Intermittent Ride Control System Issues in Heavy Equipment

[MikePhua]

The ride control system is an essential feature in many modern pieces of heavy equipment, especially in loaders and skid-steer machines. It’s designed to improve operator comfort by minimizing the impact of rough terrain, ensuring a smoother ride. However, when ride control works intermittently, it can cause significant discomfort to the operator and, in some cases, lead to long-term damage to the equipment if not addressed. Understanding the causes behind these intermittent issues and how to troubleshoot them can save time and prevent costly repairs.
What is Ride Control and Why Is It Important?
Ride control is a hydraulic system that reduces the impact of rough surfaces by cushioning the movement of the loader or skid steer. It essentially acts as a shock absorber for the machine's hydraulic lift arms. This system helps to:

• Minimize operator fatigue: Rough, uneven terrain can cause the operator to experience vibrations and jolts that lead to discomfort and tiredness. Ride control reduces these effects, making it easier for operators to work longer hours with less physical strain.
  
• Protect sensitive equipment: By reducing the shocks and vibrations transmitted through the equipment, ride control also helps protect critical components, such as hydraulic systems and the chassis, from wear and tear.
  
• Improve load stability: When transporting materials, the ride control system helps stabilize the load, preventing it from shifting or spilling due to uneven terrain.
  

While ride control is a vital feature, when it malfunctions and only works intermittently, it can disrupt operations and affect productivity. This can be particularly problematic for operators who rely on consistent performance for safety and comfort.
Common Causes of Intermittent Ride Control Failures
Intermittent ride control failures can be caused by several factors, ranging from simple mechanical issues to more complex hydraulic or electrical malfunctions. Below are some of the most common causes of this issue:

1. Low Hydraulic Fluid Levels
   • Hydraulic systems, including ride control, require an adequate amount of fluid to function correctly. Low fluid levels can lead to inconsistent operation or total failure of the ride control system.
     
   • If the fluid levels are low, it can cause the ride control system to engage intermittently, as the hydraulic pressure required to activate the shock-absorbing mechanism may fluctuate.
     
2. Faulty Hydraulic Valves
   • Hydraulic valves are responsible for directing the flow of fluid through the ride control system. If one or more of these valves is malfunctioning or clogged, the system may work intermittently or not at all. A valve could stick in the open or closed position, preventing proper fluid flow to the necessary components.
     
   • These valves can also be affected by contamination in the fluid, causing them to stick or become slow to respond.
     
3. Damaged or Worn Ride Control Cylinders
   • Ride control cylinders, typically located at the lift arms, are responsible for absorbing shocks and vibrations. Over time, these cylinders can develop leaks or internal damage, which reduces their ability to maintain proper pressure and fluid flow.
     
   • If the seals in these cylinders wear out or break, the ride control function will work intermittently, causing a noticeable drop in system performance.
     
4. Faulty Ride Control Switch or Electrical Connections
   • The ride control system is often activated and deactivated by an electronic switch or control panel. If the switch is faulty or there is a poor electrical connection, the ride control system may fail to engage or disengage properly.
     
   • Loose or corroded electrical connections can also cause intermittent operation by preventing the necessary signals from reaching the ride control system’s control valves.
     
5. Clogged or Dirty Hydraulic Filters
   • Hydraulic filters are designed to remove contaminants from the hydraulic fluid, preventing damage to critical components. If the filters become clogged or dirty, it can cause the fluid to become contaminated, leading to inconsistent operation of the ride control system.
     
   • A clogged filter can also cause pressure fluctuations, leading to erratic performance or complete failure of the system.
     
6. Air in the Hydraulic System
   • Air trapped in the hydraulic lines can cause erratic behavior in the ride control system. Air pockets disrupt fluid flow and pressure, leading to inconsistent performance. This problem is often referred to as "aeration," and it can be caused by improper fluid refills, leaks, or damaged seals.
     

