This can be detected by installing a vacuum gauge directly at the pump suction. The maximum vacuum at the pump suction should never exceed 15 of mercury. Troubleshooting tips for hydraulic pumps womack machine. When the pump is activated, it supplies hydraulic fluid under pressure to the function manifold, where the control valves are located. Hydraulic system troubleshooting pellerin milnor corporation figure 35. Positive displacement pumps allow liquid to flow into an open cavity trap the liquid in the pump transport liquid from the suction to discharge port mechanically force liquid out of the pump. The correct way to test the hydro system would be use a bidirectional flow meter. Replace the diaphragm after fixing the cause of the rupture. Hydraulic troubleshooting is one of our specialties here at bernell hydraulics. We love having folks bring in worn or damaged parts and ask us to help them figure out the possible causes of the problem.
When a hydraulic issue occurs, the pump usually is one of the first components changed out, but it actually should be the last. Understanding and troubleshooting hydrostatic systems. Please read and observe the hydraulic product safety page before proceeding further. Pump fault mcc or standby pump fault mcc identified by pump motor output gives alarm to control desk if that pump. This paper will describe a few operations where gear pumps improved a process, how they are used in unstable processes, and approaches to troubleshooting lines using gear pumps.
The hydraulic hand pump is a handheld hydraulic sealant injection pump that is rated to 10,000 psi and operates in any position. And besides, there are no books devoted entirely to hydraulic troubleshooting in a meaningful way. Because a pump is the most timeconsuming part to replace and the most expensive. Get the hydraulic troubleshooting handbook boo k pdf file for free from our online library pdf file. Pressure pump and related control components components on top of press dbet card in control box legend 1. Because of this, the following points should be considered. Momentarily remove the suction hose from the bottom of the pump and lower it into an oil drain container, making certain there is sufficient flow.
Relief valves and fixed displacement pumps provides a flow path for the pump volume back to tank. The prv can be piped back to the suction side of the pump or into the supply tank. They were using a lowviscosity hydraulic oil formulated for use at low temperatures. Refer to the recommended lubricant chart attached to the hydraulic tank or refer to the units operators manual to determine the required hydraulic oil. Troubleshooting guide continued troubleshooting guide part 2 problem possible cause corrective action rapid pump wear abrasives in fluid install suction strainer. The definitive guide to hydraulic troubleshooting is not a book. Vanes, rotary group, bearings, causing internal leakage. It should never be changed before several tests are conducted. The swashplate is moved by two internal cylinders, which are controlled by a separate valve or manual lever. If your pump has a case drain line a quick check for inefficiency is to remove the case drain line and drop it into a bucket. The pump is probably the component most subject to wear in a hydraulic system, and the one most likely to cause a sudden or gradual failure in the system.
The denison vane pump technology is a heavy duty engineering design that will last years if elementary precautions are taken. Loosen the hose clamp securing the suction hose to the hydraulic gear pump using a 516 socket or a flatblade screw driver. Ot tractor hydraulics troubleshooting practical machinist. Hydraulic line from proportional valve to pump control port 4. Hydraulic gear pump and motor failure analysis and repair. Vane pumps generally are quieter than piston and gear pumps. Dec 22, 2011 1650 otto van guericke invents the piston vacuum pump, which used leather washers to prevent leakage between the cylinder and the piston 1675 sir samuel morelandan english academic, diplomat, spy, inventor and mathematicianpatents the packed plunger pump, capable of raising great quantities of water with far less proportion of strength than a chain or other pump. Dc power unit troubleshooting guide kti hydraulics, inc. Some components must be mounted in a specific position with respect to other components or the lines. The hydraulic troubleshooting handbook identifies and explains 12 principles that are essential for the effective troubleshooting of any type of system. The hydraulics for the draft gear 3 point hitch lift have one control valve. Models 1012, 1053 and 1056 concentric oipm pn 2690165. Series dhm fixed displacement gear pumps service manual.
Hydraulic pumpmotor division hydraulic flow is developed as the pump rotating group is driven by a prime mover hydraulic pump basics fluid is forced out of pump at the pump outlet a partial vacuum is created at the pump inlet and atmospheric pressure forces fluid into pump from the reservoir. All lines must be of proper size and free of restrictive bends. Find popular gear pump lines brought to you by major. Take, for example, a system that runs a 16 cm3 gear pump at 1450 rpm, and, say, the system pressure cant go higher than 100 bar because the pump is severely wornout. Gradual or sudden loss of pressure or flow resulting in a loss of power is common in hydraulic system failure. Before the pump is removed or disassembled, check the following list of common. Amatrols basic hydraulic troubleshooting learning system 950htb1 teaches learners how to troubleshoot hydraulic systems and their components, such as hydraulic motors, directional control valves, and cylinders. The hydraulic oil is discolored or the pump is losing oil.
