HLY-TS-04: Hydraulic Core Jamming, Sync Cylinder Pressure Drop & Release Manual

Fault 1: Inner Core Locked Solid During Collapse Cycle (Pump Stalls at Relief)

Root Causes:

1. Cement slurry intruded into corner wedge slider grooves and set rock-hard;
2. Mechanical lock pins left engaged;
3. Concrete shrinkage clamp force exceeding hydraulic retraction capacity.

Corrective Actions:

1. Verify all 4 safety wedge pins are removed;
2. Pulse hydraulic valve between expand/retract to break stiction;
3. Blow debris out of corner keyways with 0.8 MPa air jets.

Fault 2: Asymmetric Cylinder Retraction Tilting the Core Assembly

Root Causes: Jammed spool in flow-divider valve; internal piston bypass leak in one cylinder.

Corrective Actions:

1. Flush flow-divider valve block; replace degraded ISO 46 hydraulic fluid;
2. Test cylinder hold pressure and rebuild piston seal packs (Glyd ring + O-ring).

Fault 3: Hydraulic Fluid Overheating (>65°C)

Root Causes: Continuous unloader valve bypass; clogged fan heat exchanger.

Corrective Actions: Re-adjust unloader circuit; clean air cooler radiator fins.