Troubleshooting and Diagnosing Intermittent Ride Control Issues
Troubleshooting intermittent ride control issues requires a systematic approach to identify the underlying cause. Here are the steps you can take to diagnose the problem:

1. Check Hydraulic Fluid Levels
   • Start by checking the hydraulic fluid levels. Low fluid can cause inconsistent operation, so ensure that the fluid is at the correct level as specified in the machine’s operator manual. Top up the fluid if necessary, using the recommended type and grade.
     
   • While checking fluid levels, inspect the fluid quality. If the fluid appears dark or contains debris, it might be time for a change and filter replacement.
     
2. Inspect Hydraulic Hoses and Fittings
   • Check for leaks in the hydraulic hoses and fittings. A small leak can cause pressure loss, leading to intermittent ride control operation. Look for signs of hydraulic fluid around the hoses, cylinder seals, and other connection points.
     
   • If any hoses appear cracked or damaged, replace them immediately.
     
3. Examine Hydraulic Valves
   • Inspect the ride control valves for proper operation. You may need to test the valves with a hydraulic pressure gauge to ensure that they are opening and closing correctly. If a valve is not responding as expected, it may need to be cleaned or replaced.
     
   • Pay attention to any signs of contamination or wear around the valve areas.
     
4. Inspect Ride Control Cylinders
   • Inspect the ride control cylinders for leaks or signs of damage. Leaking cylinders are a common cause of intermittent performance. Check for any fluid around the cylinder seals, and if the seals appear worn or cracked, they should be replaced.
     
   • If the cylinders appear to be in good condition, check for internal damage by testing the pressure and movement of the cylinders.
     
5. Test the Ride Control Switch
   • Test the ride control switch to ensure it is working properly. A faulty switch could prevent the system from engaging or disengaging correctly. If the switch is not responding or has intermittent electrical connections, it may need to be replaced.
     
   • Check the wiring and connections to ensure there is no corrosion or loose connections that could be affecting the signal to the hydraulic system.
     
6. Replace or Clean the Hydraulic Filter
   • If the hydraulic filter is clogged, it can cause poor fluid flow and pressure problems. Replace or clean the filter according to the manufacturer's recommendations. Be sure to use the correct type of filter to ensure optimal performance.
     
7. Bleed the Hydraulic System
   • If you suspect that air has entered the hydraulic system, bleed the system to remove the air pockets. Follow the machine’s manual for the correct procedure to remove air from the system. This may involve loosening certain fittings and allowing the air to escape until the fluid runs clear.
     

Preventive Measures and Maintenance Tips
To prevent intermittent ride control issues from recurring, consider these preventive maintenance tips:

1. Regular Fluid Checks: Routinely check the hydraulic fluid levels and quality. Ensure that the fluid is clean and at the proper level to avoid issues with system performance.
   
2. Scheduled Inspections: Regularly inspect hydraulic hoses, valves, and cylinders for wear and damage. Address any issues as soon as they are detected to avoid larger, more expensive repairs.
   
3. Clean Filters: Clean or replace hydraulic filters as part of your regular maintenance routine. Dirty filters can cause fluid contamination, leading to a decrease in performance.
   
4. Avoid Overloading: Do not exceed the recommended load capacity of the machine, as this can place unnecessary strain on the hydraulic system and cause damage to the ride control components.
   
5. Proper Training: Ensure that operators are trained to use the ride control system properly. Misuse or improper operation can lead to premature wear on the system.
   

Conclusion
The ride control system is a vital component of heavy machinery that provides operator comfort and enhances the machine's longevity by reducing the effects of rough terrain. When this system works intermittently, it can affect both performance and safety. By understanding the potential causes of intermittent ride control issues, performing regular maintenance, and addressing problems early, operators can ensure smooth, uninterrupted operation. Regular checks on hydraulic fluid, seals, valves, and the ride control system itself will help maintain the reliability and performance of these essential systems.