Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system. If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system.
If you are experiencing hydraulic problems then this article is a must to read because it is based on "known best practices"? Think about it.
Hydraulic Systems are very delicate systems, if contamination enters the systems failure will occur in the form of partial functional failure or total functional failure.
Training, education, and standardization is the only path to success. It is all about the "Failure Modes" and their causes.
This short assortment of slides provides recommended actions to solve these problems at the end.
Good Luck and God Speed.
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system.
If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally except hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure.
Hydraulic Valves and Hydraulic System AccessoriesRAHUL THAKER
Hydraulic Valves and Hydraulic System Accessories:
Direction control valves,Pressure control valves, Flow control valves, Non-return valves, Reservoirs,Accumulators, Heating & cooling devices, Hoses. Selection of valves for circuits.
Control of a single-acting and double-acting cylinder, regeneration, motor braking, speed control, synchronisation, fail safe, two handed, application of counterbalance, sequence, unloading, pressure reducing, pilot operated check valve
Following presentation consist of a fundamental steps that took place during a pump overhaul.
this presentation will give you the basic idea about maintenance .
Hydraulic Systems are very delicate systems, if contamination enters the systems failure will occur in the form of partial functional failure or total functional failure.
Training, education, and standardization is the only path to success. It is all about the "Failure Modes" and their causes.
This short assortment of slides provides recommended actions to solve these problems at the end.
Good Luck and God Speed.
Most companies spend a lot of money training their maintenance personnel to troubleshoot a hydraulic system.
If we focused on preventing system failure then we could spend less time and money on troubleshooting a hydraulic system. We normally except hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s spend the time and money to eliminate hydraulic failure rather than preparing for failure.
Hydraulic Valves and Hydraulic System AccessoriesRAHUL THAKER
Hydraulic Valves and Hydraulic System Accessories:
Direction control valves,Pressure control valves, Flow control valves, Non-return valves, Reservoirs,Accumulators, Heating & cooling devices, Hoses. Selection of valves for circuits.
Control of a single-acting and double-acting cylinder, regeneration, motor braking, speed control, synchronisation, fail safe, two handed, application of counterbalance, sequence, unloading, pressure reducing, pilot operated check valve
Following presentation consist of a fundamental steps that took place during a pump overhaul.
this presentation will give you the basic idea about maintenance .
The pressure energy is fed to the actuator through a number of control block called valves.
• Various type of valve are used in hydraulic system to control or regulate the flow medium.
• Basicallyvalvesareexpectedtocontrol: – Direction
– Pressure
– Flow
– Otherspecialfunctions.
System Components, Hydraulic Oils, Fluid Properties and FilterRAHUL THAKER
System Components, Hydraulic Oils, Fluid Properties and Filter:
Hydraulic & Pneumatic Symbols as per ISO/ANSI, Types, Properties, physical characteristics & functions of hydraulic Oils, Classification- Mineral based, Fire resistant& Biodegradable Oils, Filters, Contaminations, location of filter
the presentation includes basic ideas about water pumps, various terminology generally used for the pumps, classification of pumps and ideas about the types its construction and working
The pressure energy is fed to the actuator through a number of control block called valves.
• Various type of valve are used in hydraulic system to control or regulate the flow medium.
• Basicallyvalvesareexpectedtocontrol: – Direction
– Pressure
– Flow
– Otherspecialfunctions.
System Components, Hydraulic Oils, Fluid Properties and FilterRAHUL THAKER
System Components, Hydraulic Oils, Fluid Properties and Filter:
Hydraulic & Pneumatic Symbols as per ISO/ANSI, Types, Properties, physical characteristics & functions of hydraulic Oils, Classification- Mineral based, Fire resistant& Biodegradable Oils, Filters, Contaminations, location of filter
the presentation includes basic ideas about water pumps, various terminology generally used for the pumps, classification of pumps and ideas about the types its construction and working
Best Practices for Mobile Hydraulic DesignDesign World
With ever-rising fuel prices, designing efficient hydraulic systems can pay big dividends for users of mobile hydraulic vehicles. Join Design World as we take an in-depth look at three critical areas of mobile hydraulic system design: filtration, sensors and sealing. Our expert panel presents critical design tips and answering your questions.
