Troubleshooting Hydraulic Circuits: Fluid Power
Troubleshooting Hydraulic Circuits: Fluid Power
Troubleshooting Hydraulic Circuits: Fluid Power
86271-10
Instructor Guide
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Fluid Power
A
First Edition
Published May 2013
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Safety and Common Symbols
III
Safety and Common Symbols
IV
To the Instructor
In this guide, the faulty components are presented by numerical order with a
description of the mechanical modification, an exercise suggesting where to use the
faulty components, the answers to procedure step questions obtained with the faulty
components, and the answers to Troubleshooting Reports.
The exercises suggested in this manual are taken from the conventional manual
Hydraulics Fundamentals, part number 30794, or from the manuals in job sheet
format corresponding to the five units of the manual Hydraulics Fundamentals. The
manuals in job sheet formats are titled Introduction to Hydraulics (part
number 39888), Fundamentals (part number 39889), Basic Circuits (part
number 39890), Functional Circuits (part number 39891), and Troubleshooting (part
number 39892).
Once the students have completed the Procedure steps of the suggested exercise,
they must complete the Troubleshooting Report shown in Appendix A to demonstrate
that they have correctly identified the component in trouble. It is suggested that you
duplicate the Appendix A and supply a copy to each student group who begins to
troubleshoot a circuit.
Since the students should not know which component is faulty when they perform
the exercises, it is suggested that you setup the circuits to troubleshoot when the
students are absent.
The order in which the faulty components are used is not important.
If you have many hydraulic systems, you can set up many faulty circuits to provide
work for many student groups. In this case, it is suggested to also set up some
circuits without faulty component.
Identification
The faulty components are identified by the letter F or G in the base of the
component. The component must be turned over to see the letter. On the cylinders,
the letter is also engraved on the flange of the cylinder. See Figure 1.
V
To the Instructor
Two Directional Valves, Lever-Operated have been modified. One is identified by the
letter F, and the second by the letter G.
Figure 1. The arrow points toward the letter identifying a faulty component.
The answers to procedure step questions that are not affected by the faulty
components are not included in this guide.
Prerequisite
Before performing the troubleshooting tasks suggested in this guide, the students
should have completed the conventional manual Hydraulics Fundamentals, part
number 30794 [or the corresponding manuals in job sheet format titled Introduction
to Hydraulics (part number 39888), Fundamentals (part number 39889), Basic
Circuits (part number 39890), Functional Circuits (part number 39891), and
Troubleshooting (part number 39892)]. This manual (or the corresponding manuals
in job sheet format) is(are) required to perform the exercises suggested in this guide.
Security
C Make sure that the students understand the objectives of the work to be done.
VI
Table of Contents
VII
VIII
Troubleshooting Hydraulic Circuits
Model 6320-F
FAULT DESCRIPTION
The port A of the Directional Valve, Lever-Operated has been partially blocked,
causing an important oil flow rate reduction through this port.
APPLICATION
C Set up the circuit shown in Figure 4-11 of Exercise 4-2 using the faulty
Directional Valve, Lever-Operated, Model 6320-F.
C Ask the students to perform Procedure steps 1 to 19 of Exercise 4-2,
Hydraulic Motor Circuits.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 2-4 of Job Sheet 2 in the manual
Functional Circuits (part number 39891) using the faulty Directional
Valve, Lever-Operated, Model 6320-F.
C Ask the students to perform Procedure steps 1 to 19 of Job Sheet 2,
Hydraulic Motor Circuits.
G 11.
Note: The students should observe that the flow rate is limited
to approximately 1.3 L/min (0.34 gal(US)min) when the Relief
Valve is set to 2800 kPa (400 psi). They may stop their
experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.
1
Troubleshooting Hydraulic Circuits
THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY
Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.
THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY
Unable to set the flow rate to more than 1.3 L/min (0.34 gal(US)/min)
Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.
TROUBLESHOOTING REPORT
G 1. No. Unable to set the flow rate to the values asked in the exercise
procedure.
2
Troubleshooting Hydraulic Circuits
Model 6320-G
FAULT DESCRIPTION
The identification of ports A and B has been reversed on the subplate of the
valve. The valve operation is reversed. See Figure 2.
APPLICATION
C Set up the circuit shown in Figure 3-5 of Exercise 3-1 using the faulty
Directional Valve, Lever-Operated, Model 6320-G.
3
Troubleshooting Hydraulic Circuits
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 1-5 of Job Sheet 1 in the manual Basic
Circuits (part number 39890) using the faulty Directional Valve,
Lever-Operated, Model 6320-G.
