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Hydraulic Systems Volume 6 Troubleshooting and Failure Analysis

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 Hydraulic Systems Volume 6

Troubleshooting and
Failure Analysis

Dr. Medhat Kamel Bahr Khalil, Ph.D., CFPHS, CFPAI.

Director of Professional Education and Research Development,
Applied Technology Center, Milwaukee School of Engineering,
Milwaukee, WI, USA.

CompuDraulic LLC
www.CompuDraulic.com
 CompuDraulic LLC
Hydraulic System Volume 6

Troubleshooting and Failure Analysis

ISBN: 978-0-9977634-6-1

Printed in the United States of America

First Published by June 2022
Revised by ----------------------

All rights reserved for CompuDraulic LLC.

3850 Scenic Way, Franksville, WI, 53126 USA.
www.compudraulic.com

No part of this book may be reproduced or utilized in any form or by any means, electronic or
physical, including photocopying and microfilming, without written permission from
CompuDraulic LLC.

Disclaimer

The content of this book provides guidelines based on the author's experience. However, it is
always advisable to review the relevant standards and the recommendations from the system
manufacturer. However,

Any portion of information presented in this book might not be suitable for some applications
due to various reasons. Since errors can occur in circuits, tables, and text, the author/publisher
assumes no liability for the safe and/or satisfactory operation of any system designed based on
the information in this book.

The author/publisher does not endorse or recommend any brand name product by including
such brand name products in this book. Conversely the author/publisher does not disapprove
any brand name product not included in this book. The publisher obtained data from catalogs,
literatures, and material from hydraulic components and systems manufacturers based on
their permissions. The author/publisher welcomes additional data from other sources for
future editions. This disclaimer is applicable for the workbook (if available) associated with
this textbook.
 1 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Table of Contents

Hydraulic Systems Volume 6

Troubleshooting and Failure Analysis

PREFACE, 6
ACKNOWLEDGEMENT, 7
ABOUT THE BOOK, 9
ABOUT THE AUTHOR, 12
Chapter 1: Hydraulic Systems Troubleshooting Logical Methodology, 13
1.1- Fault Detection Methodology
1.2- Logic Fault Detection Procedure
1.3- General Components Check
1.4- Noisy Unit
1.5- Excessively Hot Unit

Chapter 2: Basic Troubleshooting Equipment, 20

2.1- Snap-Check Pressure Gauge Test Kit
2.2- Hydrostatic Transmission Pressure Gauge Test Kit
2.3- Pressure/Leak Test Kit
2.4- Universal Flow Meter Test Kits
2.5- Portable Digital Hydraulic Multimeter
2.6- Adaptor Kit
2.7- Test Points and Pressure Measurement Hoses
2.8- Fluid Leakage Test Kit
2.9- Surface Temperature Thermometers
2.10- Vibration Indicators
2.11- Tachometers
2.12- Multimeters
2.13- Proportional Valve Tester
2.14- Servo Valve Tester

Chapter 3: Troubleshooting and Failure Analysis of Sealing Elements, 33

3.1- Hydraulic Seal Inspection
3.2- Hydraulic Seal Troubleshooting
3.3- Hydraulic Seals Failure Analysis
3.3.1- Manufacturing Defects - Improper Molding
3.3.2- Manufacturing Defects - Insufficient Material Properties
3.3.3- Design Defects – Extrusion
3.3.4- Design Defects - Gland (Groove) Sharp Corners
3.3.5- Design Defects - Rough Surfaces
3.3.6- Design Defects - Blow-By Effect
 2 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Table of Contents