Attendees will learn:
* How to use in-cylinder position sensing to optimize hydraulic functions on mobile equipment
* How to select the appropriate filtration grade for a specific application
* How do shaft requirements impact mobile hydraulic sealing products
The panel includes: Dr. Christian Bauer, Staff Scientist, Pall Corp.; Haubold “Hub” vom Berg, Technical Marketing Manager, MTS Sensors, Mobile Hydraulic; and Joel Johnson, VP of Technology, Simrit. The panel is moderated by Design World Editorial Director, Paul J. Heney.
Hidrolik dan Elektro-Hidrolik (Hydraulic and Electrical-Hidraulic)gunawanzharfan
Introduction and problem solving of Hydraulic in Engineering
Including the steps how to design hidraulic system
Pengenalan dan penyelesaian masalah dari Teknologi Hidrolik
Termasuk langkah-langkah perancangan sistem hidrolik
How many organizations accept Hydraulic Leaks because they do not understand how hydraulic leaks is a major source of contamination to any hydraulic system. Use this Tool Box Talk to educate your maintenance staff.
How to Extend the Lifespan of Your Hydraulic Industrial Lift?Rainsuit
In industrial settings, hydraulic lifts play a pivotal role in facilitating efficient material handling and movement. These robust machines are vital assets, and ensuring their longevity is paramount for smooth operations and cost-effectiveness. Proper maintenance is key to extending the lifespan of hydraulic industrial lifts, minimizing downtime, and maximizing productivity. Here are some essential tips to help you maintain and care for your hydraulic lift.
A vacuum pump is a mechanical device that removes gas molecules from a sealed volume, creating a partial or near-total vacuum. The runtime of a vacuum pump depends on various factors, such as the type of pump, the size of the system, and the application. Generally, most vacuum pumps are designed to run continuously for several hours, with some models capable of running for days or weeks without being shut off. However, it is essential to check the manufacturer's specifications and recommended maintenance schedule to ensure the safe and optimal operation of the pump. Overuse or inadequate maintenance of a vacuum pump can lead to reduced performance, premature wear, and potential safety hazards
Having experience as a Maintenance Manager and Maintenance Consultant I wrote this article. The one Maintenance Manager that inspired me the most was Rick Mullen, former Engineering and Maintenance Manager at Anheuser Busch, who by far the #1 Maintenance Manager I ever met.
What does a "Day in the Life of a Proactive Maintenance Planner" look like. This article was writen based on my experience at Alcoa Mt Holly (Certified as World Class Maintenance).
Having worked with companies all over the world I decided to write this article based on my experience as a Maintenance Advisor and a Maintenance Leader.
How to know if your maintenance planning and scheduling is not effectiveRicky Smith CMRP, CMRT
Many times companies have Maintenance Planning and Scheduling however it is not effective as they like it to be. This article helps anyone who is struggling the Planning and Scheduling with a few ideas.
If you have questions email me at rsmith@worldclassmaintenance.org
Ever wondered what a "Day in the Life of a Proactive Maintenance Supervisor". Checkout this article and see how it matching where you are. If you have questions send Ricky an email to rsmith@worldclassmaintenance.org
A proactive maintenance technician is a highly trained professional who is an expert in his or her skills area, has knowledge of other skills areas, including safety and production, and has a desire to learn more. This professional knows and can
implement a failure-modes driven maintenance strategy for any piece of equipment.
A proactive maintenance technician uses knowledge and experience to ensure the maintenance process is optimized by making constructive recommendations to
management concerning improvement areas.
To ensure success, a proactive maintenance technician is proactive in everything he or she does. This person constantly reviews information to ensure procedures are accurate and issues are resolved quickly and does what is required to ensure the work is repeatable. Such a professional leads by example and takes responsibility for training new employees on how to be a proactive and effective maintenance technician.
The objective of the Parts Checkout process to ensure the right part is in stock when required by Maintenance / Operations to provide Production with Reliable Assets.
