Correct Installation And Commissioning of Custom Hydraulic Systems

Correct installation and commissioning of custom hydraulic systems

The installation of the customized hydraulic system is a crucial step in determining whether the hydraulic system can operate normally.

1. Installation personnel

Although the hydraulic transmission system shares many similarities with the mechanical transmission system, it does have its own unique characteristics. Only personnel who have received professional training and possess certain installation experience can undertake the installation of the hydraulic system.

II. Review of the hydraulic system

The main task is to assess whether this design can achieve the expected work objectives, whether it can enable the machine to operate as intended and meet all performance indicators. Whether the installation process is feasible. A comprehensive understanding of the composition of each part of the overall design, and an in-depth understanding of the functions of each part. The main contents of the review include the following points:

Review the design of the hydraulic system;

2. Evaluate the rationality of the hydraulic system schematic diagram;

3. The manufacturing process level of the evaluation system;

4. Check and confirm the cleanliness level of the hydraulic system;

5. Confirmation of hydraulic system components.

III. Technical Preparation Before Installation

Before installing the customized hydraulic system, all necessary preparations should be made in accordance with the relevant technical documents.

1. Preparation and Familiarization of Technical Materials

Customized hydraulic system schematic diagrams, electrical schematic diagrams, piping layout diagrams, hydraulic components, accessories, pipe fittings lists, and sample parts of related components should all be prepared in full. This is to enable engineering technicians to familiarize themselves with and study each specific content and technical requirements item by item.

2. Material Preparation

According to the customized hydraulic system diagram and the list of hydraulic components, check the quantity of the hydraulic components and confirm the quality status of all hydraulic components. In particular, strictly inspect the quality of the pressure gauges, determine the delivery date of the pressure gauges, and re-calibrate the pressure gauges that have exceeded the inspection time.

3. Quality Inspection

Hydraulic components are highly prone to contamination and rust during transportation or storage. If stored for an extended period, the seals in the components will age and lose their sealing properties. Some hydraulic components may have poor processing and assembly quality, resulting in compromised performance. Therefore, strict quality checks must be conducted on the components.

A) Quality inspection of hydraulic components

The models of all hydraulic components must be consistent with those listed in the component list.

2. It is necessary to investigate whether the hydraulic components have been stored for an excessively long time or if the storage environment does not meet the requirements. Attention should be paid to the degree of aging of the internal seals of the hydraulic components. If necessary, they should be disassembled, cleaned, replaced, and tested for performance.

3. The adjustment screws, adjustment handwheels, locking nuts, etc. on each hydraulic component must be intact and undamaged.

4. The surface quality of the sealing components attached to the hydraulic components should meet the requirements; otherwise, they should be replaced.

5. The connection surfaces of the plate-type connection elements must be free from defects. The processing accuracy of the groove dimensions for installing the sealing pieces should comply with relevant standards.

6. The connection screw threads of the tubular connecting element must not have any damage or loose threads.

7. The connection surface of the installation base plate for the plate valve must be free from any unevenness or defects. The connection threads must not have any damage or loose threads.

8. Block off the oil outlet and remove it. Then check if the interior of the component is clean.

9. Inspect the electromagnetic core and the surface condition of the solenoid valve. Do not use it if any abnormalities are found.

10. All the accessories on each hydraulic component must be complete.

B) Quality Inspection of Hydraulic Accessories

1. The fuel tank must meet the specified quality requirements. All necessary accessories on the fuel tank must be present. There should be no rust inside the tank. Before filling the fuel, the interior of the tank must be thoroughly cleaned.

2. The model and specification of the oil filter to be used must be consistent with the design requirements. The accuracy grade of the filter element should be confirmed. The filter element must not have any defects. The connection screw holes must not be damaged. All the accompanying accessories must be complete.

3. The appearance quality of all seals must meet the requirements, and the storage period of the seals received should be determined. Any seals with abnormalities or those that have been stored for an excessively long period are not allowed to be used.

4. The quality of the accumulator must meet the requirements, and all the accessories should be complete. Determine the storage period, and conduct a strict quality inspection on accumulators that have been stored for a long time. Accumulators that do not meet the technical standards and usage requirements shall not be used.

5. The air filter is used to remove dust from the air. The ventilation resistance should not be too high, and the pressure inside the box must be the same as the atmospheric pressure. Therefore, the air filter must have sufficient capacity to allow air to pass through.

C) Quality inspection of pipes and joints

a) The material, diameter, wall thickness of the pipe, as well as the model specifications and processing quality of the joints must all meet the design requirements.

b) The pipes used must be free from any defects. The following abnormalities are not allowed and shall not be used:

The inner and outer surfaces of the pipe have been corroded or have changed color significantly.

2. The depth of the cracks and wounds on the surface of the pipe is more than 10% of the pipe's wall thickness.

3. There are small holes inside the pipe wall.

4. The degree of indentation on the surface of the pipe exceeds 10% of the pipe's diameter.

c) When using bent pipes, the following conditions are strictly prohibited:

The inner and outer surfaces of the bent part of the pipe have irregular curves or are serrated.

2. The ellipticality of the bent part of the pipe is more than 10%.

3. The outer diameter of the flattened and curved part is less than 70% of the original pipe's outer diameter.

d) The connectors used must be free from any defects. If any of the following abnormalities occur, they must not be used:

The threads of the joint body or the nut have scratches, burrs or broken strands.

2. The processing accuracy of each joint surface of the connector body does not meet the technical requirements.

3. The connection body does not fit properly with the nut, resulting in looseness or sticking.

4. The dimensions and processing accuracy of the groove for installing the sealing ring do not meet the specified technical requirements.

e) The following defects in the hoses and connectors are unacceptable and shall not be used:

There are damaged coatings or signs of aging on the surface of the hose.

2. The joint body shows signs of rust.

3. The threads have scratches, burrs, broken fasteners, and there are signs of looseness and jamming in the fit.

f) The following defects in the flange parts are unacceptable and shall not be used:

The sealing surface of the flange has pores, cracks, burrs and radial grooves.

2. The dimensions and processing accuracy of the flange sealing groove do not meet the design requirements.

3. The sealing metal gasket on the flange must not have any defects. The hardness of the material should be lower than that of the flange.