3.3.7- Assembly Defects - Passing Over Sharp Edges

3.3.8- Operational Defects - Overpressure
3.3.9- Operational Defects - Pressure Trapping
3.3.10- Operational Defects - Overheating
3.3.11- Operational Defects – Over-speeding
3.3.12- Operational Defects - Contamination
3.3.13- Operational Defects - Fluid Incompatibility
3.3.15- Operational Defects - Hydrolysis
3.3.16- Operational Defects – Explosive Decompression
3.3.17- Operational Defects - Dieseling
3.3.18- Operational Defects - Side Loading
3.3.19- Operational Defects - Vibration
3.3.20- Operational Defects - Spiral Failure
3.3.21- Operational Defects - Seal Wear
3.3.22- Operational Defects - Fatigue
3.3.23- Normal Aging Defects - Hardening
3.3.24- Normal Aging Defects - Splits
3.3.25- Storage Defects - Swelling
3.3.26- Storage Defects - Ozone Cracking

Chapter 4: Troubleshooting and Failure Analysis of Pumps, 68

4.1- Hydraulic Pumps Inspection
4.2- Hydraulic Pumps Troubleshooting
4.2.1- No Flow Out of the Pump
4.2.2- Low Flow Out of the Pump
4.2.3- Erratic Flow Out of the Pump
4.2.4- Excessive Flow Out of the Pump
4.2.5- No Pressure at the Pump Outlet
4.2.6- Low Pressure at the Pump Outlet
4.2.7- Erratic Pressure at the Pump Outlet
4.2.8- Excessive Pressure at the Pump Outlet
4.2.9- Leaking Pump
4.2.10- Excessive Pump Wear or Inside Parts Broken
4.2.11- Air Leaks into Pump
4.2.12- Excessive Pump Noise and Vibration
4.3- Hydraulic Pumps Failure Analysis
4.3.1- Pump Failures due to Contamination
4.3.2- Pump Failures due to Overheating
4.3.3- Pump Failures due to Cavitation
4.3.4- Pump Failures due to Fatigue Stress
4.3.5- Pump Failures due to Overpressure
4.3.6- Pump Failures due to Insufficient Charge Pressure
4.3.7- Pump Failures due to Dry Run
4.3.8- Pump Failures due Low Quality
 3 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Table of Contents

4.3.9- Pump Failures due Oil Breakdown

4.3.10- Pump Failures due Shaft Misalignment
4.3.11- Pump Failures due Improper Priming
4.3.12- Pump Failures due Lack of Overhauling

Chapter 5: Troubleshooting and Failure Analysis of Motors, 108

5.1- Hydraulic Motors Inspection
5.2- Hydraulic Motors Troubleshooting
5.3- Hydraulic Motors Failure Analysis

Chapter 6: Troubleshooting and Failure Analysis of Cylinders, 116

6.1- Hydraulic Cylinders Inspection
6.2- Hydraulic Cylinders Troubleshooting
6.3- Hydraulic Cylinders Failure Analysis
6.3.1- Cylinder Failure due to Particulate Contamination
6.3.2- Cylinder Failure due to Improper Mounting
6.3.3- Structural Failure due to Improper Load Attachment
6.3.4- Cylinder Failure due to Side Loading
6.3.5- Cylinder Failures due to Over Pressurization
6.3.6- Cylinder Seal Failures due to Over Heating
6.3.7- Cylinder Seal Failures due to Fluid Incompatibility
6.3.8- Cylinder Rod Corrosion due to Saltwater
6.3.9- Cylinder External Leakage
6.3.10- Cylinder Rod Collapse due to Pressure Intensification

Chapter 7: Troubleshooting and Failure Analysis of Valves, 129

7.1- Hydraulic Valves Inspection
7.2- Hydraulic Valves Troubleshooting
7.3- Hydraulic Valves Failure Analysis
7.3.1- Hydraulic Valves Failure due to Particulate Contamination
7.3.2- Hydraulic Valves Failure due to Chemical Contamination
7.3.3- Solenoid Burn Out due to Inrush Current
7.3.4- Spool Failure due to Dry Operation

Chapter 8: Troubleshooting and Failure Analysis of Accumulators, 147

8.1- Hydraulic Accumulators Inspection
8.2- Hydraulic Accumulators Troubleshooting
8.3- Hydraulic Accumulators Failure Analysis

