IF HOSE BRUST WHAT SHOUILD WE DO? [Fault 5]

Trouble in Hydraulic Hose Assembly

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Now we study about "Hydraulic Hose Assembly"

What  the fault acctually is? 

Fitting blew off    at the end of the hose. 

Why it happen?

1.   It may be due to  the wrong fitting has been put on the hose. In the case of a crimped fitting the wrong machine setting may have been used resulting in over or under-crimping.   

2.  The fitting may have been fixed improper-ly to the hose. 

 What should we do?

1.  Check manufacturer's instructions.  The hose should be installed with enough slack to compensate for the possible 4% shortening that may occur when the hose is pressurized.  Recheck the manufacturer’s specification and part nos. 

 2.  The fitting should be fixed properly. 

IF HOSE BRUST WHAT SHOUILD WE DO? [Fault 6]

Trouble in Hydraulic Hose Assembly

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Hose Assembly"

What  the fault acctually is? 

The hose fitting has been pulled out of the hose.  The hose has been consider- ably stretched out in length.  

Why it happen?

1. This may not be high pressure application hose. 

2. Insufficient support of  the hose.  It is essential  to support very long lengths of hose, especially if they are vertical.   

 What should we do?

1. Use the hose as per the pressure of fluid line. 

2. All    the  hoses should be supported by clamping the same at proper distance giving sufficient slacks between two clamps to make up for the possible 4% shortening that could take place when the hose is pressurised. 

IF HOSE BRUST WHAT SHOUILD WE DO? [Fault 4]

Trouble in Hydraulic Hose Assembly

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Hose Assembly"

What  the fault acctually is? 

Hose appears to be flattened out in one or two areas and appears to be kinked.  It has burst in this area and also appears to be twisted. 

Why it happen?

Torquing of a hydraulic control hose will tear off the reinforcement layers and allow the hose to burst through the enlarged gaps between the braided plaits of wire strands. 

 What should we do?

Use swivel fittings or joints to be sure that  there is no twisting force on a hydraulic hose. 

IF HOSE BRUST WHAT SHOUILD WE DO? [Fault 3]

Trouble in Hydraulic Hose Assembly

You are on n4net and this is indian railway track machine trouble shooting technology with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Hose Assembly"

What  the fault acctually is? 

Hose has burst. An examination indicates the wire braid is rusted and the cover has been cut, abraded or deteriorated badly. 

Why it happen?

The primary function of the cover is to protect the reinforcement. Elements that may destroy or remove the hose covers are: 
1. Abrasion. 
2. Cutting 
3. Battery Acid. 
4. Chemical Cleaning Solutions. 
5. Heat. 
6. Extreme Cold. 
  

What should we do?

Once the cover protection is gone, the wire reinforcement is susceptible to attack from moisture or other corrosive matter. hence take care of  :-
1. Abrasion. 
2. Cutting 
3. Battery Acid. 
4. Chemical Cleaning Solutions. 
5. Heat. 
6. Extreme Cold. 

HOSE BROKEN CAUSE 2 [Fault 2]

Trouble in Hydraulic Hose Assembly

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Hose Assembly"

What is the fault acctually?

The hose has burst, but there is no indication of multiple broken wires in the entire length of the hose.  The hose may have burst in more than one place. 

What is cause for the fault developing?

This would indicate that the pressure has exceeded the minimum burst strength of the hose.   

How to fix this problem?

Either a stronger hose is needed or the hydraulic circuit has a mal-function which is causing unusually high pressure conditions. 

IF HOSE BRUST WHAT SHOUILD WE DO? [Fault 1]

Trouble in Hydraulic Hose Assembly

You are on n4net and this is indian railway track machine trouble shooting technology with you.

This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Hose Assembly"

What  the fault acctually is? 

The hose has burst on examination after stripping back the cover of the wire reinforcement reveals random broken wires in the entire length of the hose. 

Why it happen?

