Due to the diversity and complexity of the causes of the heating failure of the hydraulic system, it is extremely difficult to trace the source of the on-site diagnosis. Taking the heating failure of the hydraulic system during the jacking process of a certain tower crane as an example, the virtual fault information obtained from the fault tree analysis is injected into the thermal fluid simulation model of the tower crane jacking hydraulic system, and the influence characteristics of the virtual fault on the system pressure and oil temperature are obtained. The fault diagnosis is realized by comparing with the temperature rise curve of the fault hydraulic system on the test bench. The research results show that the fault characteristics caused by the lowering of the set pressure of the relief valve are highly consistent with the test results, so it is determined that the overflow caused by the lowering of the set pressure of the relief valve is the main cause of the system heating fault, and the fault can be solved after on-site adjustment. The virtual simulation method of hydraulic system based on fault injection can effectively reproduce the real fault characteristics of hydraulic system and provide necessary reference for fast and effective fault diagnosis of complex hydraulic system.

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