Maintenance of Hydraulic System

Note: When maintaining hydraulic power station,

only professional person are allowed.
I. Trial Run of the Hydraulic System
1. Cleanliness of the hydraulic system
Prior to filling the oil, cleanliness of the reservoir, cylinders and piping must be
checked and ensured. If any contamination is found in the system it must be
cleaned thoroughly. The pump station on the crane may be used as oil supply
for the system blushing with some additional auxiliary piping. The cleaning
should be done as the following:
1.1. Clean up the appropriate site working area first;
1.2. The reservoir must be cleaned first. Then fill with oil and heat the oil up to
45°C~55°C. During flushing oil flow rate in piping shall reach 5~7m/s as far as
possible, and the relief valve shall be set less than 5.0MPa. A filter shall be
mounted on the return line.
1.3. Flushing is made for main piping and may be performed separately for sections
into which the piping is divided. Discharge or drain ports of hydraulic valves
should temporarily be shut off and connected to the flushing pipeline. The
directional valves should be activated to a certain position to make oil circulation
possible.
1.4. During system flushing piping should be shocked frequently and slightly by
hammer to assist the dirt and rust. 30 minutes later, the splotches of rust should
be removed and checked, then cleaned and reassembled. Repeat flushing
several times until the oil filter has no obvious contamination. This will take
about 2~3 hours for one flushing section. If it is cleaned by hydraulic oil, then
after cleaning the hydraulic oil must be tested and if the test result shows the oil
is satisfactory in respect of physical and chemical properties it can still be used.
1.5. Check oil's cleanliness after all the pipes have been cleaned. If the oil reach
NAS8, pipes can reset and repair to commission the hydraulic system. If not, you
shall repeat 1.3 and 1.4 until the oil cleanliness is NAS8.
1.6. Please check the oil cleanliness again after finishing commissioning the
hydraulic system. Repeat 1.1~1.5 if oil cleanliness has not reach NAS8.
2. Adjusting and testing of the hydraulic system:
 It is necessary for either new or repaired hydraulic equipment to adjust and test
the performance data to fit practical data required for the specified application.
2.1. Purpose of the adjustment and test
We can know and familiarize with system performance and technical conditions
by adjustment and trial running. Defects and faults found during trial run shall
be eliminated and remedied immediately and thus reliable operation of hydraulic
system can be ensured.
2.2. Main contents of adjustment and test
2.2.1. Main data, such as force, speed, start point and end point of stroke, period of
each motion and total time taken for duty cycle, are to be adjusted to the valve
determined during original designing.
2.2.2. Adjustment of the complete system to make the system performance reaching
stable and reliable operation.
2.2.3. During adjustment the power loss of the hydraulic system should be evaluated
and the temperature rise of oil should be observed.
2.2.4. Reliability of each adjustable components should be checked.
2.2.5. Reliability and sensitivity of each control mechanism should be checked.
2.2.6. All those components which are not in compliance with design requirement
and/or with certain defects found should be remedied or replaced.
2.3. Method of adjustment and points for attention
In hydraulic system the power is transmitted by fluid pressure so that reasonable
setting is very important for ensuring normal system operation.
2.3.1. Familiarize with hydraulic system and its technical performance.
a) It is necessary to familiar with each pressure component and the entire system
feature. And it is also necessary to understand the function and characteristics
of the equipment adjusted, the equipment design, fabrication accuracy and
