HydraulicSyst.ppt

1、6 August 2020,1,Hydraulic System Management,6 August 2020 Slide No 2,Situation,Hydraulics representa growing portion ofyour o/o costs Up to 60% depending on the type & size of your machine.(excluding bucket, UC & GET costs) Together we canincrease machineproductivity andreduce these costs,6 August 2

2、020 Slide No 3,“75-85% of hydraulic system failures are caused by contamination.” - Hydraulics & Pneumatics June 1998 - Equipment Today August 1997,6 August 2020 Slide No 4,Peak System Efficiency = Maximum Production Lowest Cost,Hydraulic Performance,6 August 2020 Slide No 5,Hydraulic Performance In

3、dicators,6 August 2020 Slide No 6,Hydraulic Performance Indicators,6 August 2020 Slide No 7,Contamination Control,SOS Fluid Analysis,Detection,Technical Inspections,Inspection,Prevention,6 August 2020 Slide No 8,Efficiency,Time,Significant efficiency loss possible before operator detection,Effects o

4、f Contamination,Accelerates wear (all components) Reduces system efficiency,Up To 20% !,6 August 2020 Slide No 9,Contamination - # 1 Enemy,The Cost of the Parts Is Just the Beginning!,6 August 2020 Slide No 10,Contamination - #1 Enemy,The Facts Dont Lie!,$ 10,000 - Parts + $ 7,000 - Labor $ 17,000,6

5、 August 2020 Slide No 11,Contamination - #1 Enemy,The Facts Dont Lie!,$ 10,000 - Parts + $ 20,000 - Labor $ 30,000,6 August 2020 Slide No 12,Contamination - #1 Enemy,$ 10,000 - Parts + $ 20,000 - Labor $ 30,000,The Facts Dont Lie!,Plus Downtime!,6 August 2020 Slide No 13,THE SYSTEM,Chemical,Dirt,Met

6、als,Particles,Heat,Water,Air,What Are Contaminants?,6 August 2020 Slide No 14,5,30,40,80,Smallest Visible to the Eye,Human Hair,Cat Hydraulic System Clearances,Small Particles Can Do Big Damage!,6 August 2020 Slide No 15,How Particles Get In,Oil Machineoperation Maintenance/Repair,6 August 2020 Slid

7、e No 16,If Oils Getting Out, Dirts Getting In,6 August 2020 Slide No 17,Contamination Control,1/2 teaspoon of fine dust is unacceptable and is enough to contaminate a 55 - Gallon Barrel / System,6 August 2020 Slide No 18,Contamination Control -Caterpillar,Components kept packaged New oil filtered Us

8、e of cleanout filter Purging of system Oil samples taken,6 August 2020 Slide No 19,Cat,Dealer,Customer,Contamination Control - Working Together,Prevention Detection Inspection,6 August 2020 Slide No 20,Contamination - Prevention,During operation Fix leaksimmediately Keep tank full Properly maintaino

9、il cooler andrelief valves Use rod protectors inharsh applications,6 August 2020 Slide No 21,Contamination Control,Customers Need to educate operators and service personnel Need to practice contamination control System Management Oil storage and handling Oil sampling Hose assembly and storage Machin

10、e operation,6 August 2020 Slide No 22,Contamination - Prevention,During maintenance Fluids Use barrel covers Follow recommendedchange intervals Drain when warm &agitated Limit agitation andfilter oil during transfer Store drums inside Filter new & system oil Clean drum openings Use clean & capped li

11、nes & nozzles,6 August 2020 Slide No 23,Contamination - Prevention,During Maintenance - Fluids Use hydraulic oilwith proper additives.Oxidation and foam inhibitorsAnti-wear agents Cat pumps require at least .09% zinc. Cat hydraulic oilcontains .13% Follow recommended change intervals at every 2000 h

12、ours,6 August 2020 Slide No 24,Contamination - Prevention,During maintenance - Filters Follow recommended filter change intervals every 500 hours Remove old ones with care Keep new ones packaged untilinstallation Use Clean Out Filters after system invasion Use Standard Cat Liquid Filters to maintain

13、optimum system cleanliness After maintenance and / or service Use High Efficiency Filters for first 250 hours,6 August 2020 Slide No 25,Contamination - Prevention,During hose assembly Use Cat Hose Cleaner Group After hose assembly Use caps and plugs,6 August 2020 Slide No 26,Contamination - Preventi

