Hydraulic Power Unit Troubleshooting: Identifying Symptoms, Causes, and Solutions

Car Lift Repair Tampa Florida

Hydraulic power units (HPUs) equipped with multiple pumps serve various functions. For instance, a controlled crown roll HPU requires pumps for:

1. High-pressure pumps for regulating shell deflection via hydrodynamic or hydrostatic load shoe bearings.

2. Lubrication pumps to lubricate shell load shoes, rotating bearings, and to manage temperature.

3. Scavenger pumps for oil return to the hydraulic unit.

Pump failures can result in product quality issues and production downtime. Typically, there are backup pumps to minimize the impact of a failure on production.

Car Lift Repair Tampa Florida Hydraulic power units consist of several components, including pumps, motors, oil tanks, pressure filters, return filters, oil level switches, temperature switches, pressure switches, oil coolers/heaters, thermostat valves, thermometers, electric terminal boxes, and circulation/pressure circuits.

Troubleshooting:

1. **Symptom**: Inadequate Fluid Delivery from the Pump.

   – Possible Causes and Fixes:

     – Verify Car Lift Repair Tampa Florida pump rotation direction indicated by the arrow on the pump body.

     – Inspect for broken drive shaft or sheared shaft key; repair if necessary.

     – Unblock intake pipe or adjust oil viscosity for priming; ensure clean fluid and proper temperature.

     – Check for air leaks in the intake connections; tighten securely.

     – Address loose connections in outlet line to ensure priming and proper fluid level.

2. **Symptom**: Low Hydraulic System Pressure.

   – Possible Causes and Fixes:

     – Adjust relief valve using a pressure gauge if set too low.

     – Replace worn pump parts causing internal leakage.

     

3. **Symptom**: Excessive Noise from the Pump.

   – Possible Causes and Fixes:

     – Clear any blockage or restriction in intake strainer/pipe; clean or replace as necessary.

     – Replace defective bearings and inspect pump shaft.

     – Address air leaks at pump intake pipe joints or shaft seal; tighten joints and replace seals if needed.

     – Ensure correct drive for the pump and alignment of coupling.

4. **Symptom**: Leakage from Pump Shaft Seal.

   – Possible Cause and Fix:

     – Replace worn or damaged seals.

5. **Symptom**: Pump Experiencing Excessive Heat (Over 400°F).

   – Possible Causes and Fixes:

     – Check for excessive thrust on Car Lift Repair Tampa Florida pump bearings and align shafts properly.

     – Monitor fluid temperature and overhaul pump if excessively hot.

Maintenance Notice:

Regular maintenance, especially filter upkeep, is crucial for Car Lift Repair Tampa Florida hydraulic system longevity and performance. Annually clean and inspect the reservoir for corrosion and other damage to prevent contamination of the oil. Ensure the cover plate remains in place except during inspection or refilling. The reservoir must be adequately sized to handle all machinery oil and should be cleaned more frequently if needed.

1. VERIFY YOUR DIRECTIONAL CONTROL SETTINGS

While seemingly straightforward, directional controls can be inadvertently altered without the knowledge of maintenance personnel. Taking a moment to confirm the position of manual controls and inspecting the settings of electrically operated solenoid controls is a simple step that can prevent unnecessary replacement of functional pumps.

2. ENSURE YOUR PUMP RECEIVES ADEQUATE FLUID

Various factors such as restrictions or blockages can hinder the flow of fluid to your Car Lift Repair Tampa Florida pump, leading to diminished performance. Common issues include air leaks in the suction line, presence of air during startup, insufficient oil supply to the pump, clogged or dirty fluid filters, obstructed inlet lines or hoses, and blocked reservoir breather vents.

3. CONFIRM THE CORRECT ROTATION OF YOUR DRIVE MOTOR

After verifying the directional control, it’s essential to ensure that the drive motor is rotating in the correct direction. Improper installation can result in mismatched pipe routings between control valves and motors, causing flow reversal. Check that the motor is turning the pump in the intended direction, and inspect piping if necessary.

4. VERIFY THE OPERATION OF YOUR DRIVE MOTOR

Inspect the pump drive motor to ensure it is turning properly and generating the required speed and torque. Misalignment can lead to binding of the drive shaft, hindering motor rotation. Correct any misalignment and examine the motor for damage, proceeding with overhaul or replacement if needed.

5. INSPECT YOUR PUMP COUPLING FOR DAMAGE

Examine the coupling between the Car Lift Repair Tampa Florida pump and motor to ensure it is intact. A sheared pump coupling can result in failure, although assessing this can be challenging due to the pump’s location within hydraulic systems. Careful inspection can prevent overlooking this potential issue.

6. CHECK THE OPERATION OF YOUR PUMP RELIEF VALVE

Improper adjustment of the relief valve may divert the entire flow, preventing pressure development. Verify that the relief valve is set according to the pump specifications and the application requirements.

7. LOOK FOR SIGNS OF MECHANICAL DAMAGE

Seized bearings or internal damage within the pump can render it inoperable. If all other checks yield no issues, uncouple the pump and motor to examine if the pump shaft can turn freely. If not, consider overhauling or replacing the pump to restore functionality.

Troubleshooting Guide for Hydraulic Pumps

Hydraulic systems play pivotal roles across diverse industries, from automotive and agriculture to construction and oil refining. Central to these systems are hydraulic motors and pumps, ensuring the smooth movement of hydraulic fluid to accomplish various tasks efficiently.

Despite their crucial role, hydraulic components may experience a decline in performance over time. Identifying and rectifying the underlying causes is essential to prevent potential damage to other system parts and components.

Common Causes of Pump Failure and Hydraulic Issues

Pinpointing the root cause of pump failure and hydraulic issues requires understanding the system’s optimal functioning. Even without comprehensive knowledge, you can watch out for these prevalent hydraulic problems:

1. Power Loss: Inability of the system to perform intended tasks due to power loss necessitates identifying and resolving the underlying issue promptly.

2. Overheating: Overheating may stem from inadequate cooling of hydraulic fluid, fluid leaks, or malfunctioning relief valves impeding fluid recycling.

3. Aeration: Introduction of air into hydraulic oil can lead to various issues, including power loss and damage to motors and pumps.

4. Over-Pressurization: Excessive pressure within the system poses risks of failure and necessitates immediate attention.

5. Oil Contamination: Entry of dirt, debris, or particles into the oil can harm pumps and the system, emphasizing the importance of effective filtration.

6. Implosion: Air bubbles within the fluid collapsing as they pass through the pump can generate shock waves, potentially damaging the pump.

7. Improper Fluid Viscosity: Using incorrect fluid type or irregular fluid changes can result in viscosity-related issues, impacting system performance.

8. Aging: Natural wear and tear over time can lead to system malfunctions and eventual failure, highlighting the need for periodic component replacement.