> Parts / Material Checkout Guiding Principles:
•All parts/material used for an asset will be charge to the asset via a Work Order
•No blanket work orders – blanket work orders lead to lack of failure information due to failure threads of like parts/material
•Overnight ordering of parts is an exception and not the general rule
•The Materials Management Process will be managed with Leading and Lagging KPIs
... and so much more
Best Maintenance Lubrication Practices are essential to
optimal life for ball and rolling element bearings.
There are four factors that are important when
lubricating bearings:
1. What type of lubrication?
2. How much lubrication?
3. How frequently should lubrication be applied?
4. How should the lubrication be applied to ensure
contamination control?
... and so much more covered on this document
Maintenance Planning and Scheduling is critical to success of any Maintenance Organization resulting in a significant increase in Wrench-time (Hands on Tool Time). Planning and Scheduling are two distinct functions which are dependent on each other.
Top 7 Reasons why Maintenance Work Orders are Closed Out AccuratelyRicky Smith CMRP, CMRT
Closing out work orders accurately is critical for leadership to make the “right decisions at the right time with accurate data” and it can only occur if work orders are “Closed with the Right Information/Data”.
If metrics and Key Performance Indicators are so important where are people pulling the data from without their work orders having the right data on them when they are closed into that dark hole called the CMMS or EAM.
Without good data you are lost and probably are making decisions based on passion and not facts.
Very few organizations pay attention to hydraulic leaks and how they can impact production capacity, asset reliability, and reactivity when a mitigation strategy is in place.
This Tool Box Talk may help you take that next step.
Preventive Maintenance - Actions performed on a time- or machine-run-based schedule that detect, preclude, or mitigate degradation of a component or system with the aim of sustaining or extending its useful life through controlling degradation to an acceptable level. (Definition Source: SMRP Best Practices)
Maintenance Skills Training for industry is a hot subject right now. In many areas of the country, companies are competing for skilled maintenance personnel.
“A Deloitte study found that the skills gap may leave an estimated 2.4 million positions unfilled between 2018 and 2028, with a potential economic impact of $2.5 trillion”
The skill level of the maintenance personnel in most companies is well below what industry would say is acceptable. In the past, I have been involved with the assessment of the skill level for hundreds of maintenance personnel in the U.S. and Canada and found 80% of the people assessed scored less than 50% of where they need to be in the basic technical skills to perform their jobs. The literacy level of maintenance personnel is also a problem. In some areas of the United States we find that up to 40% of maintenance personnel in a plant are reading below the eighth grade level. After performing the Gunning FOG index, we find the reading level for mechanical maintenance personnel should be the twelfth year level and electrical maintenance personnel the fourteenth year level (associate degree).
Much has been written about lean manufacturing and the lean enterprise—enough that nearly all readers are familiar with the concepts as well as the phrases themselves. But what about lean maintenance?
Is it merely a subset of lean manufacturing? Is it a natural fall-in-behind spinoff result of adopting lean manufacturing practices?
Much to the chagrin of many manufacturing companies, whose attempts at implementing lean practices have failed ignominiously, lean maintenance is neither a subset nor a spinoff of lean manufacturing. It is instead a prerequisite for success as a lean manufacturer. This article will explain why.
Every wondered what the life of a Proactive Maintenance Technician looks like. This article was written based on my experience as a Proactive Maintenance Technician.
Read| The latest issue of The Challenger is here! We are thrilled to announce that our school paper has qualified for the NATIONAL SCHOOLS PRESS CONFERENCE (NSPC) 2024. Thank you for your unwavering support and trust. Dive into the stories that made us stand out!
Welcome to TechSoup New Member Orientation and Q&A (May 2024).pdfTechSoup
In this webinar you will learn how your organization can access TechSoup's wide variety of product discount and donation programs. From hardware to software, we'll give you a tour of the tools available to help your nonprofit with productivity, collaboration, financial management, donor tracking, security, and more.
Palestine last event orientationfvgnh .pptxRaedMohamed3
An EFL lesson about the current events in Palestine. It is intended to be for intermediate students who wish to increase their listening skills through a short lesson in power point.