CENTERED Stationary
Table 3-1 (or job sheet Table 1-1). Power Unit action versus lever position.
CENTERED Stationary
Table 3-1 (or job sheet Table 1-1). Power Unit action versus lever position.
4
Troubleshooting Hydraulic Circuits
CENTERED Stationary
Table 3-2 (or job sheet Table 1-2). Power Unit action versus lever position.
CENTERED Stationary
Table 3-2 (or job sheet Table 1-2). Power Unit action versus lever position.
G 23.
Note: In this step, the students should observe that the Power
Unit is lowering instead of raising when the lever of the
directional valve is moved outward from the valve body.
G 24.
Note: In this step, the students should observe that the Power
Unit is raising instead of lowering when the lever of the
directional valve is moved toward the valve body.
TROUBLESHOOTING REPORT
G 1. No. The Power Unit lowers when it should raise, and raises when it
should lower.
5
6
Troubleshooting Hydraulic Circuits
Model 6323-F
FAULT DESCRIPTION
The O-rings of the main spool have been removed. This fault allows the oil to
bypass the main spool, and to simultaneously flow through the regulated and tank
ports. The pressure regulation is erratic, and the circuit pressure is limited
because of the oil flow that continuously returns to the tank. See Figure 3.
APPLICATION
C Set up the circuit shown in Figure 4-18 of Exercise 4-3 using the faulty
Pressure Reducing Valve, Model 6323-F.
C Ask the students to perform Procedure steps 1 to 21 of Exercise 4-3,
Pressure Reducing Valves.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 3-6 of Job Sheet 3 in the manual
Functional Circuits (part number 39891) using the faulty Pressure
Reducing Valve, Model 6323-F.
C Ask the students to perform Procedure steps 1 to 21 of Job Sheet 3,
Pressure Reducing Valves.
7
Troubleshooting Hydraulic Circuits
G 12. With a standard component: Increasing the circuit pressure does not
increase the pressure level downstream
from the Pressure Reducing Valve since the
pressure reading at Pressure Gauge B
remains stuck at 1400 kPa (200 psi) as the
circuit pressure is increased to 3500 kPa
(500 psi).
With the faulty component: No. Unable to increase the circuit pressure
to 3500 kPa (500 psi).
G 13. With a standard component: The pressure level downstream from the
Pressure Reducing Valve (Pressure Gauge
B) should still be 1400 kPa (200 psi).
8
Troubleshooting Hydraulic Circuits
G 16.
Note: With the faulty component, the circuit pressure at
gauge A is about 2100 kPa (300 psi) instead of 3500 kPa
(500 psi) as obtained with a standard component.
9
Troubleshooting Hydraulic Circuits
TROUBLESHOOTING REPORT
G 1. No. The pressure regulation is erratic, and the circuit pressure is limited
to about 2100 kPa (300 psi).
10
Troubleshooting Hydraulic Circuits
Model 6340-F
FAULT DESCRIPTION
The U-cup packings and the magnet of the cylinder piston have been removed.
This modification allows the oil to bypass the piston. The lack in sealing causes a
reduction in power capability of the cylinder. See Figure 4.
Figure 4. The U-cup packings and the magnet of the cylinder piston have been removed.
APPLICATION
C Set up the circuit shown in Figure 1-26 of the Exercise 1-2 using the faulty
Double-Acting Cylinder, 2.54-cm Bore, Model 6340-F.
C Ask the students to perform Procedure steps 12 to 25 of Exercise 1-2,
Demonstration of Hydraulic Power.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 2-7 of Job Sheet 2 in the manual
Introduction to Hydraulics (part number 39888) using the faulty Double-Acting
Cylinder, 2.54-cm Bore, Model 6340-F.
C Ask the students to perform Procedure steps 12 to 25 of Job Sheet 2,
Demonstration of Hydraulic Power.
11
Troubleshooting Hydraulic Circuits
G 16. With a standard component: The Power Unit should go up until the
piston rod is fully retracted, then it should
stop.
With the faulty component: The Power Unit should go up until the
piston rod is fully retracted. Once the lever
of the Directional Control Valve is released,
the Power Unit should slowly move
downward.
G 18. With a standard component: The cylinder rod should stop. Thereafter,
the Power Unit should remain immobile
With the faulty component: Momentarily, the cylinder rod should stop.
Thereafter, the Power Unit should move
downward because of the lack in sealing.
With the faulty component: Yes. The Power Unit may be already lying
on the floor.
