reduce the possibility of
fire.
• After the work is completed, keep the area tidy and clean. Check for any leakages and confirm correct operation
of the system.
• Many components contain springs under pressure. If released in an uncontrolled manner, these can fly out at high
speed and cause injury. Springs should be removed with utmost care.
The phenomenon of wear due to fluid
contamination
• Excessive contaminants in the working fluid prevent
proper lubrication of components such as pumps,
motors, valves and actuators.
• This can result in wear and scoring which affect the
performance and life of these components and leads to
their eventual failure.
• A typical example of this is the scored piston seal and
cylinder bore of cylinders causing severe internal leakage
and resulting in premature cylinder failure.
 Problems due to entrained gas in fluids
• Entrained gas or gas bubbles in the hydraulic fluid is caused by the sweeping of air out of
a free air pocket by the flowing fluid and also when pressure drops below the vapor pressure of
the fluid.
• Vapor pressure is that pressure at which the fluid begins changing into vapor.
• This vapor pressure increases with increase in temperature.
• This results in the creation of fluid vapor within the fluid stream and can in turn lead to
cavitation problems in pumps and valves.
• The phenomenon of cavitation is in fact the formation and subsequent collapse of the vapor
bubbles.
This collapse of the vapor bubbles takes place when they are exposed to the high-pressure
conditions at the pump outlet, creating very high local fluid velocities, which impact on the
internal surfaces of the pump.
These high-impact forces cause flaking or pitting on the surface of components such as gear
teeth, vanes and Pistons leading to premature pump failure.
Additionally the tiny metal particles tend to enter and damage other components in the
hydraulic system.
Cavitation can also result in
increased wear on account of the
reduced lubrication capacity.
Cavitation is indicated by a loud
pump noise and also by a
decreased flow rate as a result of
which the pressure becomes
erratic.
Air also tends to get trapped in the
pump line due to a leak in the
suction or on account of a
damaged shaft seal.
It has to be also ensured that air
escapes through the breather while
the fluid is in the reservoir or
otherwise it tends to enter the
pump suction line.
To counter the phenomenon of cavitation in pumps, the following steps are
recommended by manufacturers:

1. Suction velocities to be kept below 1.5 m/s .

2. Pump inlet lines to be kept as short as possible.
3. Pump to be mounted as close to the reservoir as
possible.
4. Low-pressure drop filters to be used in the suction line.
5. Use of a properly designed reservoir that will help
remove the trapped air in the fluid
6. Use of hydraulic fluid as recommended by the
manufacturer
7. Maintaining the oil temperature within prescribed
limits, i.e. around 65 °C .
Cleanliness
• Most hydraulic and pneumatic faults are caused by dirt. Very small particles can nick seals,
abrade surfaces, block orifices and cause valve spools to jam.
• These should be taken to a clean workshop equipped with proper workbenches.
• Components and hoses come from manufacturers with their orifices sealed with plastic
plugs, to prevent dirtngress during transit.
• These should be left as they are during storage and removed only when the component is to
be put to use.
• Filters are meant to remove dirt particles, but only work until they are clogged. A dirty filter
may cause the fluid to bypass and can make things far more worse by accumulating the
particles and then releasing them all in one lump. Filters should be regularly checked and
cleaned or changed when required.
• The oil condition in a hydraulic system is also crucial for maintaining reliability.
• Oil, which is dirty, oxidized or contaminated, forms a sticky gummy sludge which blocks small
orifices and causes the valve spools to jam.
• The oil condition should be regularly checked and the suspect oil changed before problems
develop
Preventive maintenance

• The most important part of the maintenance department's

responsibility is to perform routine planned maintenance otherwise
known as preventive maintenance.
Preventive maintenance primarily deals with:
• Regular servicing of the equipment
• Checking for correct operation
• Identification of potential faults and their immediate rectification or
correction.
 Preventive maintenance
For preventive maintenance techniques to be really effective, it is necessary to
have a good reporting and recording system. These reports should include the
following:
1. The type of symptoms encountered and how they were detected along with
the respective date
2. A description of the maintenance repairs performed. This should include the
replacement of parts, the amount of downtime and the date
3. Records of dates when the oil was tested, added or changed
4. •Records of dates when the filters were cleaned or replaced.
 Static seal flange joints

Dynamic seals are subject to wear and tear as one of the

mating parts rubs against the seal.
The most widely used seals of this type are:
• O-rings
• Compression packings
• Piston cup packings
• Piston rings
• Wiper rings.
Excessive noise
Excessive noise can result from:
1. Problems related to wear and misalignment.
2. Pump cavitation or the presence of air in the hydraulic fluid.
3. Presence of contaminants in the hydraulic fluid that may cause a
relief valve to chatter and produce noise.
4. Low reservoir levels and contaminated filters.
5. Excessive drive speed and loose intake lines.
6. High fluid viscosity .
7. Damaged or worn couplings.
Probable Causes of Noisy pump
(a) Air entering the pump inlet
(b) Misalignment of the pump
(c) Excessive oil viscosity
(d) Dirty inlet strainer
(e) Chattering relief valve
(d) Damaged pump
(f) Excessive pump speed
(g) Loose or damaged inlet.
Incorrect flow