The Roman Empire A Historical Colossus.pdfkaushalkr1407
The Roman Empire, a vast and enduring power, stands as one of history's most remarkable civilizations, leaving an indelible imprint on the world. It emerged from the Roman Republic, transitioning into an imperial powerhouse under the leadership of Augustus Caesar in 27 BCE. This transformation marked the beginning of an era defined by unprecedented territorial expansion, architectural marvels, and profound cultural influence.
The empire's roots lie in the city of Rome, founded, according to legend, by Romulus in 753 BCE. Over centuries, Rome evolved from a small settlement to a formidable republic, characterized by a complex political system with elected officials and checks on power. However, internal strife, class conflicts, and military ambitions paved the way for the end of the Republic. Julius Caesar’s dictatorship and subsequent assassination in 44 BCE created a power vacuum, leading to a civil war. Octavian, later Augustus, emerged victorious, heralding the Roman Empire’s birth.
Under Augustus, the empire experienced the Pax Romana, a 200-year period of relative peace and stability. Augustus reformed the military, established efficient administrative systems, and initiated grand construction projects. The empire's borders expanded, encompassing territories from Britain to Egypt and from Spain to the Euphrates. Roman legions, renowned for their discipline and engineering prowess, secured and maintained these vast territories, building roads, fortifications, and cities that facilitated control and integration.
The Roman Empire’s society was hierarchical, with a rigid class system. At the top were the patricians, wealthy elites who held significant political power. Below them were the plebeians, free citizens with limited political influence, and the vast numbers of slaves who formed the backbone of the economy. The family unit was central, governed by the paterfamilias, the male head who held absolute authority.
Culturally, the Romans were eclectic, absorbing and adapting elements from the civilizations they encountered, particularly the Greeks. Roman art, literature, and philosophy reflected this synthesis, creating a rich cultural tapestry. Latin, the Roman language, became the lingua franca of the Western world, influencing numerous modern languages.
Roman architecture and engineering achievements were monumental. They perfected the arch, vault, and dome, constructing enduring structures like the Colosseum, Pantheon, and aqueducts. These engineering marvels not only showcased Roman ingenuity but also served practical purposes, from public entertainment to water supply.
Acetabularia Information For Class 9 .docxvaibhavrinwa19
Acetabularia acetabulum is a single-celled green alga that in its vegetative state is morphologically differentiated into a basal rhizoid and an axially elongated stalk, which bears whorls of branching hairs. The single diploid nucleus resides in the rhizoid.
Operation “Blue Star” is the only event in the history of Independent India where the state went into war with its own people. Even after about 40 years it is not clear if it was culmination of states anger over people of the region, a political game of power or start of dictatorial chapter in the democratic setup.
The people of Punjab felt alienated from main stream due to denial of their just demands during a long democratic struggle since independence. As it happen all over the word, it led to militant struggle with great loss of lives of military, police and civilian personnel. Killing of Indira Gandhi and massacre of innocent Sikhs in Delhi and other India cities was also associated with this movement.
Instructions for Submissions thorugh G- Classroom.pptxJheel Barad
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2024.06.01 Introducing a competency framework for languag learning materials ...Sandy Millin
http://sandymillin.wordpress.com/iateflwebinar2024
Published classroom materials form the basis of syllabuses, drive teacher professional development, and have a potentially huge influence on learners, teachers and education systems. All teachers also create their own materials, whether a few sentences on a blackboard, a highly-structured fully-realised online course, or anything in between. Despite this, the knowledge and skills needed to create effective language learning materials are rarely part of teacher training, and are mostly learnt by trial and error.
Knowledge and skills frameworks, generally called competency frameworks, for ELT teachers, trainers and managers have existed for a few years now. However, until I created one for my MA dissertation, there wasn’t one drawing together what we need to know and do to be able to effectively produce language learning materials.
This webinar will introduce you to my framework, highlighting the key competencies I identified from my research. It will also show how anybody involved in language teaching (any language, not just English!), teacher training, managing schools or developing language learning materials can benefit from using the framework.
1. Maintenance of Hydraulic Systems
2. TURBULENCE IS AVOIDED
BY FORCING THE FUILD TO
TAKE AN INDIRECT PATH TO
TO RETURN
THE PUMP INLET.