TROUBLESHOOTING REPORT
G 1. No. The Power Unit moves downward when the Directional Valve, Push-
Button Operated is at the center position (which is a blocked center).
12
Troubleshooting Hydraulic Circuits
Model 6341-F
FAULT DESCRIPTION
A restriction has been added to the quick-connect fitting at the rod-end of the
cylinder. This restriction limits the oil flow rate causing the extension and
retraction times of the cylinder rod to be longer.
APPLICATION
C Set up the circuit shown in Figure 3-5 of Exercise 3-1 using the faulty Double-
Acting Cylinder, 3.81-cm Bore, Model 6341-F.
C Ask the students to perform the Procedure steps of Exercise 3-1, Cylinder
Control.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 1-5 of Job Sheet 1 in the manual Basic
Circuits (part number 39890) using the faulty Double-Acting Cylinder, 3.81-cm
Bore, Model 6341-F.
C Ask the students to perform the Procedure steps of Job Sheet 1, Cylinder
Control.
PRESSURE
SYSTEM PRESSURE RETRACTION TIME
CYL. MOVING CYL. STOPPED
2800 kPa (400 psi) 2.5 s @ 38EC (100EF) 1700 kPa (250 psi) 2800 kPa (400 psi)
3500 kPa (500 psi) 2.5 s @ 38EC (100EF) 1700 kPa (250 psi) 3500 kPa (500 psi)
Table 3-3 (or job sheet Table 1-3). Effect of pressure control on cylinder speed.
13
Troubleshooting Hydraulic Circuits
PRESSURE
SYSTEM
RETRACTION TIME
PRESSURE
CYL. MOVING CYL. STOPPED
2800 kPa (400 psi) 5 s @ 38EC (100EF) 2700 kPa (390 psi) 2800 kPa (400 psi)
3500 kPa (500 psi) 5 s @ 38EC (100EF) 3400 kPa (490 psi) 3500 kPa (500 psi)
Table 3-3 (or job sheet Table 1-3). Effect of pressure control on cylinder speed.
Table 3-4 (or job sheet Table 1-4). Effect of flow control on cylinder speed.
Table 3-4 (or job sheet Table 1-4). Effect of flow control on cylinder speed.
14
Troubleshooting Hydraulic Circuits
TROUBLESHOOTING REPORT
G 1. No. The extension and retraction times of the cylinder rod are much
longer than normal. The cylinder seems to operate with difficulty.
15
16
Troubleshooting Hydraulic Circuits
Model 6342-F
FAULT DESCRIPTION
One of the quick-connect fittings of the Motor has been partially blocked causing
an important oil flow rate reduction through this fitting.
APPLICATION
C Set up the circuit shown in Figure 4-11 of Exercise 4-2 using the faulty
Bidirectional Motor and Flywheel, Model 6342-F.
C Ask the students to perform Procedure steps 1 to 19 of Exercise 4-2, Hydraulic
Motor Circuits.
If you are using the manuals in job sheet format, perform the following:
C Set up the circuit shown in Figure 2-4 of Job Sheet 2 in the manual Functional
Circuits (part number 39891) using the faulty Bidirectional Motor and Flywheel,
Model 6342-F.
C Ask the students to perform Procedure steps 1 to 19 of Job Sheet 2, Hydraulic
Motor Circuits.
G 11.
Note: The students should observe that the flow rate is limited
to approximately 1.3 L/min (0.34 gal(US)/min) when the Relief
Valve is set to 2800 kPa (400 psi). They may stop their
experimentation at this moment and start with the
troubleshooting, or continue to detect other symptoms.
17
Troubleshooting Hydraulic Circuits
THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY
Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.
THEORETICAL VOLUMETRIC
FLOW RATE ACTUAL SPEED
SPEED EFFICIENCY
Unable to set the flow rate to more than 1.3 L/min (0.34 gal(US)/min)
Table 4-4 (or job sheet Table 2-2). Motor speed and efficiency versus flow rate.
TROUBLESHOOTING REPORT
G 1. No. Unable to set the flow rate to the values shown in the exercise
procedure.
18
Appendix A
Troubleshooting Report
G 1. Once the Procedure steps are completed, can you conclude that the
circuit operates normally? If not, describe the symptom(s).
G 3. Analyze your circuit and/or test the suspected components (out of the
circuit or by modifying the circuit connections) to identify the component
that is the most probable cause of the fault. You may also compare the
actual results with those previously obtained with the standard
components.
Name the faulty component and give a brief description of the fault
(where applicable, describe your approach to identify the component).
A-1
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