This indicates high frequency pressure impulse condition.  SAE impulse test require- ments are as under: 
(a) For a double wire braid reinforcement are 2,00,000 cycles of 133% of recommended working pressure. 
(b)For a four spiral wrapped reinforcement (100R-9) are 3,00,000 cycles at 133% maximum operating pressure at +200 0 F (93 0 C). 

 What should we do?

If the extrapolated impulses in a system amount to over a million in a relatively short time a spiral reinforced hose would be the better choice. 

WHY MOTOR LOST IT'S SPEED [Fault 3]

Trouble in Hydraulic Motor

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Now we study about "Hydraulic Motor"

3) Fault :-  Speed loss on motor. 

Probable causes and Remidial action.

1.  Inlet pressure too low. 
>>> Increase pressure by resetting relief valve.
2.  Motor parts defective. 
>>>   Change defective parts. 
3.   Oil temperature too high 
 >>>   Check cooling circuit Hydraulic oil cooler may be defective . 
4. Out let pressure too high      
 >>>  Check the system pressure. 
5.  Port plate does not  make contacts.                                  
>>>   Dismantle the motor and repair as per requirement. 

Why Motor overheats [Fault 2]

Trouble in Hydraulic Motor

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Now we study about "Hydraulic Motor"

2) Fault :-  Motor overheats

Probable causes and Remidial action.

1. Wrong oil grade.
>>>  Fill oil as recommended. 
2. Oil speed in system too high.
>>>  Install pipes of proper size. 
3. Motor rotor groove worn out.
>>> Change motor parts. 
4. Radial or axial loading too high.
>>> Limit to acceptable amount, check alignment limit.  
5.  Initial speed rises
>>> Check max, pressure, if  needed replace with larger  capacity  and install pipes of  nominal bore. 
6.  Inadequate cooling.
>>>  Increase cooling capacity
7. Cooling system is dirty. 
 >>> Clean the cooling system
8. Differential pressure too low.
>>> Increase pressure setting of relief valve. 
9. Pressure too high.
>>> Reduce pressure setting. 
10. Wrong type of pressure valve.
>>>Replace by appropriate type of valve. 
11. Wrong seal size.
>>> Replace by suitable seals. 
12. Motor running speed high.
>>>Reduce speed. 
13.Cavitation.
>>> Bleed the system
14.Oil foams.
>>> Vent the system. 
15.Venting dirty.
>>> Clean the  vents. 
16.System contaminated.
>>> Flush the system. 
17.Sharp bends in suction line.
>>> Eliminate bends or at least reduce them. 
18.Motor is of under capacity.
>>> Install motor of proper capacity.

WHY MOTOR MAKES NOISE [Fault 1]

Trouble in Hydraulic Motor

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Motor"

1) Fault :-  Motor makes loud noise.  

Probable causes and Remidial action.

1. Vane spring broken. 
>>>  Change the spring. 
2.  Shaft seal leaks.
>>>  Replace the seal. 
3.  Casing leaks. 
>>> First tighten bolts, then check for cracks and sealing. 
4. Oil  temperature  too high. 
>>> Check cooling circuits. 
5.  Motor  parts defective. 
>>> Replace defective parts. 
     Tighten bolts uniformly. 
6.  Aeration. 
>>>  i) Fill  the reservoir with the oil up-to required level to prevent aeration. 
        ii) Check all connections on inlet side of motor and pour hydraulic oil over suspected leak. If noise stops,  leakage has been found,.  Fill hydraulic tank to the full mark. 
        iii) Check condition of motor shaft seal.  Change, if required. 
7. Intake line or  suction filter partly  clogged. 
>>>  Clean or replace the filter or 
      line. 
8.  Motor  running too fast. 
>>> Reduce speed up to prescribed limit. 
9. Coupling misaligned (Due to this, bearing may get damaged, there will be a play at shaft, abnormal sound will be observed). 
>>> Realign the motor shaft. 
10. Air leaks at  motor intake pipe joints and air drawn through inlet line. 
>>>   Take action as explained in s.no.1, item no. 4. 
11.  Oil  viscosity  too  high. (In cold climate, oil viscosity becomes high so no free flow will take place and cavitation will occur). 
>>>   Start  the  engine  for  few minutes to warm-up the hydraulic oil used in machine for proper flow.  Use only  proper grade of oil. 
12.  Cavitation. 
>>>  i) Check condition of suction filter and return line filters. Clean or change as necessary. 
         ii) Check clogging of inlet line.  Clean or change as necessary. 
         iii) Check loose fittings on suction lines.  Tighten, if required. 
         iv) Clean hydraulic tank breather.   
13.  Foams in oil. 
>>>    Vent  the system. 
14.  Casing leaks.  
 >>> First tighten bolts, then check for cracks  and sealing. 
15.  Motor stressed. 
>>>  Check mounting alignment. Tighten bolts uniformly. 
16. Foreign bodies in  suction line. 
>>>  Remove   foreign   bodies, if need flush the system. 
17. System dirty. 
>>>   Flush the system. 
18. Sharp bends in suction line. 
>>>  Eliminate or reduce the bends in   suction line. 
19. Motor   worn  or  damaged.  
>>> Motor should be overhauled or replaced. 