application as well as relationship between mechanical, electrical and hydraulic
systems.
b) It is also necessary to analyze seriously structure, function, performance and
adjusting range of the component and the practical location of each component
on the equipment should be known.
c) Pressure adjustment method and steps and operation procedure should be
developed to avoid damage to the equipment and personnel injury as far as
possible.
2.3.2. Pressure adjustment method
Working pressure is developed when an external force acts on the fluid surface.
Therefore adjustment of the system pressure is essentially resistance to free flow
of the fluid. The method is as follows:
a) Before pressure adjustment the adjustable screw of the pressure relief valve is
loosened and the limit position of the actuator should be adjusted.
b) The actuator moves to the limit and stops, or shut off the oil flow by some
component to build op pressure in the system.
c) Pressure should be adjusted according to design required working pressure or
practical necessary pressure (it should not exceed design working pressure) to
decrease power consumption and temperature rise as far as practicable and to
minimize possible leakage due to high temperature.
d) Pressure should be set(adjusted) gradually till the valve needed. After that the
adjustable screw should be secured by fastening the locking nut to avoid
loosening.
2.3.3. Pressure adjustment (setting) range
Reasonably set pressure of various components in the system is significant for
normal and stable operation of the system as well as for limiting temperature rise.
If system pressure is set inadequate excessive energy loss and high temperature
rise may be resulted in and cooperation of motions may be affected harmfully
and even fault may happen. Therefore, pressure setting must meet the
requirement under specifications or according to practical application conditions.
Pressure setting is to be determined with consideration of construction, quantity,
piping used.
a) Pressure relief valve rated pressure shall 150% of its set max. working pressure
at least.
b) If there is a pressure relay in the system, the pressure relay adjusting pressure
shall 0.2~0.5MPa high or low than the working pressure of executive agency
which is controlled by the pressure relay.
c) Accumulator's charging pressure is 80~90% of its min. working pressure if there
is a accumulator in the hydraulic system. Pressure relief valve of accumulator
adjusting pressure is 110~120% of the its max. working pressure.
d) Range of return line back pressure is 0.1~0.3MPa.
2.3.4. Point for attention during pressure setting
a) Pressure adjusting under actuator(hydraulic cylinders, motors) motion is not
allowed.
b) Pressure gauge should be checked before pressure adjustment and must be
replaced if it is abnormal.
c) Pressure is not allowed to be adjusted without pressure gauge. It is necessary to
install a pressure gauge then pressure can be adjusted.
d) Pressure setting should be as specified in operation instruction or as practical
necessary (but freighter than specified is not allowed) to prevent from excessive
pressure and resulted temperature rise.
e) The locking nut should be secured anti-loosened after pressure set.
2.4. Speed regulation and others
2.4.1. Pump output oil supply to the executive agency at all, so you need not adjust
speed.
2.4.2. The cylinder's speed are almost the same for the multi-function hydraulic
system. Speed error range is 1% if adjust the throttle valve.
2.4.3. There is a throttle valve in the system which mount a accumulator. So
accumulator output flow quantity can controlled and avoid shock.
2.4.4. Low oil level alarm device is installed in the oil reservoir. In case of lose
breakage or seal damage at valves that may result in a large amount of leakage
and later oil will be under “the low level” in reservoir, the alarm device will be
activated and pump-motor stops. The alarm is activated when the level fall to
“the low level”.