Chapter 9: Troubleshooting and Failure Analysis of Reservoirs, 153

9.1- Hydraulic Reservoirs Inspection
9.2- Hydraulic Reservoirs Troubleshooting
9.3- Hydraulic Reservoirs Failure Analysis
 4 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Table of Contents

Chapter 10: Troubleshooting and Failure Analysis of Trans. Lines, 158

10.1- Hydraulic Transmission Lines Inspection
10.2- Hydraulic Transmission Lines Troubleshooting
10.3- Hydraulic Transmission Lines Failure Analysis

Chapter 11: Troubleshooting and Failure Analysis of Heat Exchangers, 169

11.1- Heat Exchangers Inspection
11.2- Heat Exchangers Troubleshooting
11.3- Heat Exchangers Failure Analysis

Chapter 12: Troubleshooting and Failure Analysis of Filters, 176

12.1- Filters Inspection
12.2- Filters Troubleshooting
12.3- Filters Failure Analysis

Chapter 13: Hydraulic Systems Troubleshooting, 181

13.1-Features of Hydraulic Systems Failures
13.2-Main Causes of Hydraulic Systems Failures
13.2.1-Design-Related Failure Causes
13.2.2-Commissioning-Related Failure Causes
13.2.3-Operationl-Related Failure Causes
13.3- Fluid Aeration
13.4- Pump Cavitation
13.5- Excessive System Noise & Vibration
13.6- Excessive System Heat
13.7- Low Power System
13.8- Faulty System Sequence
13.9- External Leakage
13.10- Troubleshooting of Open Hydraulic Circuits
13.11- Troubleshooting of Closed Hydraulic Circuits (Hydrostatic Transmissions)
13.12- Actuator Slow Performance
13.13- Actuator Fast Performance
13.14- Actuator Erratic Performance
13.15- Actuator Moves in Wrong Direction
13.16- Actuator Stops to Move
13.17- Actuator Load Drifts
13.18- Actuator Leaks

Chapter 14: Examples of Hydraulic Systems Troubleshooting, 222

14.1-Case Studies Using Logic Fault Detection Methodology
14.1.1- Slow Actuator on a Manufacturing Machine
14.1.2- Interrupted Duty Cycle of a Manufacturing Machine
14.1.3- A Winch Failed to Move
 5 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Table of Contents

14.1.4- EH Cylinder Deceleration System Isn’t Working Properly

14.1.5- Steady State Error in Cylinder Position Control System
14.1.6- Loss of Power Accompanied by an Increase of Pump Noise
14.1.7- Mold of an Injection Molding Machine is Partially Filled
14.1.8- Excavator Experiencing Low Power
14.2- Case Studies Using Analytical Fault Detection Methodology for Industrial Applications
14.2.1- Assembly Machine
14.2.2- Forging Machine
14.2.3- Hydraulic Press
14.2.4- Scrap Steel Winder
14.2.5- Gold Mine Crusher
14.2.6- Training Stand
14.2.7- Log Splitter
14.2.8- Walking Beam
14.2.9- Load Sense Pump
14.2.10- Food Processing Equipment
14.2.11- Hydraulic Elevator
14.2.12- Polishing Machine
14.2.13- Power Unit
14.2.14- Hydraulic Press
14.2.15- Regenerative Circuit
14.2.16- Forging Machine
14.2.17- Hot Dog Machine
14.2.18- Steel Mill
14.3- Case Studies Using Analytical Fault Detection Methodology for Mobile Applications
14.3.1- Post-Hole Hammer
14.3.2- Forklift
14.3.3- Cargo Ship
14.3.4- Lumberyard Stacker
14.3.5- Digger Derrick Truck

APPENDIXES, 268
APPENDIX A: LIST OF FIGURES, 268
APPENDIX B: LIST OF TABLES, 275
APPENDIX C: LIST OF TROUBLESHOOTING CHARTS, 277
APPENDIX D: LIST OF REFERENCES, 287

INDEX, 287
 6 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
Preface

PREFACE

Troubleshooting and failure analysis are very important experience to resolve hydraulic
systems problems and to find the root causes of such problems. Gaining such experience help
to avoid future unexpected shutdowns, hence improve system reliability. This book introduces
the approach of logic and analytical troubleshooting fault detection methodologies.

