Principles of Hydraulic Test Equipment
A hydraulic system with an excessive increase in
heat or noise is a potential failure. Should either of
these conditions be noticed, immediately stop the
machine, turn off the engine, locate the cause of
the trouble, and correct it before allowing the ma-
chine to be used again. Continued use of an im-
properly functioning hydraulic system could lead to
extensive internal damage.
6. Determine which cause is most likely the problem:
∑
Look at your list of most possible causes and
determine which are the most likely. Use the
troubleshooting charts in the Service Manual.
7. Test your findings
∑
Operate the machine with a hydraulic tester
connected to the suspected malfunctioning
circuit.
∑
It may be necessary to replace or adjust a
component to verify your findings.
When troubleshooting a hydraulic problem:
1.
Know the hydraulic system for the machine:
∑
Study the schematics, Operators Manual and
Service Manual.
∑
Know how the system works and what the re-
lief valve setting and the pump output should
be.
2.
Talk to the operator:
∑
How did the machine act just as it started to
malfunction?
∑
∑
Was any “do-it-yourself” service performed or
did anyone else attempt to repair the ma-
chine?
How was the machine used and when was
maintenance last performed?
Figure 1
3.
Operate the machine:
∑
Operate the machine in conditions simulating
when the malfunction occurred. Verify what
the operator described.
∑
Are the gauges and warning lights operating
correctly.
∑
∑
Do the controls feel spongy or stick.
Check for any unusual sounds, smells, or
smoke. At what speed or operating cycles
does this occur.
4.
Inspect the machine:
∑
Check the hydraulic fluid level and condition.
Is the fluid dirty or filters plugged?
Figure 2
∑
∑
Check for overheating. Does the oil have a
burnt odor? Is the oil cooler plugged or lines
caked with dirt?
Look for bent or collapsed fluid lines. Check
for leaks, loose fasteners, cracked welds,
binding pivot points, damaged linkage, etc.
5.
List possible causes:
∑
Note what was reported by the operator and
verified by you.
∑
∑
List what you found during your inspection.
Remember that there may be more than one
cause leading to the failure or malfunction.
Figure 3
23
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