PUMP LINE
3. OIL IS COOLED AND 1. RETURN FLOW IS DIRECTED
OUTWARD TO TANK WALL
AIR SEPARATED OUT WHEN
IT REACHES INLET
BAFFLE PLATE
By Ricky Smith CMRP
Most companies spend a lot of money training their maintenance personnel to
troubleshoot a hydraulic system. If we focused on preventing system failure then we could
spend less time and money on troubleshooting a hydraulic system. We normally except
hydraulic system failure rather than deciding not to except hydraulic failure as the norm. Let’s
spend the time and money to eliminate hydraulic failure rather than preparing for failure. I
worked for Kendall Company in the 1980’s and we changed our focus from reactive to
proactive maintenance on our hydraulic systems and thus eliminating unscheduled hydraulic
failure. We will talk about the right way to perform maintenance on a hydraulic system utilizing
the “Maintenance Best Practices”.
Lack of maintenance of hydraulic systems is the leading cause of component and
system failure yet most maintenance personnel don’t understand proper maintenance
techniques of a hydraulic system. The basic foundation to perform proper maintenance on a
hydraulic system has two areas of concern. The first area is Preventive Maintenance which is
key to the success of any maintenance program whether in hydraulics or any equipment
which we need reliability. The second area is corrective maintenance, which in many cases
can cause additional hydraulic component failure when it is not performed to standard.
Preventive Maintenance
Preventive Maintenance of a hydraulic system is very basic and simple and if followed
properly can eliminate most hydraulic component failure. Preventive Maintenance is a
discipline and must be followed as such in order to obtain results. We must view a PM
program as a performance oriented and not activity oriented. Many organizations have good
PM procedures but do not require maintenance personnel to follow them or hold them
accountable for the proper execution of these procedures. In order to develop a preventive
maintenance program for your system you must follow these steps:
1st: Identify the system operating condition.
a. Does the system operate 24 hours a day, 7 days a week?
2. b. Does the system operate at maximum flow and pressure 70% or better
during operation?
c. Is the system located in a dirty or hot environment?
2nd: What requirements does the Equipment Manufacturer state for
Preventive Maintenance on the hydraulic system?
rd
3 : What requirements and operating parameters does the component
manufacturer state concerning the hydraulic fluid ISO particulate?
th
4 : What requirements and operating parameters does the filter company
state concerning their filters ability to meet this requirement?
5th: What equipment history is available to verify the above procedures for
the hydraulic system?
As in all Preventive Maintenance Programs we must write procedures required for each
PM Task. Steps or procedures must be written for each task focused on the failure modes of
that part, component, and equipment. These tasks must be accurate and understandable by
all maintenance personnel from entry level to master.
Preventive Maintenance procedures must be a part of the PM Job Plan which includes:
Tools or special equipment required performing the task.
Parts or material required performing the procedure with store room number.
Safety precautions for this procedure.
Environmental concerns or potential hazards.
Specifications and standards
A list of Preventive Maintenance Task for a Hydraulic System could be:
1. Change the (could be the return or pressure filter) hydraulic filter.
Failure Mode – Hydraulic Valve Fails to Shift
Cause – Contaminated Fluid
2. Obtain a hydraulic fluid sample
Failure Mode – Hydraulic Valve Fails to Shift
Cause – Oil Contaminated Fluid
3. Filter hydraulic fluid for 60 minutes after PM Service
Failure Mode – Hydraulic Valves Fails to Shift
Cause – Oil Contaminated Fluid from PM (adding oil without filtering it or opening
the system to contamination)