14、on,Scheduled Oil Sampling Detects contamination and internal wear,Wear Rate Analysis (Wear Metal Analysis),Oil Condition Analysis (Infrared Analysis),Oil Cleanliness Analysis (particle Count),6 August 2020 Slide No 27,The best advice . . .,Keep the hydraulic system CLEAN COOL CLOSED CAT,6 August 202

15、0 Slide No 28,System Management,Effects of Efficiency Loss,Operator Vol. Loss Cycles Fuel Used,1 New Pump 15 0.1 l/hr,1 Worn (15% Loss) 12 2.5,2 New Pump 23 0.4,2 Worn (15% Loss) 21 2.8, 10% decrease in machine productivity,Assuming 2 shifts 10 hrs., 5 days/week, 2/hr $.25/liter $3,000 fuel costs/yr

16、 due to decreased pump efficiency,6 August 2020 Slide No 29,Contamination - Detection,Your Role Regular oil sampling Every 6 months / 250 hours Use proper samplingtechniques Use valve probewhen possible Fill out labelcompletely,6 August 2020 Slide No 30,Contamination - Detection,Our role Testing Wea

17、r Metal Analysis Infrared Analysis Particle Count Interpretation Recommendations,6 August 2020 Slide No 31,Contamination - Inspection,Your role Listen to your operators Excessive drift = seal orcontrol valve problem Noisy operation =pump wear or low oil Slow cycle times =pump wear Leaks = worn seals

18、 Hose blisters = overheating,6 August 2020 Slide No 32,Hydraulic System Management,Informed Decisions = Greater MachineProductivity Lower Operating Cost,6 August 2020 Slide No 33,Custom Hydraulic Service,Technical Inspections Performance Drift rates Cycle times Track motor efficiency Diagnostic Hydr

19、aulic system pressures SOS Fluid Analysis Recommendcorrective action,6 August 2020 Slide No 34,Customer Hydraulic Service,Program for managing hydraulic systems Includes performance / diagnostic test, SOS Fluid Analysis, walkaround inspection Benefits Restores / helps maintain peak hydraulic system

20、efficiency Improves machine productivity and availability Lower operation costs,Solutions,6 August 2020 Slide No 35,Custom Hydraulic Service,Like-new Efficiency,New,Efficiency,Time,Recommended Action Taken from CHS Inspection Hydraulic System Restored to New Machine Specs,Controlled studies show tha

21、t hydraulic system efficiency can fall off by as much as 20% before detection by operators,6 August 2020 Slide No 36,300 B- Series Field Performance Data, Empty bucket, engine stop, hyd oil temp.55+/- 5deg # Constant speed, power mode, empty bucket,6 August 2020 Slide No 37,Hydraulic Test Performanc

22、e Summary,6 August 2020 Slide No 38,Oil Cleanliness Analysis,A MUST !,Detects buildup of ALL particles, including those 10 microns Quantifies non-metallic AND metallic particles Predicts before-failure repairs Expressed in ISO Codes,Oil Cleanliness Analysis,Wear Rate Analysis,UNITS,HOURS,6 August 20

23、20 Slide No 39,Interpreting ISO Codes,18,15,Top number represents number of particles equal to or greater than 5 microns,Bottom number represents number of particles equal to or greater than 15 microns,Why were these sizes selected?,Smaller size (5 microns) indicated wear particles that cause “silti

24、ng” or clogging of oil flow,15 microns particles indicate the presence of rapid wear and potential early failure,6 August 2020 Slide No 40,ISO,ISO :,What does it Mean?,= OR 5 Micron,= OR 15 Micron,Human Hair,= 80 microns,18 =,15 =,+,ISO 18 / 15,6 August 2020 Slide No 41,Contamination Control,(ISO Co

25、des),5 Microns & Greater,15 Microns & Greater,Very Dirty Dirty Clean Very Clean,24,160,000,19,5,000,21,20,000,17,1,300,18,2,500,15,320,16,640,13,80,6 August 2020 Slide No 42,Importance of Hyd Oil Maintenance,Hex failure incidents by SIMS About 1/4 is hydraulic related, 70% is due to poor oil mainten

26、ance. Oil deterioration by property change. Chemical change under high temperature. Sludge formation by oxidation. Mixture of water. Oil contamination by foreign materials When refilling / changing oil, or changing attachment. From oil leak area (e.g. hose, implement) Technology advancement and its