II. Maintenance of hydraulic system

Proper operation and careful maintenance for the equipment is necessary for
prevention from earlier worn-out and damage, and results in extended service
life. Regular maintenance of the equipment will make it always in proper
technical condition and having desired efficiency.
1. Maintenance requirement of the hydraulic system:
1.1. It is necessary to have skilled operation, reasonable adjustment, careful
maintenance and regular inspection and appropriate repair to ensure expected
productivity and stable, reliable technical performance of the hydraulic
equipment. In addition, the following requirements must be met during
hydraulic equipment operation:
1.1.1. Reasonably setting of working pressure and speed in accordance with design
requirement. After pressure and speed (flow) setting to specified valve
adjustable screw should locked securely to prevent from loosing, or adjustable
handle (if applicable) should be locked.
1.1.2. Hydraulic oil should be selected as specified in the operation instruction.
The oil must be filtered to NAS8 before filling into the system. Samples must
periodically be taken from the system and be tested. If the oil quality is found
unsatisfactory it must be replaced.
1.1.3. Temperature of the oil in hydraulic system on the crane should not be over
60°C, normally it should be limited within the range of 0°C~60°C. Whenever
the oil temperature exceeds specified valve the cause must be found and
eliminated.
1.1.4. To ensure normal operation of the pressure relief valves stable power voltage
is necessary and voltage surge should be limited within 5%~15%.
1.1.5. Operation with defective or without pressure gauge is not permitted.
1.1.6. Electrical panel, junction box, operation console and master switch box etc.
should be equipped with cover or door normally closed during operation and
operation with opened covers or doors is not allowed.
1.1.7. When some portion failure of the system occurs(such as unstable pressure ,low
pressure ,vibration etc.) it must immediately be checked and the cause must be
found. Do not continue operation with this failure or accident may happen.
1.1.8. Regularly check the cooler and heater operation performance.
1.1.9. Frequently check and fasten pipe fittings, flanges etc. to prevent from
loosening . Hydraulic hoses must be periodically replaced.
1.1.10. Periodically replace seals, usually the seal life is one and half to two years.
1.1.11. Periodically measure the main components performance or regularly replace
or repair them.
1.2. Operation and maintenance procedure:
In addition to the conventional requirements for usual mechanical
equipment ,there are Some special requirements which must be met by the
hydraulic equipment as follows:
1.2.1. The operator must familiar with the function of hydraulic components used on
the crane and hydraulic system principle and operation sequences well.
1.2.2. Operator shall frequently observe hydraulic system operation condition,
working pressure, speed, cylinder condition to ensure stable and reliable system
operation.
1.2.3. When temperature in reservoir reaches 60°C, the system condition must be
paid attention to and appropriate measure for inspection and maintenance should
be taken.
1.2.4. The operator shall not damage the system interlock devices, not damage or
move any limit switches.
1.2.5. The operator is not allowed to adjust or replace any hydraulic component
without permission of the related authority.
1.2.6. The operator is not allowed to do any thing with the fault when some trouble
in hydraulic system occurs. He should immediately notify maintenance
department of the trouble. Maintenance department must immediately send
personnel related to the job site for trouble shooting.
1.2.7. Hydraulic equipment must be maintained clean and protected from dust cotton
waste etc. getting into the reservoir.
1.2.8. The operator shall carefully make "point inspection" according to equipment
point inspection cards.
1.3. Point inspection and periodic inspection
Point inspection is the basic of equipment maintenance. Point inspection of
hydraulic equipment should be made for specified items to check if the hydraulic
is in proper condition and the operation is normal by observing appearance and
listening to the running or measuring by simple tools and instruments. This is
done for advanced finding out abnormal problems or imperfect condition which
maybe solved in advance to minimize risk of accident the latter will affect
productivity of the crane. All abnormal problems and imperfect condition may be
eliminated at their beginning through point inspection. According to the data
obtained by point inspection the items which need to be repaired can be
determined and a repair plan can be developed, also the regularity of trouble
occurring in the system and service life of oil, seals and components and period
of their replacement may be find out.
Point inspection is divided into two categorizes: routine point inspection made
by the operator and periodic inspection means inspection after an interval of
more than one month made by maintenance personnel after crane be stopped.
 Point inspection cargo shall be included in technical files and can be one of the
bases for repairing.
Contents of the point inspection are as follows:
1.3.1. Check if there is external leakage at any valve, cylinder and/or pipe fitting.
1.3.2. Check if there is abnormal noise during pump running.
1.3.3. Check if the cylinders move smoothly and normally.
1.3.4. Check if all of the pressure measuring points are in specified range and
pressure is stable.
1.3.5. Check if oil temperature is within allowable range.
1.3.6. Check if there is high frequency vibration during system operation.
1.3.7. Check if the solenoid and electric controlled directional valves are sensitive
and reliable.
1.3.8. Oil level in reservoir is within normal level range or not.
1.3.9. Check if there is position deviation of limit switches or limit blocks, fastening
bolts ate secured reliably.
1.3.10. Check if there is abnormal condition during manual or automatic system
operation duty cycle.
1.3.11. Periodically take samples from reservoir to check oil quality.
1.3.12. Periodically check accumulator performance.
1.3.13. Periodically check the cooler and heater performance.
1.3.14. Periodically check and fasten all main bolts, nuts, fittings and flange bolts.
Point inspection is made by listening, observing and testing. Results of
inspection (check) may marked by four symbols: "√" means perfect; "Δ" means
abnormal: "X" means waiting for be repaired; "⊗" means already repaired.
These symbols shall be printed in the following table.
 Daily Point Inspection Card

Operator:
Mechanical:
Electrical:
Hydraulic:
Equipment No: Model: Date:
Contents of Point Inspection 1 2 3 30 31