Can you suggest some tips to find a solution to this problem. Efficiencies were calculated for a 36 gpm input flow to the motor fig. The hydraulic troubleshooting learning system consists of a system, troubleshooting and servicing package, student learning materials for both theory and lab, and teachers guide. The pumps will stop automatically if the level drops to the shutdown level. Basic hydraulic troubleshooting training system amatrol. If you do see the pump heat up instantly you just found your culprit, and it took you but a couple of minutes. Hydraulic imbalance in a double suction pump a horizontal, doublesuction pump may be fitted with a 90deg elbow mounted on the suction nozzle in such a way that the line leading to the elbow is parallel with the axis of the pump shaft see figure 1.
Demonstrative drawing of the pz2 type gear pump structure. Experience x20 a small pump with big power thats built for better productivity, fuel efficiency, control and reliability. Hydraulic gear pump and motor failure analysis and repair guide. If the line is hot, the relief valve is either stuck partially open or is set too low. Basically, the flow meter will show the loss of oil flow at different pressures. Vickers systems to the extent permitted by law accept no liability for loss or damage suffered as a result of the use of this guide. When pump troubleshooting, this issue is most frequently caused by a ruptured diaphragm. Save this book to read the hydraulic troubleshooting handbook boo k pdf ebook at our online library. This problem will not occur if inlet vacuum and rated. Pat clark of lifting gear hire demonstrates a few troubleshooting solutions for your hydraulic cylinders and pumps in the hopes of ensuring a successful and productive project. Hydraulic system troubleshooting 45 conversion tables 48 hydraulic oil and filtration 38. The hydraulic system is powered by a singlesection gear pump. The pump volume can range from zero to the maximum amount.
Rotary gear pump model numbers include design style, port. Rexroths complete line of hydraulic pumps serve virtually every industry in manufacturing and technology applications such as railway engineering, chemical process plants, power and environmental engineering, automotive engineering, plastics processing machinery, paper industry, presses, test rigs and simulation systems, marineoffshore. Troubleshooting tips for hydraulic systems download data sheet this data sheet describes a stepbystep checkout procedure for hydraulic systems which have previously been working satisfactorily but which have developed trouble, usually over a 24hour working period, which renders them inoperative. Hydraulic gear pump and motor failure analysis and repair guide page 2 of 32 alamo industrial 1502 e walnut st, seguin, tx 78155. Vaporization caused by higher vacuums will generally result in capacity drop off. The heart of a hydraulic system is the hydraulic pump. Hydraulic system troubleshooting pellerin milnor corporation. It is very portable making it easy to keep one in your pickup for quick topups and. For example, an inadequate size filter on the inlet of a pump can cause cavitation and subsequent damage to the pump. The pump is the component that receives the mechanical energy supplied by the tractor or engine, and converts it to fluid energy with the use of the hydraulic oil. This document has been produced to support pump users at all levels, providing an invaluable reference tool. Troubleshooting and preventive maintenance of hydraulic. Logical troubleshooting in hydraulic systems is intended as a guide to systematic fault findings in a hydraulic system. When a hydraulic system has problems, it is common practice to first look at the pump.
When this happens, you must discard the hydraulic oil and thoroughly flush the gearbox. The suction lift is too great or the suction line is too small or too long. Criterial quantities providing the wear symptoms identification of tested pumps, were separated during the pump characteristics empirically obtained analysis. To protect from overpressurization of the hydraulic system, the pump is provided with a pressure relief valve, set at 3200 psi. Thanks for viewing, comment, rate and subscribe for more videos. A healthy pump will allow the mower system to perform at its maximum level of effectiveness. It includes information on general centrifugal pump problems and their effect on centrifugal pumps with suggestions as to probable causes and solutions. So, whenever you detect insufficient pressure in a gear pump driven hydraulic system, check the pump body for instant overheating. We will introduce many aspects ofwe will introduce many aspects of troubleshooting hydraulic systems and will share information that will help you to bettershare information that will help you to better understand and enhance the operation of your hydraulic equipment. Obviously this cannot be true, but when preliminary troubleshooting analysis focuses on the pump, a series of steps can pinpoint the specific problem and lead to the. While the pump is in compensation, monitor how much fluid is coming from the case drain.
Hydraulic pumps fixed displacement pumps the gpm of the fixed displacement pump can not be varied. Install a flow meter in the case drain line and check the flow rate. Hydraulic plumbing installation revised midsize system plumbing installation. Hydraulic oil used in the majority of systems contains about 10% dissolved air by. Its a training program which combines printed materials, computer simulation and screencapture videos. The winner will be notified, and his or her name will be printed in a future issue. The hydreco model 1919 motor has a theoretical displacement of 4. When start solenoid not shown is activated power is provided to dc motor 124515 which turns gear pump pl2. Troubleshooting gear pump assisted singlescrew extrusion. When using a gear pump a pressure relief valve must be fitted to protect the pump if deadheaded against a closed valve or blockage. Learners will use these components in realworld applica ons while studying major topics like hydraulic pump troubleshoo ng, hydraulic actuator. Condensed table causes of trouble and their effects in hydraulic installations. Troubleshooting hydraulic pumps machinery lubrication.