27、& its effect on oil (improvements of performance: faster cycle time, higher breakout force) Use of higher system pressure & lighter weight design for pump / motor. Less refill capacity for hydraulic tank. Use of electronic control.,6 August 2020 Slide No 43,* Please see SEBU6250 for the latest Cat M

28、achine Lubricant Recommendations.,Hydraulic Lubricant Recommendations,6 August 2020 Slide No 44,Formulated with Balanced Additive System Quality Offering Maximum Protection & Component Life Field-Proven Performance Integral Part of the Machine Design Factory Fill,Cat HYDO Benefits,6 August 2020 Slid

29、e No 45,Hydraulic Oil Additives,Anti-wear Agents Defoamers & Air Release Agents Anti-oxidants Rust & Corrosion Inhibitors Detergents/Dispersants,6 August 2020 Slide No 46,Cat HYDO Benefits,Water Dispersion,Cat Hydraulic Oil,Industrial Hydraulic Oil,During system maintenance, Select the right oil Oxi

30、dation inhibitors Form inhibitors Anti-wear agents (Zinc) Cat Pumps require 0.09% Cat HYDO 0.13%,6 August 2020 Slide No 47,Effects on Hydraulic Oil: Oil Change VS. Flushing,Need 4 to 5 changes to achieve new oil cleanliness,By Flushing:-,Close to new oil cleanliness,Caution! Life of hyd cannot be ex

31、tended by flushing. Periodic oil change is needed even flushing is done.,OIL IN TANK,OIL IN TANK,OIL IN TANK,OIL IN LINES,OIL IN TANK,OIL IN TANK,OIL IN LINES,OIL IN LINES,OIL IN LINES,OIL IN LINES,6 August 2020 Slide No 48,Storage of New Oil,Prepare an exclusive storage area to store new oil Keep s

32、torage area clean & dust free Be careful when transporting oil. Rough handling will cause peeling off inside coating of container & growth of form in the oil Do not store the oil outside. By direct sunlight & cooling at night, moisture in the air is condensed & mixed in the oil.accelerate oxidation

33、When supplying oil from a drum, wipe around the cap to remove dust & dirty oil. Do not supply or change oil in rainy day,It is necessary to pay special attention for handling of new oil:-,6 August 2020 Slide No 49,Summary,Hydraulics representa growing portion ofyour o/o costs Up to 60% depending on

34、the type & size of your machine.(excluding bucket, UC & GET costs) Together we canincrease machineproductivity andreduce these costs,6 August 2020 Slide No 50,6 August 2020 Slide No 51,Maintenance Section,6 August 2020 Slide No 52,SOS Fluid Analysis Test Report,A,E,B,C,D,6 August 2020 Slide No 53,Sy

35、stem Management,Operators Failed to Detect Efficiency Loss!,Boom Up and Down,Increasing Leakage,15% Efficiency Loss,“Slower”,22.25% Efficiency Loss,#1,#2,#3,#4,“Faster”,“Cant Tell”,“Cant Tell”,“Faster”,“Slower, Not Drastic”,“Cant Tell”,6 August 2020 Slide No 54,SYSTEM SERVICE,SYSTEM MANAGEMENT,-,MAX

36、IMUM PRODUCTIVITY LOWEST COST,SUPERIOR SYSTEM,6 August 2020 Slide No 55,Superior System Components,Hose & Couplings Manufactured by Cat Superior construction and testing XT Hose Reusable Couplings,6 August 2020 Slide No 56,Superior System Components,Cylinders Bore skiving & rollerburnishing Thick tu

37、be stock,6 August 2020 Slide No 57,Superior System Components,Rods Inertia welding Induction hardening,6 August 2020 Slide No 58,Superior System Components,Pumps & Motors Designed to be rebuilt Precision manufacturing 100% tested,6 August 2020 Slide No 59,Cylinder Service - Reseal,Why light honing i

38、s important! Restores tube to like-new condition Corrects internal leaks Extends seal life Improves systemefficiency Seal Life Could Be Reduced ByAs Much As 75% Without Honing,6 August 2020 Slide No 60,Cylinder Service - Major,More cylinder lives Hone .030” oversize Hone .060” oversize Reman Standar

39、d Reman OversizeRe-tube Only available from Cat Dealers Seals Must Be Replaced By Oversize When Cylinder Worn Over 0.010”,6 August 2020 Slide No 61,Remember. damaged rods let in dirt!,Rod Service,Reman Rods Inertia welded Induction hardened,6 August 2020 Slide No 62,Benefits - Reman Cylinders & Rods,Fast Available off-the-shelf for most