This book is targeting industry professionals who are in charge for operating, maintaining, and
troubleshooting hydraulic systems. This book is also a great resource for mechanical engineers
and service manuals technical writers.

The book presents more than 40 troubleshooting charts to cover system-level and
components-level troubleshooting including hydraulic fluids, pumps, motors, valves, cylinders,
accumulators, reservoirs, transmission lines, heat exchanges, filters, and sealing elements. The
book also contains proposed inspection sheets for the aforementioned components and
investigations for the typical types of failures for each component.

The author is working hard to finish his goal of supporting fluid power professional education
by developing the following series of volumes and relevant software:

▪ Hydraulic Systems Volume 1: Introduction to Hydraulics for Industry Professionals.

▪ Hydraulic Systems Volume 2: Electro-Hydraulic Components and Systems.
▪ Hydraulic Systems Volume 3: Hydraulic Fluids and Contamination Control.
▪ Hydraulic Systems Volume 4: Hydraulic Fluids Conditioning. Under Development
▪ Hydraulic Systems Volume 5: Safety and Maintenance.
▪ Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis.
▪ Hydraulic Systems Volume 7: Modeling and Simulation for Application Engineers.
▪ Hydraulic Systems Volume 8: Design Strategies of Hydraulic Systems. (Under Development).
▪ Hydraulic Systems Volume 9: Design Strategies of Electro-Hydraulic Systems. (Under Development).
▪ Hydraulic Systems Volume 10: Hydraulic Components Modeling and Simulation. (Under Development).

Dr. Medhat Kamel Bahr Khalil

7 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis

ACKNOWLEDGEMENT
This book was written during the hardship of Covid-19 Virus.

All praises are to Allah who granted me the knowledge, resources and health to finish this
work

To the soul of my parents who taught me the values of believe in God

To my wife who offered me all the best she can to make this work completed

To my family: wife, sons, daughters in law, and grandson “Adam”

To my best teachers and supervisors

The author also thanks the following gentlemen for their effective support in developing this
book:
▪ Kamara Sheku, Dean of Applied Researches at Milwaukee School of Engineering.
▪ Tom Wanke, CFPE, Director of Fluid Power Industrial Consortium and Industry
Relations at Milwaukee School of Engineering.

The author also thanks the following companies (listed alphabetically) for granting the
permission to use portions of their copyrighted literatures in this book.

▪ American Technical Publishers

▪ Assofluid
▪ Bosch Rexroth
▪ C.C. Jensen Inc
▪ Donaldson
▪ Fluid Power Safety Institute
▪ Gates Corporation
▪ Hydraulic and Pneumatic Magazine
▪ Insane Hydraulics
▪ Liebherr
▪ Noria Corporation
▪ Pall Corporation
▪ Parker Hannifin
▪ Spectro Scientific
▪ Wandfluh
▪ Womack
 8 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis

Lastly, the author extends his thanks to the following sources of public information used to
enrich the contents of the book.