Why a VALVE fails to completely unload pump. [FAULT 2]

Trouble in Hydraulic Unloader  Valve

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Now we study about "Hydraulic Unloader  Valve"

2) Fault :-  Fails to completely unload pump. 

Probable causes and Remidial action.

1.  Valve pressure setting too high. 
>> Set valve at proper pressure. 
2.  Valve  spool  binding  in body. 
>>  Clean the spool and oil in the tank. 
3.  Incorrect assembly. 
>>  Assemble as per proper drawing. 
4.  Nil   or  low   nitrogen pressure in the accumulator. 
>>   Check pressure and recharge the accumulator    ( 80 to 85 bar). 
5.  Punctured bladder. 
>>   Change the bladder. 

CAUSE OF LOW PRESSURE OR NO PRESSURE [FAULT 1]

Trouble in Hydraulic Unloader  Valve

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Unloader  Valve"

1) Fault :-  Low or No pressure.  

Probable causes and Remidial action.

1. Orifice of main piston choked. 
>>  Clean the orifice. 
2.  Vent connection open to tank. 
>> Plug the vent connection. 
3. Safety valve  at  zero setting 
>>  Set  the safety valve at proper pressure. 
4.  Broken  or weak spring 
>>  Replace the spring. 
5.  Worn ball  or seat. 
>>  Replace. the ball  or seat. 

WHY OVER-HEATING VALVE [FAULT 5]

Trouble in Hydraulic Relief Valve

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Now we study about "Hydraulic Relief Valve"

5) Fault :-  Valve over heating.

Probable causes and Remidial action.

1. System pressure too high. 
>> Adjust spring pressure. 
2. Dirt in the system. 
>> Clean the system. 
3. Spool sticks. 
>> Check and clean spool. 
4. Spool defective 
>>  Check and replace spool, if defective.

WHY VALVE NOT FUNCTIONING PROPERLY [FAULT 4]

Trouble in Hydraulic Relief Valve

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Now we study about "Hydraulic Relief Valve"

4) Fault :-  Valve not function.

Probable causes and Remidial action.

1. Spool sticks. 
>> Clean stuck spool. 
2. Water conden- sation in system. 
>> Check condensed water. 
3. Oil temperature too high. 
>> Check the function of oil cooler and clean the radiator fins. 
4. Oil speed too high. 
>> Check speed of the pump. 
5. Internal leakage. 
>> Prevent leakage. 
6. Tank line under high pressure. 
>> Check pressure in tank line. 
7. Control line dirty.  
>>  Clean lines properly. 

WHY EXESSIVE NOISE OR CHATTER [FAULT 3]

Trouble in Hydraulic Relief Valve

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Now we study about "Hydraulic Relief Valve"

3) Fault :-  Excessive noise or chatter. 

Probable causes and Remidial action.