4. Check hydraulic actuators for external rod leakage
Failure Mode – Cylinder Rod Seal Leaking Oil
Cause – Worn Piston Rings
Cause – Cylinder not in alignment from Blind end to Rod end during stroke
5. Clean the inside of a hydraulic reservoir.
Failure Mode – Hydraulic Valves not Functioning to Standard
Cause – Oil Contamination from hydraulic leaks
Cause – Contamination from New Hydraulic Fluid not filtered to 3 microns
6. Clean the outside of a hydraulic reservoir
Reason – Housekeeping (NO Failure Mode)
7. Check and record hydraulic pressures
Record on cycle one: _____ (minimum acceptable 140 bar)
Record on cycle two: _____ (minimum acceptable 300 bar)
Failure Mode: See Pump Below
3. 8. Check and record pump flow
Record Flow at Operating Pressure ____ (minimum acceptable is 10 GPM)
Failure Mode – Worn Swash Plate in Pump
Cause – Oil Contamination
9. Check hydraulic hoses for leaks or wear
Failure Mode – Hydraulic hoses not installed properly
Cause – Maintenance Personnel not knowing standard for installing hoses
10. Check and record mili-amp reading to proportional or servo valves.
Failure Mode – Amplifier Cards out of Calibration (10 mili-amps – 300 bar, 6 mili-
amps – 140 bar)
Cause – Normal Wear
Condition Monitoring
Take vibration readings on AC Induction Motor
Part - Bearing
Failure Mode – Abrasion
Cause – Improper Installation
Cause – Improper Lubrication
Part – Motor Assembly
Failure Mode – Fatigue
Cause – Misalignment
Cause – Age
Part – Rotor
Failure Mode – Defected Rotor Bar
Cause – Crack
Note: Validate with Motor Circuit Analysis offline
Preventive Maintenance is the core support that a hydraulic system must have in order to
maximize component and life and reduce system failure. Preventive Maintenance procedures
that are properly written and followed properly will allow equipment to operate to its full
potential and life cycle. Preventive Maintenance allows a maintenance department to control
a hydraulic system rather than the system controlling the maintenance department.
In order to validate your preventive maintenance procedures you must have a good
understanding and knowledge of “Best Maintenance Practices” for hydraulic systems. We will
convey these practices to you.
Best Maintenance Practices for Hydraulic Systems
Component Component Knowledge Best Practices Frequency
Hydraulic Fluid Filter There are two types of filters on a 1. Clean the filter cover or Preferred: based
hydraulic system. 1.) Pressure Filter - housing with a cleaning agent on historical
Pressure filters come in collapsible and and clean rags. trending of oil
non-collapsible types. Preferred filter is samples.
the non-collapsible type. 2.) Return Filter -
2. Remove the old filter with Least Preferred:
clean hands and install new
Typically has a bypass, which will allow Based on
filter into the filter housing or
contaminated oil to bypass the filter before equipment
screw into place.
indicating the filter needs to be changed. manufacture’s
CAUTION: NEVER allow your hand
recommendations.
to touch a filter cartridge. Open the
plastic bag and insert the filter
without touching the filter with your
hand.
4. Reservoir Air Breather The typical screen breather should not be 1. Remove and throw away the Preferred: Based
used in a contaminated environment. A filter. on historical
filtered air breather with a rating of 10 trending of oil
micron is preferred because of the samples.
introduction of contaminants to a hydraulic Least Preferred:
system. Based on
equipment
manufacture’s
recommendations
Hydraulic Reservoir A reservoir are used to: 1. Clean the outside of the If any of the
1. Remove contamination. reservoir to include the area following
under and around the conditions are
2. Dissipate heat from the fluid. met.
reservoir.
3. Store a volume of oil. 1. A hydraulic
2. Remove the oil by a filter pump
into a clean container, which pump fails.
has not had other types of fluid 2. If the system
in it before. has been
3. Clean the insides of the opened for
reservoir by opening the major work.
reservoir and cleaning the 3. If an oil
reservoir with a “Lint Free” rag. analysis
4. Afterwards spray clean states
hydraulic fluid into the reservoir excessive
and drain out of the system. contamination
Hydraulic Pumps A maintenance person needs to know the 1. Check and record flow and Pressure checks:
type of pump they have in the system and pressure during specific Preferred -
determine how it operates in their system. operating cycles. Daily
Example: What is the flow and pressure 2. Review graphs of pressure and Least Preferred:
of the pump during a given operating flow. Weekly
cycle. 3. Check for excessive fluctuation
This information allows a maintenance of the hydraulic system. Flow & Pressure
person to trend potential pump failure and (designate the fluctuation checks:
troubleshoots a system problem quickly. allowed) Preferred-
Two weeks
Least preferred
Monthly
Figure 2. Maintenance Practices for Hydraulic Systems
Hydraulic Knowledge
People say knowledge is power. Well this is also true in hydraulic maintenance. Many
maintenance organizations do not know what their maintenance personnel should know. I
believe in an industrial maintenance organization that we should divide the hydraulic skill
necessary into two groups. One is the hydraulic troubleshooter, they must be your experts in
maintenance and this should be as a rule of thumb 10% or less of your maintenance
workforce. The other 90% + would be your general hydraulic maintenance personnel. They
are the personnel that provide the preventive maintenance expertise. The percentages I
gave you are based on a company developing a true Preventive / Proactive maintenance
approach to their hydraulic systems. Let’s talk about what the hydraulic troubleshooter
knowledge and skills.