Most variable displacement pumps bypass percent of the maximum pump volume through the case drain line. However, we dont want you to have to make the trip in with your part unnecessarily. These stepbystep procedures should help you locate and remedy. May 11, 2015 a gear pump used with a twostage, vented screw can allow high operating rates at higher discharge pressures while not causing material to flow into the vent. Hydraulic pump troubleshooting guide no oil flow from pump. The tap4nn gear pump is available in a displacement range from 60. For standard multiple pumps, see multiple pump technical manual.
A gear pump uses two meshing, toothed cogs to force water from the inlet of the pump through to the outlet. When troubleshooting an internal gear pump or any other pump for that matter, develop a clear, concise, and objective statement of the problem. For gear pump assisted extrusion, the extruder control algorithms are set to maintain a constant pressure to the inlet side of the pump by the extruder. Do not use teflon tape on pipe thread fittings pump is hot. They are suited for use in log splitters and other applications, such as. If your hydraulic layout is suffering from any issues, make sure to check your hydraulic gear pumps and other components.
Try this simple tip before you blame your gear pump for. Workers couldnt figure out why the pump shaft seal in their trenching excavators. Try to set preconceived ideas of what could be wrong aside and base your statement on facts that are accurate and unbiased. Positive displacement pump problems 5 overview of pump problems typically found on positive displacement pumps. Eaton product literature library hydraulic components. Check all components, particularly the relief valve for proper settings.
Hydraulic troubleshooting learning system 950ht1 teaching advanced hydraulics, system tuning, installation, and maintenance. Sauerdanfoss high performance gear pumps are fixed displacement pumps which. When understood and adhered to, these 12 principles become the anchor for a logical, stepbystep troubleshooting process anyone can follow. Ratings and data for tap4nn gear pumps are based on operating with premium hydraulic fluids. The new pump is delivering a maximum pressure of 1,000 psi and appears to be creating heat. Aug 17, 2017 hydraulic troubleshooting learning system 950ht1 teaching advanced hydraulics, system tuning, installation, and maintenance. When the new pump also did not build pressure, the manual valve in the outlet line was. We will introduce many aspects of troubleshooting hydraulic systems and will share information that will help you to better understand and enhance the operation of your hydraulic equipment.
Cavitation cavitation is caused by excessive vacuum at the pump inlet. Each component in the system must be compatible with and form an integral part of the system. The hydraulic troubleshooting handbook would be a bargain at twice the price. The pump is arguably the heart of almost every hydraulic system and, as such, has traditionally been blamed for almost every operating problem.
These reliable, highefficiency pumps can provide a continuous, smooth flow. Connect the work hoses to their mid new style designated ports reference the table below for details with scraper pla plb paa sca sab scb saa hb ha pab t2 a s p ls designation function size sae p pump inlet 12 ls load sense 4 a auger 10 s spinner 10 t2 tank 12 paa. An undersized or restricted line results in a pressure drop in the line itself. Centrifugal pumps develop pressure by increasing the velocity of the liquid liquid is literally flung out of the cutwater. Measure the shortest diameter of the elliptical bore d. In any troubleshooting situation, no matter how simple or complex the hydraulic system, always start with the basics. Gear pump hydraulic schematic figure 1 figure 2 dimensions description our two stage, hilow, external gear hydraulic pumps, models 1012, 1053 and 1056, are designed to be directdriven by gas engines or electric motors. Volumetric efficiency of gear pumps at 90% is lowest of the three pump types. Highperformance hydraulic gear pumps from grainger can convert mechanical power into hydraulic energy to help run industrialgrade hydraulic systems. Typically, gear pumps are used at pressures up to about 150 bar and capacities of around 150 gpm 6751 min1. This occasionally happens with suspected gear pump failures. In figure 2, the pump swashplate is in the vertical position, which means the pump output is zero gallons per minute gpm.
The gear pump failure states, that occurred most often, were identified in chapter 3. They can either be plumbed just to the pump to test the pump or they can be plumbed inline between the pump and wheel motor to test both at the same time. Condition likely cause correction muncie power products. If your system is suffering from any of these symptoms, then that could be a clear sign that you need to repair, clean, or replace parts of your system. A pistontype pump is always used in a hydrostatic system. Basic hydraulic troubleshooting learning system 950htb1 fo. In todays video, we are assembling anad inspecting a positive displacement high pressure hydraulic gear pump. Hydraulic gear pump assembly and inspection youtube. Deadheading the gear pump on a japanese tractors hydraulic system and firing up the engine, will either stall the engine or will likely burst the pump casing before you realize it happened. This cast iron prince manual doubleacting pump head is ideal for a hydraulic press, dump, plow, snowblade, platform, frame straightener or other lowflow equipment use. If you dont detect it, theres a good chance the problem is elsewhere.