Hydraulic motor malfunctions will delay the production schedule and increase additional costs. This page will outline the most common hydraulic motor failures, repair methods and maintenance practices to help you quickly resolve equipment issues.
How to Troubleshoot and Repair the Hydraulic Motor Failures?
Understanding the common warning signs of hydraulic motor failures can help you quickly identify the problem and carry out repairs.
Unusual Noises
Pay attention to knocking, banging, or hissing noises coming from the Hydraulic motor. These sounds may indicate problems such as the pipeline is clogged, air in the system, worn out bearings, or the drive for the motor is wrong.
- The pipeline is clogged.The hydraulic motor must be able to smoothly absorb the liquid; otherwise, cavitation will occur. You can drain all the liquid from the device and clean the pipes, then add new and suitable liquid. You should ensure the liquid levels are within optimal range.
- There is air in the system. If the noise intensifies as the motor speed increases, and the noise disappears briefly when the machine is restarted after being shut down, this indicates that there is air inside the system. You should bleed all the air from the device and then tighten the joints.
- Worn-out bearings. You can manually rotate the motor shaft. If there is any abnormal noise or jamming, you need to replace the bearing of the same model. In addition, you can also check whether the blades, valve plate, stator, rotor, etc. of the motor have any scratches or wear. For minor damages, they can be repaired by grinding. For severe damages, replacement of the corresponding parts of the same model is necessary.
- The drive for the motor is wrong. Check whether the motor is operating at the correct speed. The speed should not be too low or cause overload.
Hydraulic Leak
Hydraulic motors have two types of leaks: external leaks and internal leaks. It is necessary to precisely locate the leak points and carry out targeted repairs.
- External leak. We can usually spot external leaks quite easily. You should inspect the connections at the inlet and outlet ports for looseness and tighten them to the specified torque. If the threaded joints are damaged or the seals are deformed, replace them with joints or seals of the same specifications.
- Internal leak.For plunger motors, you can inspect the mating surfaces between the distributor plate and cylinder block for scratches, wear, or deformation. When there is slight wear and tear, it can be polished and repaired; in severe cases, the component needs to be replaced. For gear motors, you can check whether the clearance between the gears and end cover is excessive or if the gear tooth surfaces show wear. You should replace it with suitable components as needed.
Hydraulic Motor Overheating
Overheating of hydraulic motors accelerates fluid degradation and seal damage. Maintaining proper temperatures ensures stable machine operation and reduces component wear.
- Hydraulic fluid impact.You can check the motor fluid level. If it is at the minimum mark, replenish with the same grade of hydraulic fluid.At the same time, you also need to check the quality of the liquid and observe whether there is any turbidity or metal shavings or dust and other contaminants. If cleanliness is poor, immediately replace the fluid, flush the hydraulic tank, and replace the filter element.
- Inspect the hydraulic circuit and pressure. You canuse a pressure gauge to test the system pressure. If it exceeds the motor’s rated pressure, adjust it below the rated value. In addition, you can also disassemble the inlet and outlet pipes to check if any impurities have caused blockage. And promptly clear the blockage and replace the filter element.
- Inspect the cooling system.You can clean the radiator by using compressed air or a low-pressure water jet to flush away dust and grease from its surface, ensuring unobstructed heat dissipation pathways. Additionally, you need to test the cooling components: for air-cooled systems, verify that the fans are operating; for water-cooled systems, check that the cooling pump is functioning and that the water lines are free of blockages. Replace any damaged components as needed.
Low Hydraulic Pressure or Weak Operation
- Check the hydraulic liquid.You can check the hydraulic motor liquid level gauge to ensure the liquid level is within the appropriate range. At the same time, take a liquid sample and use a viscometer to inspect the liquid’s viscosity and cleanliness, and observe for any contaminants or discoloration. If you detect any abnormalities in the fluid, you will need to flush the tank and replace the liquid.
- Test System Pressure.Connect a pressure gauge at the oil inlet of the hydraulic motor to monitor the pressure. When you notice that the pressure is far below the rated value, you need to check the hydraulic pump. If the pressure is normal but the hydraulic motor is weak, you need to disassemble the motor to inspect whether there is any wear on internal parts such as the blades, the flow distributor, the bearings, etc., and then perform grinding repair or replacement in time.
Tools for Effectively Troubleshooting Hydraulic Motor Failures: Pressure Gauges and Flow Meters, Thermal Imaging Cameras,Ultrasonic Leak Detectors,Viscometer. These tools can help you quickly locate the faulty area and carry out repairs.
Maintain the Hydraulic Motor to Maximize its Usability
- Regularly conduct inspections and keep records.You can clean the oil filter every two weeks or monthly and inspect the piping, as well as check the system pressure. Check the condition of the motor bearings every quarter. Replace the hydraulic oil in time if the oil quality exceeds the standard. You need to inspect the internal core components of the motor every year, replace the worn parts, and thoroughly clean the hydraulic motor system.
- Use originalOEM parts supplied from the manufacturer. After conducting the troubleshooting, if you need to replace the parts, you should choose the original components provided by the manufacturer. Similarly, when adding hydraulic oil, you should use the same type of hydraulic oil to prevent accelerated wear.
- Maintain an appropriate environmental temperature and humidity.If the operating environment temperature is too high, it is likely to cause the system to overheat, thereby accelerating the degradation of the fluid and damaging the seals. If the humidity of the environment is too high, water vapor may enter the liquid motor, affecting its lubricity and also causing rusting of the metal components.
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Conclusion
Removing the fault of the hydraulic motor is not a difficult task. By mastering these basic techniques, you can quickly identify and solve the problem. Regular inspections and maintenance can effectively prevent problems from occurring and save time and resources.