Hydraulic Troubleshooter:
Knowledge –
Mechanical Principles / force, work, rate, simple machines
Math / basic math, complex math equations
5. Hydraulic Components / application and function of all hydraulic system
components.
Hydraulic Schematic Symbols / understanding all symbols and their
relationship to a hydraulic system.
Calculate flow, pressure, and speed.
Calculate the system filtration necessary to achieve the system’s proper ISO
particulate code.
Skill –
Trace a hydraulic circuit to 100% proficiency.
Set the pressure on a pressure compensated pump.
Tune the voltage on an amplifier card.
Null a servo valve.
Troubleshoot a hydraulic system and utilize “Root Cause Failure Analysis”.
Replace any system component to manufacturer’s specification.
Develop a PM Program for a hydraulic system.
Flush a hydraulic system after a major component failure.
General Hydraulic:
Knowledge –
Filters / function, application, installation techniques
Reservoirs / function, application
Basic hydraulic system operation
Cleaning of hydraulic systems
Hydraulic lubrication principles
Proper PM techniques for hydraulics
Skills –
Change a hydraulic filter and other system components.
Clean a hydraulic reservoir.
Perform PM on a hydraulic system.
Change a strainer on a hydraulic pump.
Add filtered fluid to a hydraulic system.
Identify potential problems on a hydraulic system.
Change a hydraulic hose, fitting or tubing.
Measuring Success
In any program we must track success in order to have support from management and
maintenance personnel. We must also understand that any action will have a reaction,
negative or possible. We know successful maintenance programs will provide success but we
must have a checks and balances system to ensure we are on track.
In order to measure success of a hydraulic maintenance program we must have a way
of tracking success but first we need to establish a benchmark. A benchmark is method by
which we will establish certain key measurement tools that will tell you the current status of
your hydraulic system and then tell you if you are succeeding in your maintenance program.
Before you begin the implementation of your new hydraulic maintenance program it
would be helpful to identify and track the following information.
1. Track all downtime (in minutes) on the hydraulic system with these questions
answered. / Tracked daily /
What component failed?
Cause of failure?
Was the problem resolved?
6. Could this failure have been prevented?
2. Track all cost associated with the downtime. / tracked daily /
Parts and material cost?
Labor cost?
Production downtime cost?
Any other cost you may know that can be associate with a hydraulic system
failure.
3. Track hydraulic system fluid analysis. Track the following from the results. / take
samples once a month /
Copper content
Silicon content
H2O
Iron content
ISO particulate count
Fluid condition (Viscosity, additives, and oxidation).
When the tracking process begins you need to trend the information that can be trended. This
allows management the ability to identify trends that can lead to positive or negative
consequences.
Press Hydraulic System
Hydraulic Fluid Samples
Component Potential
Failure Component
Failure
200
Particle Count / PPM
150
100
50
0
1 2 3 4 5 6 7 8 9 10 11 12
Month
Monthly Samples
Figure 3. Hydraulic Fluid Samples
Fluid analysis proved the need for better filtration. The addition of a 3-micron absolute return
line filter to supplement the “kidney loop” filter solved the problem.
7. Many organizations do no know where to find the method for tracking and trending the
information you need accurately. A good Computerized Maintenance Management System
can track and trend most of this information for you.
Recommended Maintenance Modifications
Modifications to an existing hydraulic system need to be accomplished professionally.
A modification to a hydraulic system in order to improve the maintenance efficiency is
important to a company’s goal of maximum equipment reliability and reduced maintenance
cost.
