Studies have shown that in most applications, machine performance can degrade by as much as 20% before an operator will be aware of it.
That can mean lower breakout forces, slower cycle times -- all without the operator noticing.
The most popular and effective tools for the majority of earthmoving applications today are excavators, wheel loaders and backhoe/loaders.
The hydraulic systems on these machines are the key to their operation and if the hydraulic system isn`t in peak condition, performance will suffer.
At the same time, their use of quick hitch systems and various attachments: hydraulic hammers, different buckets, etc, means there are more opportunities for contamination to enter the system during the changeover process.
While on the subject of attachments, it is of vital importance to ensure any coupled attachments that source hydraulic power via the pump system of the carrier have their own filtration system.
This should take the form of `in-line` full-flow filters or `line strainers` which meet the manufacturers` approval.
This ensures that any failure in one system (such as a hammer), will not result in expensive collateral damage to the carrier`s hydraulic circuit.
As demand has increased for machines that can produce more, cycle faster, have greater breakout force and burn less fuel, so has the sophistication of hydraulic systems.
Today`s hydraulic systems have higher system pressures, closer tolerances and electronic management controls, with the majority using piston type pumps and motors.
These systems and components are far more susceptible to dirt and contamination than with the older open-circuit systems that used gear and vane pumps.
Most hydraulic components have operating clearances of less than 40 microns. The smallest the human eye can see is 40 microns -- in other words, fine dirt particles that you can`t even see can be doing significant damage to your system.
Contaminants include:
-- dirt
-- grinding and welding residue
-- paint
-- metal
-- even the dust and residue from dry oil-absorbent materials
Even if your system filters catch these contaminants -- and most modern machines have filters that are less than 10 microns which will catch just about everything. Often contaminants will cycle through the system for some time before the filters collect them.
You`ll start getting internal bypassing of the filters, which will have a number of consequences.
Firstly, it will allow contaminants into those closely toleranced components, with predictable results.
Secondly, high-pressure internal bypassing in a hydraulic system generates heat. In hot conditions, or in a high-production environment, that accelerates component wear.
Don`t overlook the fact that on-going problems can continue to occur after a component failure, due to the system not being properly cleaned out of debris resulting from the failure.
Doing this properly requires disassembly and flushing of all lines, valves and components that may have received contamination.
Special 3 to 5 micron filters are then installed and replaced up to three times in the next 100 hours to ensure all contaminants are removed.
This is a time-consuming and often expensive procedure but absolutely critical if you want to achieve normal component life and no repeat failures.
Most equipment supplier`s can provide you with detailed clean out procedures and special clean out filters.
Consequences of allowing contaminants into your hydraulic system include:
-- poor equipment performance
-- lower productivity
-- reduced component life
cover some "do`s and don`ts" to minimise the potential for contaminant "infection" of your hydraulic system. They were taken during a quick stroll around Komatsu Australia`s used equipment yard and workshop -- plus we set up a couple of "don`ts" as examples.