1. High oil velocity  through valve.  
>> Check  valve  flow rating.  Replace with larger valve, if necessary .   
2. Distorted control spring. 
>>  Replace spring.
3. Worn poppet or seat in cover. 
>> Replace popet or seat.
4. Vent line too long. 
>>  Replace restrictions e.g. needle valve  or orifice. Plug in vent line next to the relief valve. 
5. Valve    pressure setting  too close  to that of another  valve in circuit. 
>>  Set relief valve pressure  atleast  150 PSI higher than other valves in circuit. 

WHY NO PRESSURE OR LOW PRESSURE GENRETED BY HYDRAULIC RELIEF VALVE [FAULT 2]

Trouble in Hydraulic Relief Valve

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Now we study about "Hydraulic Relief Valve"

2) Fault :-  Low pressure or no pressure.  

Probable causes and Remidial action.
                     

1.   Valve   improperly  adjusted.  
=>  Adjust  valve  by  adjusting knob to proper pressure setting. 
2. Vent connection  is open  (at the time of starting the work, if vent remain open, then oil will go to the tank and no pressure will develop). 
=>   Plug the vent connection.  
3. Balance      hole  in main  piston choked. 
=>   Remove  piston  and clean the orifice.  Clean the tank and replace hydraulic oil. 
4.  Poppet   in cover  not seating. (So, oil will continuously go to tank  line and pressure will drop). 
=>  Check   the  poppet condition.  If required, replace it. 
5. Broken   or weak spring (oil will push the poppet easily and go to tank.  So  pressure will  drop).  
=>  Replace  the  spring and again set the pressure with adjusting knob. 
6 .  Dirt, chip etc keeps  
     valve partially open. 

 >>  Clean   the  complete valve. 

WHY GENRETED ERRATIC PRESSURE IN HYDRAULIC RELIEF VALVE [FAULT 1]

Trouble in Hydraulic Relief Valve

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Now we study about "Hydraulic Relief Valve"

1) Fault :-  Erratic pressure.  

Probable causes and Remidial action.

1.  Foreign material in the oil. 
=> Drain the oil, clean the tank  and refill with clean oil.                       
2. Worn poppet valve or   seat . 
      (oil  from pilot stage will go to tank due to worn poppet  valve or seat and pressure will drop). 
=>  Replace poppet  valve or seat as required.
3. Piston sticking  in main body. 
=> Clean piston after dismantling. Check free movement after re- assembling . 

TROUBLE IN HYDRAULIC PUMP fault 5

Trouble in Hydraulic Pump

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Now we study about "Hydraulic Pump"

5)  Fault :-  Speed loss on pump.

Probable causes and Remidial action.

 1. Inlet pressure too low. 
=>  Increase pressure. 
2. Outlet pressure too high. 
=>  Check system pressure. 
3. Port plate does not make contact. 
=> Dismantle the pump and repair as required. 
4. Oil temperature too high. 
=>  Check circuit. 

TROUBLE IN HYDRAULIC PUMP fault 4

Trouble in Hydraulic Pump

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Now we study about "Hydraulic Pump"

4) Fault :-  Pump develops  no pressure.

Probable causes and Remidial action.

1. Wrong pressure setting. 
=> Modify the pressure setting. 
2    Pressure valve  spool stuck. 
=>  Repair/Replace the valve. 
3.  Leakage in system. 
=>  Replace defective parts. 
4.  Pump shaft broken.  
=>  Replace shaft . 
5.  System contaminated. 
=>  Flush system completely . 
6.  Improper  gaskets and seal. 
=> Replace seals and gaskets. 

TROUBLE IN HYDRAULIC PUMP fault 3

Trouble in Hydraulic Pump

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This is a series of trouble shooting technique  for the track machine working in Indian Railway.  When you study  this you able to rectify a fault of machine. If this is helpful for you than share with others. It may helps them. Thanks for sharing.

Now we study about "Hydraulic Pump"

3) Fault :-  Pump overheats.

Probable causes and Remidial action.

