An efficient hydraulic power system is incredibly important in the movement and operation of construction vehicles, cars and other machinery and, thus, also is important in urban development projects. The UN has predicted that over 68% of the world’s population is projected to live in urban areas by 2050, This staggering statistic highlights, on a macro scale, just how fast urban development is taking place, and on a micro scale how efficient power vehicles need to be.
With this in mind, construction companies need to make sure that their hydraulic equipment is regularly maintained and kept in good nick, especially if they want to reduce future repair costs. Of course, no matter how much we look after things, sometimes they can break, and if that is the case then you do need to find an experienced professional like a hydraulic repair service to help.
This blog post will detail the various hydraulic problems that you should be aware of, as well as how to put a regular maintenance plan in place with your construction team to make sure that everything consistently runs smoothly.
Common Hydraulic Problems
Hydraulics is a complex combination of technology, applied science, engineering and chemistry. Created from the Greek words hydro for water, and aulos meaning pipe, it is the transmission of power using pressurised liquids, and is a sophisticated invention that can be traced back to the Ancient Greek and Hellenistic Age. Even though hydraulics systems are a man-made invention that is most associated with engineering, the same principles occur in natural organisms like the human body with the vascular system and erectile tissue.
Very much like the human body, sometimes everything doesn’t work properly. When crisis strikes within your hydraulic systems it’s imperative that you get an experienced hydraulic repair company near you to sort out the problems. Below, we will highlight the most common hydraulic problems that occur with some of the key components: the hydraulic pump, hydraulic hose and hydraulic cylinder. Being aware of these problems, as well as how they are repaired, will help you put a preventative maintenance plan in place.
Hydraulic Pump Repair
There are two different kinds of hydraulic pumps; the rotary vane pump and the radial siston pump. The rotary vane pump is a positive-displacement pump that consists of vanes mounted to a motor and it rotates within the cavity. A radial siston pump is where working pistons extend in a radial direction symmetrically around the drive shaft.
Within the valve pump and radial siston pump, there are a variety of different issues that you need to be aware of. These are listed below:
Excessive pump noise
If the system feels too hot
The pump not delivering the required pressure
The pump not delivering the required amount of oil
If there is a leakage at the oil seal
If there is a lack of volume in the pump
If there is a bearing failure
If there is an overloading motor
If any of these problems above do occur, then it is most likely that you will need to take a closer look or get a professional out to help you. There are, however, a variety of ways you can solve the problem yourself. Such as, for vane pumps, if there is excessive pump noise the problem could be that there are air bubbles in the intake line, there is low oil level or some of the parts are worn down. These problems can be simply solved by yourself by replacing the parts and filling the reservoir with oil and baffles, which will save your repair costs.
Yet, for each warning sign, there are countless amounts of problems that it could be. So, with this in mind, you should get an experienced hydraulic repair company who can perform a full diagnostics and inform you of the next steps to take.
Hydraulic Hose Repair
Like hydraulic pumps, there are a variety of reasons as to why a hydraulic hose will not be performing well or not performing at all. However, the most common reasons are:
Tube Erosion – Erosion of the hydraulic hose tube will most likely lead to leakages. Erosion is inevitable due to the concentration of the high velocity of liquid as well as the small particles in the liquid. Though hydraulic parts are designed to withstand excessive wear and tear, if you find that your hydraulic tube has eroded significantly, then it is most likely time to replace it. Preventative maintenance of this is to make sure that the hose is not bent too tight and that the fluid medium is not too abrasive.
Dry Air – The inner tube of the hose can develop tiny cracks due to dry air or overheating. This may go unnoticed as it won’t lead to external leaking. Yet, it does mean that the plasticizers are breaking down and, when noticed, should be replaced with a tube that has been rated to withstand high temperatures and dry air.
Improper Assembly – Like most mechanical objects, if they are improperly assembled then it will lead to a variety of complex technical issues. You need to make sure when checking your hydraulic products that they are properly assembled.
Hydraulic Cylinder Repair
Hydraulic cylinder issues can be spotted simply through erratic movement. This can be due to valves and the cylinder sticking together, sluggish operation, low pressure in pilot control, internal leakage in the cylinder, and air in the system. When checking the hydraulic cylinder, make sure to check for any worn parts, that the viscosity of the oil is right, that there aren’t any dirt or gummy deposits, and that there aren’t any leaks.
There may also be design faults within the hydraulic cylinder such as ballooned tubes, bent rods, insufficient bearing areas and if the surface finish of the rod is too rough. If you find that your hydraulic cylinder is repeatedly failing then you may need to assess whether the design is at the core of the faults.
It is more cost-effective to repair the hydraulic cylinder than it is to replace it. However, you need to be aware of when a replacement is essential as extensive repairs could lead to loss of business.
How to install a preventative maintenance system
As illustrated above, it is clear that you need to have an efficient maintenance system in place within your company so that mistakes don’t occur simply because there is a wealth of issues that can take place within these complex parts. It has been estimated that the lack of maintenance is the leading cause of component and system failure in hydraulics, especially as there is a lack of understanding.
Check daily and weekly that your hydraulics systems are running smoothly, whether that is test driving a new construction vehicle or keeping an eye on how everything is running during a project. You should evaluate the site and the need of the construction vehicle, such as whether the site is hot and dirty and whether the vehicle runs 24 hours a day – if this is the case, then preventative maintenance may need to occur frequently as the issues could be exacerbated.
It is best that you run your preventative maintenance program in the evening after a day of work. For example, this could include:
Changing the hydraulic filter
Filtering the hydraulic fluid
Cleaning the inside and outside of the hydraulic reservoir
Check and record hydraulic pressures and pump flow
Check the hydraulic hoses, tubing and fittings
Check and record voltage readings
Check and record amperage and vacuums
Check machine cycle time and record.
Why not put a timetable in place to make sure that the checks are followed through? This will not only allow you to keep on top of repairs, but also can help improve the health and safety of your site. Make sure that those carrying out the checks are fully trained within basic hydraulic repair and can spot any major issues. This will be the core support for your hydraulic systems as well as reducing system failure – meaning that you can have more control over your construction site.
HP Hydraulics: Hydraulic Company Near You
Offering top of the range hydraulic repair in Hampshire, we are the perfect choice for hydraulic repair in a number of industries, from industrial to marine and military. We will make sure that your components are durable, long lasting and top of the range in their design. We pride ourselves on being personable and offering exceptional customer services. We can come and perform our repairs on-site to improve efficiency and ease. We also can assist with product finishing, so if your construction vehicles are looking a little worse for wear then we can make sure they look sparkling new in no time!
We hope that this blog post has enlightened you on the various problems that can occur with hydraulics as well as the importance of establishing preventative maintenance systems within your company. We all would like to keep costs down when it comes to repairs; establishing a sound maintenance system is the perfect way to do this, as well as establishing more control over the outcome of your business and construction site. Get in touch today to get a full comprehensive break down of our hydraulic services as well as how we can repair your construction vehicles and machinery.