10

11

12

Method Listening Mechanical

of in- Observing Electrical
pection Testing Hydraulic
Symbols Results of inspection should be
filled in with symbols every day.
"√" perfect, "Δ“ abnormal, Treatment
"×" to be repaired, "⊗"already
repaired.
2. Contents and requirements of periodic maintenance
System normal operation greatly depends on periodic maintenance contents of
which are as the following:
2.1. Periodic fastening:
Pipe fittings and fasteners may be loosened due to the air trapped in the
hydraulic system during operation, direction change impact, pipe vibration,
system vibration etc. Without periodic fastening of them serious leakage may
occur and accident may be resulted in that may cause equipment damage and/or
personnel injury. Therefore, those bolts, nuts and fittings which are subjected
to impact and vibration must be fastened periodically.
For intermediate pressure equipment fittings, hose fittings, flange bolts, securing
bolts of cylinders and cove bolts, piston and stopper bolts, accumulator piping,
limit switches and stop bolts etc. must be fastened once a month. For
equipment with lower pressure they may be fastened once every three months.
In addition, tension for each bolt shall be even and reaches a certain torque.
2.2. Periodic replacement of seals
Leakage and suction which often happen are trouble in hydraulic systems. So
sealing is very important and there ate two categories of method to solve the
problem of sealing:
One is clearance sealing which is dependent on pressure drop, clearance between
two sliding surfaces, seal length and oil viscosity. Another one is sealing by
elastic material—— rubber seals which depends on seal structure, material,
working pressure, application and installation etc. After long period service they
may not only be degenerated but also be permanently deformed under high
pressure for a long period that results in losing seal property. Therefore
periodic replacement is necessary. Replacement of seals is a main work of
hydraulic system maintenance. A schedule of seal replacement should be
developed according to operation conditions of the system and schedule should
be included in the technical files maintained for the appropriate equipment.
According to seal rubber manufacture and sulfuration procedure the seals have a
service life of 5 years or so.
2.3. Periodic cleaning or replacing hydraulic components
After long period operation, some dirt will go into some components due to wear,
replace valve due to fatigue. Valves shall be cleaned once approximately needed
 to after every 5 years operation. Cylinders must be cleaned once after every 8
years. At the same time seals must be replaced. After reassemble of these
components their properties shall be measurement of normal operation.
2.4. Periodic clean or replacement of filter element
After a certain period of operation the solid foreign matters (such as dirt, scraps
etc.) may build-op on the filter element and stop it affecting normal oil flow. In
this case pump noise, temperature may operation of system will occur. It is
obvious that a schedule of cleaning and replacement of filter element must be
made in accordance with the operation conditions. Normally the filter should
be cleaned every 3 months. Filter clean schedule should be included in
maintained technical files.
2.5. Periodic cleaning of the reservoir
After long term operation, contamination will be at the bottom of the reservoir.
The built-op foreign matters may be sucked by the pump into the system and
cause trouble. Special attention should be taken to the cleanliness inside of the
reservoir during replacement. Normally the reservoir should be cleaned every 3
years or so.
2.6. Periodic cleaning of the piping
Oil contamination may be accumulated at pipe bending portions and some flow
passages of manifold the longer the system is operated the more contamination is
accumulated. This not only increases flow flushed with oil flow and may block
off damping hole of some component that results in trouble. Therefore piping
must periodically be cleaning by two methods:
2.6.1. Those pipes which can be removed such as manifold, hose etc. may be
cleaned after their removing.
2.6.2. Piping may be cleaned by oil circulating once every 8 years or so.
2.7. Periodic changing of oil
2.7.1. After 500~700 hours operation following adjustment and trial run the oil in the
system filled firstly must be completely changed. After that every 3000~5000
hours operation the oil should be changed. The above figures ate only for
supervision. Accurate time interval should be determined depending on oil
quality, working temperature and other operation conditions. Attention should
be paid to that every time the oil is changed the bottom of the reservoir must be
cleaned.
2.7.2. Oil changing process:
a) Drain all the oil in hot condition.
b) Oil in the reservoir should be drained off completely.
c) When clean the reservoir to the bottom should be paid special attention.
d) Clean or replace the filter and its element at he same time.
e) If the equipment is seriously contaminated or the oil is change to another type
then the equipment (system) should be flushed to clean by the new type of oil
before it is filled into.
f) New oil should be filtered before filling into the reservoir.

LIST OF CATALOGUE
REMARK MODEL NAME
 AZPF-1X-011RCB20MB Gear Pump
AZPF-1X-008RCB20MB Gear Pump
DBDA6K 1X/315 Relief Valve
HED8 OH 2X/350K14S Pressure Switch
REXROTH
4WE6J6X/EG24N9K4 Solenoid Valve
Z2S6-1-6X/ Pilot Check Valve
ZDR6DA2-4X/210Y Reducing Valve
AB31-14/2-1A2A-Z6 Temp. Alarm
D04B2-1.0N Check Valve
STERLING
J04A2WN Throttle Valve
Low Liquid
SLWC-60-1-B250NC-01-01-1-T70NC-PG11
Position Alarm

STAUFF SNA254 B-S-T-12 Oil Level Gauge

SNA127 B-S-T-12 Oil Level Gauge

EHV20-330/88 Acc.
OLAER
EHV12-330/88 Acc.
SV10-22M-O-N-24DG Solenoid Valve
SV10-23P-O-N-24DG Solenoid Valve
HYDRAFORCE
SV16-22M-O-N-24DG Solenoid Valve
SV16-23P-O-N-24DG Solenoid Valve
CKEB-XAN Pilot Check Valve
SUN GJ050-NFCC-LCN Throttle Valve
PRFB-LAN-GJ046/S Reducing Valve
Check-throttle
PARKER 9F400SXB032
Valve
RF BN/HC160DE10ES1.0 Return Oil Filter
HYDAC
RF BN/HC110DC10ES1.0 Return Oil Filter