▪ www.alamo-industrial.com
▪ www.bonvepumps.com
▪ shop.finaldriveparts.com
▪ http://info.texasfinaldrive.com
▪ metroforensics.blogspot.com
▪ www.tractorbynet.com
▪ www.fluiddynamics.com
 9 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
About the Book

ABOUT THE BOOK

Book Description:
This book is targeting industry professionals who are in charge of operating, maintaining, and
troubleshooting hydraulic systems. This book is also a great resource for mechanical engineers
and service manuals technical writers. The book presents more than 40 troubleshooting charts
to cover system-level and components-level troubleshooting including hydraulic fluids, pumps,
motors, valves, cylinders, accumulators, reservoirs, transmission lines, heat exchanges, filters,
and sealing elements. The book also contains proposed inspection sheets for the
aforementioned components and investigations for the typical types of failures for each
component. This book is colored and has the size of standard A4. The book is associated with a
separate colored workbook. The workbook contains printed power point slides, chapter
reviews and assignments. This book is the sixth in a series that the author plans to publish to
offer complete and comprehensive teaching references for the fluid power industry. The book
contains a total of fourteen chapters distributed over 250 pages with very demonstrative
figures and tables. The contents of the book are brand non-biased and intends to introduce the
latest technologies related to the subject of the book.

Book Objectives:
Chapter 1: Hydraulic Systems Troubleshooting Logical Methodology
This chapter discusses the common methodologies applied for hydraulic system fault
detection. This chapter introduces, in a step-by-step, the logic methodology for hydraulic
system troubleshooting.

Chapter 2: Basic Troubleshooting Equipment

Servicing staff for hydraulic-driven machines should be aware of the troubleshooting
equipment that are used in detecting faults of hydraulic systems. This chapter presents
examples of troubleshooting equipment for hydraulic systems.

Chapter 3: Troubleshooting and Failure Analysis of Sealing Elements

This chapter presents guidelines for inspecting and troubleshooting hydraulic sealing
elements. The chapter also presents 26 different failure modes, their causes and suggested
solutions.

Chapter 4: Troubleshooting and Failure Analysis of Pumps

This chapter discusses hydraulic pumps inspection, troubleshooting, and failure analysis. In
this chapter, troubleshooting charts for twelve different faults of hydraulic pumps are
presented. The chapter also presents examples of defective pumps due to contamination,
overheating, cavitation, and fatigue stress for gear, vane, and piston pumps.
 10 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
About the Book

Chapter 5: Troubleshooting and Failure Analysis of Motors

This chapter discusses hydraulic motors inspection, troubleshooting, and failure analysis. In
this chapter, a troubleshooting chart for motor faults is presented. The chapter also presents
examples of defective motors due to various reasons such as contamination, clogged case
drain, shaft failure, etc.

Chapter 6: Troubleshooting and Failure Analysis of Cylinders

This chapter discusses hydraulic cylinders inspection, troubleshooting, and failure analysis. In
this chapter, a troubleshooting chart for cylinder faults is presented. The chapter also presents
examples of defective cylinder due to various reasons such as contamination, improper
mounting, improper load attachment, side loading, overpressure, overheating, fluid
incompatibility, saltwater, external leakage, etc.

Chapter 7: Troubleshooting and Failure Analysis of Valves

This chapter discusses hydraulic valves inspection, troubleshooting, and failure analysis. In this
chapter, a troubleshooting chart for valve faults is presented. The chapter also presents
examples of defective hydromechanical and electrohydraulic valves due to various reasons
such as particulate and chemical contamination, solenoid burning due to inrush current, etc.

Chapter 8: Troubleshooting and Failure Analysis of Accumulators

This chapter discusses hydraulic accumulators inspection, troubleshooting, and failure
analysis. In this chapter, a troubleshooting chart for accumulator faults is presented. The
chapter also presents examples of defective accumulators caused by various reasons such as
vessel explosion due to material defects and pressure shocks etc.

Chapter 9: Troubleshooting and Failure Analysis of Reservoirs

This chapter discusses hydraulic reservoirs inspection, troubleshooting, and failure analysis. In
this chapter, a troubleshooting chart for reservoirs faults are presented. The chapter also
presents examples of defective reservoirs.