The following are a list of common causes that might lead to incorrect
pressure conditions in a hydraulic circuit:
1. Improper reservoir level
2. Dirty, clogged filters and strainers
3. Clogged inlet line
4. Defective pump
5. Leaky connections and the presence of air in the system
6. Damaged or misaligned couplings
7. Defective control valves.
Incorrect pressure

Incorrect pressure conditions can result from:

1. Contaminated hydraulic fluid and clogged filters
2. Improper reservoir level and presence of air.
When troubleshooting hydraulic systems, it should be kept in mind that
the pump produces fluid flow. However there must be resistance to
flow in order to have a pressure.
Trouble shooting for incorrect pressure

Remedies:
(a) Change dirty filters. Replace hydraulic fluid
(b) Tighten leaky connections, fill reservoir to proper level and carry out
bleeding of the system
(c) Gas valve to be checked for leakage, charged to correct pressure and
overhauled, if defective
(d) Adjust
(e) Overhaul or replace.
5. Faulty operation
Probable Causes of No pressure
• (a) Pump rotating in the wrong direction
• (b) Ruptured hydraulic line
• (c) Low oil level in the reservoir
• (d) Pressure relief valve malfunctioning
• (e) Full pump flow by-passed to the tank due to
• faulty valve.
Probable Causes of Low or erratic pressure
• (a) Air in the fluid
• (b) Pressure relief valve set too low
• (c) Pressure relief valve not properly seated
• (d) Leak in the hydraulic line
• (e) Defective or worn-out pump
• (f) Defective or worn-out actuator.
Troubleshooting instruments

• Hydraulic systems depend on proper flow and pressure from the

pump to provide the necessary actuator motion for producing useful
work.
• The measurement of flow and pressure are two important means of
troubleshooting a hydraulic system.
• Temperature is the third important parameter measured periodically
as it affects the viscosity of oil.
• The use of flowmeters can help in determining whether or not the
pump is producing the proper flow.
High fluid temperature
• A fluid temperature above 82 °C damages seals and reduces the life of the fluid.
• At higher temperatures, inadequate lubrication due to lower fluid viscosity causes
damage to the system components. To avoid system damage due to overheating,
it is important that a temperature alarm is fitted in the system.
Probable Causes of : Actuator fails to move

(a) Faulty pump

(b) Direction control valve fails to shift
(c) System pressure too low
(d) Defective actuator
(e) Pressure relief valve stuck open
(f) Actuator load is excessive
(g) Check valve installed in the reverse direction.
Slow or erratic motion of the actuator
(a) Air in the system
(b) High viscosity of the fluid
(c) Worn or damaged pump
(d) Pump speed too low
(e) Excessive leakage through actuators
(f) Faulty or dirty flow control valves
(g) Blocked air breather in the reservoir
(h) Low fluid level in the reservoir
(i) Faulty check valve
(j) Defective pressure relief valve.
 Overheating of hydraulic fluid causes
(a) Heat exchanger turned off or clogged
(b) Undersized components or piping
(c) Incorrect fluid
(d) Continuous operation of pressure relief valve
(e) Overloaded system
(f) Dirty fluid
(g) Reservoir too small
(h) Inadequate supply of oil in the reservoir
(i) Excessive pump speed
(j) Clogged or inadequate sized air breather. of hydraulic fluid
 Incorrect fluid viscosity

• Generally, optimum operating efficiency is achieved with a fluid viscosity in the

range of 16-36 est. Maximum bearing life is achieved with a minimum viscosity of
25 est.
• A very high fluid viscosity may damage the system components through
cavitation, while low fluid viscosity may result in damage through inadequate
lubrication
 Fluid contamination
Contamination of the hydraulic fluid may occur on account of the influence of air, water,
solid particles or any other matter that impairs the function of a fluid.
Air contamination can result in damage to the system components through loss of
lubrication, overheating and oxidation of seals.
Common entry points for air contamination include the vortex effect at the pump suction
(due to low reservoir oil level) or faulty seals.
To avoid this, the reservoir oil level should always be maintained at the desired level.
Water contamination can result in damage to the system components through corrosion,
cavitation and altered fluid viscosity. In order to avoid this, ensure that all possible points
of penetration into the reservoir oil space are sealed.
Also ensure that the maximum oil level is maintained, to minimize condensation within
the reservoir.
Contamination from solid particles can result in damage to the system components
through abrasive wear or can be generated internally.
Common entry points of particle contamination are through the reservoir air space and
on the surface of the cylinder rods.
To reduce the contamination load on the system's
filters, the following measures should be undertaken:
• All penetration points into the reservoir airspace must be sealed and
an air filter of 5 µ installed in the breather.
• The chrome surfaces of the cylinder rods must be made free from
pitting, dents and scoring.
• The filters should be replaced regularly and fluid contamination levels
monitored through regular sampling.
Checklist
for a
basic visual
inspection