1st: Filtration pump with accessories:
Objective: The objective of this pump and modification is to reduce contamination that
is introduced into an existing hydraulic system through the addition of new fluid and the device
used to add oil to the system.
Additional Information: Hydraulic fluid from the distributor is usually not filtered to the
requirements of an operating hydraulic system. Typically this oil is strained to a mesh rating
and not a micron rating. How clean is clean? Typically hydraulic fluid must be filtered to 10
microns absolute or less for most hydraulic system, 25 microns is the size of a white blood
cell, and 40 microns is the lower limit of visibility with the unaided eye.
Many maintenance organizations add hydraulic fluid to a system through a
contaminated funnel and may even used a bucket that has had other types of fluids and
lubricants in them previously, without cleaning them.
Recommended equipment and parts:
Portable Filter Pump with a filter rating of 3 microns absolute.
Quick disconnects that meet or exceeds the flow rating of the Portable Filter Pump.
A ¾” pipe long enough to reach the bottom of a hydraulic container your fluids are
delivered in from the distributor.
A 2” reducer bushing to ¾”npt to fit into the 55 gallon drum, if you receive your fluid
by the drum. Otherwise, mount the filter buggy to the double wall “tote” tank
supports, if you receive larger quantities.
Reservoir vent screens should be replaced with 3/10 micron filters, an openings
around piping entering the reservoir sealed.
Show a double wall tote tank of about 300 gallons mounted on a frame for fork truck
handling, with the pump mounted on the frame work.
Also show pumping from a drum mounted on a frame for fork truck handling, sitting in a
catch pan, for secondary containment, with the filter buggy attached.
Regulations require that you have secondary containment, so make everything “leak”
into the pan.
8. Air Breather
55 Gallon Drum
10 Micron Filter
Portable Filter Pump
To Hydraulic
Reservoir
Figure 4. Filter Pumping Unit
2nd. Modify the Hydraulic Reservoir
Objective: The objective is to eliminate the introduction of contamination through oil
being added to the system or contaminates being added through the air intake of the
reservoir. A valve needs to be installed for oil sampling.
Additional Information: The air breather strainer should be replaced with a 10-micron
filter if the hydraulic reservoir cycles. A quick disconnect should be installed on the bottom of
the hydraulic unit and at the ¾ level point on the reservoir with valves to isolate the quick
disconnects in case of failure. This allows the oil to added from a filter pump as previously
discussed and would allow for external filtering of the hydraulic reservoir oil if needed. Install a
petcock valve on the front of the reservoir that will be used for consistent oil sampling.
Equipment and parts needed:
Quick disconnects that meet or exceeds the flow rating of the Portable Filter
Pump.
Two gate valves with pipe nipples.
One 10 micron filter breather.
WARNING: Do not weld on a hydraulic a reservoir to install the quick disconnects or air
filter.
9. DRAIN AIR
BREATHER MOUNTING PLATE
RETURN PUMP AND FOR ELECTRIC MOTORS
INLET FILTER AND PUMP
RETURN LINE
LINE
SEALED FLANGE
BAFFLE
PLATE
DRAIN
STRAINER
PLUG
Figure 5. Hydraulic Reservoir Modification
Root Cause Failure Analysis
As in any proactive maintenance organization you must perform Root Cause Failure
Analysis in order to eliminate future component failures. Most maintenance problems or
failures will repeat themselves without someone identifying what caused the failure and
proactively eliminate it. A preferred method is to inspect and analyze all component failures.
Identify the following:
Component Name and model number.
Location of component at the time of failure.
Sequence or activity the system was operating at when the failure occurred.
What caused the failure?
How will the failure be prevented from happening again?
Failures are not caused by an unknown factor like “bad luck” or “it just happened” or “the
manufacturer made a bad part”. We have found most failures can be analyzed and prevention
taken to prevent their reoccurrence. Establishing teams to review each failure can pay off in
major ways.
To summarize, maintenance of a hydraulic system is the first line of defense to prevent
component failure and thus improve equipment reliability. As spoken about earlier, discipline
is the key to the success of any proactive maintenance program.