1. Wrong oil grade.
=> Fill oil as recommended. 
2. Oil speed in system too high. 
=> Install pipes of proper size. 
3. Oil level too low. 
=> Fill the oil up to safe level. 
4. Pump  rotor groove worn out.
=> Change the worn out parts. 
5. Radial or axial loading too high. 
=> Loading should be  restricted to prescribed limit to acceptable amount,  check alignment limit. 
6. Initial speed rises. 
=> Check max, pressure, if needed replace with larger capacity  and install pipes of  nominal bore. 
7. Inadequate cooling. 
=> Increase cooling capacity. 
8. Cooling system is dirty.  
=> Clean the cooling system. 

9. Differential pressure too low. => Increase pressure setting of relief valve. 
10. Pressure too high. 
=>  Reduce pressure setting. 
11. Wrong type of pressure valve. 
=> Replace by appropriate type of valve. 
12. Wrong seal size. 
=> Replace by suitable size of seals. 
13. Filter dirty or too small. 
=> Clean filter or replace by larger 
14. Pump running speed high. 
=>  Reduce speed. 
15. Cavitation. 
=>  Bleed the system. 
16. Foams in oil. 
=>  Vent the system. 
17. Venting dirty. 
=> Clean the vents. 
18. System contaminated. 
=> Flush the system. 
19. Sharp bends in suction line. 
=> Eliminate bends or at least reduce them.
20. Boost pump failed. 
=> Check bolt pump and repair as 
     required. 

TROUBLE IN HYDRAULIC PUMP fault 2

Trouble in Hydraulic Pump

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Now we study about "Hydraulic Pump"

2) Fault :-  Pump makes noise 

Probable causes and Remidial action.

A) Aeration. 

    i)   Fill  the reservoir with the  oil   up-to required level to prevent aeration. 
   ii) Check all connections on inlet side of pump and pour hydraulic oil over suspected leak. If noise stops,  leakage has been found,.  Fill hydraulic tank to the full mark. 
    iii) Check condition of pump   shaft seal.  Change, if required. 
B)  Intake line or  suction filter partly  clogged. 
     Clean or replace the filter or 
       line. 
C)   Pump running too fast. 
 Reduce speed up to prescribed limit. 
D)  Coupling misaligned (Due to this, bearing may get damaged, there will be a play at shaft, abnormal sound will be observed). 
 Realign the pump shaft and      prime mover shaft. 
E)   Reservoir   not  vented properly.  
 Air breather screening element should be cleaned. 
F)   Suction Filter too small in size. 
   Replace by proper size of  filter. 
G)  Air leaks at  pump intake pipe joints and air drawn through inlet line. 
Pour hydraulic oil on intake joints and on observing abnormal sound, tighten the intake joint as required. 
H)  Oil  viscosity  too  high. (In cold climate, oil viscosity becomes high so no free flow will take place and cavitation will occur).
   Start  the  engine  for  few minutes to warm-up the hydraulic oil used in machine for proper flow.  Use only  proper grade of oil.
I)  Cavitation.
   i) Check condition of suction filter and return line filters. Clean or change as necessary. 
   ii) Check clogging of inlet line.       Clean or change as necessary. 
   iii) Check loose fittings on suction lines.  Tighten, if required. 
   iv) Clean hydraulic tank breather.   
J)   Shaft seal leaks.
      Replace the seal. 
K)   Foams in oil.
       Vent  the system. 
L)   Casing leaks. 
       First tighten bolts, then check for cracks  and sealing. 
M) Vane spring broken.
       Change spring.
N)    Any part of pump  defective.
         Replace defective parts.
O)     Pump mounting bolts are loose.
         Check   mounting alignment.  Tighten bolts uniformly. 
P)     Foreign bodies in suction line.
         Remove   foreign   bodies, if need flush the system.
Q)    System dirty.
        Flush the system.
R)    Sharp bends in suction line.
        Eliminate or reduce the bends in suction line.
S)   Oil temperature too high.
      Check the hydraulic circuit. Oil cooler may be ineffective.  Rectify the failure. 
T)  Boost pump failed.
      Check boost pump and repair if 
       required. 
U)  Vibration in system
      Check unusual occurrence in the system.
V)  Pump     worn  or damaged. 
 Pump should be overhauled or replaced.