Chapter 10: Troubleshooting and Failure Analysis of Transmission Lines

This chapter discusses hydraulic transmission lines inspection, troubleshooting, and failure
analysis. In this chapter, a troubleshooting chart for transmission line faults is presented. The
chapter also presents examples of defective transmission lines.

Chapter 11: Troubleshooting and Failure Analysis of Heat Exchangers

This chapter discusses hydraulic heat exchangers inspection, troubleshooting, and failure
analysis. In this chapter, a troubleshooting chart for heat exchanger faults is presented. The
chapter also presents examples of defective heat exchangers.
 11 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
About the Book

Chapter 12: Troubleshooting and Failure Analysis of Filters

This chapter discusses hydraulic filters inspection, troubleshooting, and failure analysis. In this
chapter, a troubleshooting chart for filter faults is presented. This chapter also presents
examples of defective filter.

Chapter 13: Hydraulic Systems Troubleshooting

This chapter introduces troubleshooting charts for failures of generic hydraulic systems. Each
troubleshooting chart includes relevant notes and examples for better understanding.

Chapter 14: Examples of Hydraulic Systems Troubleshooting

In this chapter several case studies are presented as examples of applying the logic trouble
shooting methodology for hydraulic systems fault detection. In addition, troubleshooting case
studies following analytical fault detection methodology are presented. Examples were chosen
from both industrial and mobile applications.

Book Statistics:

Pages Figures Tables Words Editing Time

Chapter #
(min)

Chapter 1 7 2 3 1557 8798

Chapter2 13 15 0 1428 8786

Chapter 3 35 49 3 4270 5429

Chapter 4 40 53 14 4828 6606

Chapter 5 8 5 2 1021 5452

Chapter 6 13 16 2 1569 5737

Chapter 7 18 17 5 3132 5759
Chapter 8 6 5 2 1065 5442

Chapter 9 5 4 2 472 5251

Chapter 10 11 16 2 1462 5569

Chapter 11 7 7 2 883 5367

Chapter 12 5 4 2 549 5264

Chapter 13 41 30 18 8091 5582

Chapter 14 46 32 2 11681 6473

Total 255 255 59 42008 85515/60 = 1,425 Hour = 60 Days

 12 Hydraulic Systems Volume 6: Troubleshooting and Failure Analysis
About the Author

ABOUT THE AUTHOR (IFPS Hall of Fam Reciepient)

Medhat Khalil, Ph.D. is Director of Professional Education & Research
Development at the Applied Technology Center, Milwaukee School of
Engineering, Milwaukee, WI, USA. Medhat has consistently been working on
his academic development through the years, starting from bachelor’s and
master’s Degrees in Mechanical Engineering in Cairo Egypt and proceeding
with his Ph.D. in Mechanical Engineering and Post-Doctoral Industrial
Research Fellowship at Concordia University in Montreal, Quebec, Canada. He
has been certified and is a member of many institutions such as: Certified
Fluid Power Hydraulic Specialist (CFPHS) by the International Fluid Power Society (IFPS); Certified
Fluid Power Accredited Instructor (CFPAI) by the International Fluid Power Society (IFPS); Member of
Center for Compact and Efficient Fluid Power Engineering Research Center (CCEFP); Listed Fluid
Power Consultant by the National Fluid Power Association (NFPA); and Listed Professional Instructor
by the American Society of Mechanical Engineers (ASME). Medhat has balanced academic and
industrial experience. Medhat has vast working experience in Fluid Power teaching courses for
industry professionals. Being quite aware of the technological developments in the field of fluid power,
Medhat had worked for several
world-wide recognized industrial
organizations such as Rexroth in
Egypt and CAE in Canada. Medhat
had designed several hydraulic
systems and developed several
analytical and educational
software. Medhat also has
considerable experience in
modeling and simulation of
dynamic systems using Matlab-
Simulink. Medhat has been
selected among the inductees for
Pioneers in fluid Power by NFPA (2012) and Hall of Fam in fluid Power by IFPS (2021).

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