Power Cube Maintenance - Revision history

KhalidH at 22:46, 27 December 2013

2013-12-27T22:46:05Z

← Older revision		Revision as of 22:46, 27 December 2013
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	==References==		==References==
	<references />		<references />
			[[category:Power Cube]]

Matt Maier at 03:59, 24 December 2011

2011-12-24T03:59:20Z

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 * Check for corroded or loose fasteners.
-===Pump Maintenance===
+===Pump/Motor Maintenance===
 Performance parameters:
 * suction pressure (Ps)
@@ Line 45: / Line 45: @@
 * use a doppler or transitime device (non-intrusive)
 * each measuring device must be calibrated (don't underestimate the importance of this)
 ===Fluid Maintenance===

Matt Maier at 05:16, 20 December 2011

2011-12-20T05:16:58Z

← Older revision		Revision as of 05:16, 20 December 2011
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	==Hydraulic System Maintenance==		==Hydraulic System Maintenance==
	===Safety===		===Safety & Cleanliness===
			<ref>[http://hydraulics.eaton.com/products/pdfs/694.pdf Hydraulic Hints and Troubleshooting Guide, Eaton]</ref>
	'''Wear your Personal Protective Equipment'''		'''Wear your Personal Protective Equipment'''

	Hydraulic systems operate under very high pressures. Shut the system down and relieve system pressure before opening any part of the system that is under pressure. Do not allow spray from any high pressure leak to contact any part of the body, as serious injection injuries may result. Pumps, valves and motor may become hot; be cautious of incidental contact between bare skin and hot surfaces. Keep hands and clothing away from moving parts of the system		Hydraulic systems operate under very high pressures. Shut the system down and relieve system pressure before opening any part of the system that is under pressure. Do not allow spray from any high pressure leak to contact any part of the body, as serious injection injuries may result. Pumps, valves and motor may become hot; be cautious of incidental contact between bare skin and hot surfaces. Keep hands and clothing away from moving parts of the system

			No grinding or welding operations should be done in the area where hydraulic components are being installed.

			All cylinder, valve, pump and hose connections should be sealed and/or capped until just prior to use.

			When installing pumps or motors, always align coupling halves as closely as possible, within 0.007 inch.

	===Generic===		===Generic===

Matt Maier at 05:12, 20 December 2011

2011-12-20T05:12:45Z

← Older revision		Revision as of 05:12, 20 December 2011
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	===Fluid Maintenance===		===Fluid Maintenance===
	<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>		<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>
			<ref>[http://www.mobil.com/IND/English/Files/tt-the-basics-of-oil-analysis.pdf Basic Oil Analysis, Mobil]</ref>
	* Control the temperature		* Control the temperature
	Excessive temperatures will oxidize the oil and can lead to varnish and sludge deposits		Excessive temperatures will oxidize the oil and can lead to varnish and sludge deposits
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	Inspect fluid filters frequently and change or clean them before they go into bypass mode.		Inspect fluid filters frequently and change or clean them before they go into bypass mode.
	* Follow an oil analysis program		* Follow an oil analysis program
			Contaminants act as a catalyst for wear. This generated wear debris further acts as a catalyst for additional component wear.
	With an effective oil analysis program, you can safely increase the standard 1 year interval while at the same time provide yourself with an “early warning” of possible mechanical problems.		With an effective oil analysis program, you can safely increase the standard 1 year interval while at the same time provide yourself with an “early warning” of possible mechanical problems.
	At minimum, check your critical and large volume hydraulic systems at least annually by oil analysis.		At minimum, check your critical and large volume hydraulic systems at least annually by oil analysis.
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	6. Refill the system with new fluid making sure to vent high points.		6. Refill the system with new fluid making sure to vent high points.
	7. Restart and check system for proper operation.		7. Restart and check system for proper operation.

			====Oil Analysis====
			1: '''Identify “Mission Critical” Equipment''' It’s not necessary to perform oil analysis on every single lubricated system. Identify critical applications that would seriously jeopardize production if they were to shut down unexpectedly.
			2: '''Register Your Equipment''' It is important to have your equipment properly registered with a lab. This supports routine trending and plays a key role in early detection of lubricant or equipment problems. There’s no need for you to decide which tests are appropriate for a particular application because the lab has already established test slates for specific applications.
			3: '''Establish Best Practices''' Establish a consistent “how-to” practice for taking oil samples from your equipment and train your maintenance personnel to use this practice. Correct sampling practices are critical to the value received from the analysis data. This extremely important step rarely gets the attention it needs.
			4: '''Sample''' Retrieve samples in accordance with your best practice and send them to the lab as soon as possible. Samples that are set aside may deteriorate and give non-representative results.
			5: '''Analyze''' A thorough analysis, keyed on trends, helps determine your systems’ conditions.
			6: '''Interpret''' Reviewing the results and determining what, if any, action is required can make or break a successful program. It’s important to remember that an alert sample does not necessarily mean imminent failure. Seek consultation on alert samples and re-sample to confirm present data before taking massive corrective action.
			7: '''Take Corrective Action and Document, Document, Document!!!''' As always, documentation is the key to knowing where you’ve been and where you’re going. Document corrective actions resulting from oil analysis.

	==Mechanical System Maintenance==		==Mechanical System Maintenance==

Matt Maier at 05:04, 20 December 2011

2011-12-20T05:04:12Z

← Older revision		Revision as of 05:04, 20 December 2011
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	==Hydraulic System Maintenance==		==Hydraulic System Maintenance==
			===Safety===
	'''Wear your Personal Protective Equipment'''		'''Wear your Personal Protective Equipment'''

			Hydraulic systems operate under very high pressures. Shut the system down and relieve system pressure before opening any part of the system that is under pressure. Do not allow spray from any high pressure leak to contact any part of the body, as serious injection injuries may result. Pumps, valves and motor may become hot; be cautious of incidental contact between bare skin and hot surfaces. Keep hands and clothing away from moving parts of the system

	===Generic===		===Generic===
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	Portable filters will supplement permanently installed filters and should be constantly rotated from system to system regardless if you think the system requires filtering or not. Systems should be filtered long enough to pass the total volume of oil through the filter at least 10 times. Portable filters should be used when transferring new oil from drums or storage tank to a system — especially for NC machines.		Portable filters will supplement permanently installed filters and should be constantly rotated from system to system regardless if you think the system requires filtering or not. Systems should be filtered long enough to pass the total volume of oil through the filter at least 10 times. Portable filters should be used when transferring new oil from drums or storage tank to a system — especially for NC machines.

	===10 Point Check===		====10 Point Check====
	'''Perform weekly'''		'''Perform weekly'''
	1. Check fluid levels. Add oil (if needed) via portable filtration(if available). DO NOT MIX OILS! Use the same oil brand andviscosity grade that is being used in the system.		1. Check fluid levels. Add oil (if needed) via portable filtration(if available). DO NOT MIX OILS! Use the same oil brand andviscosity grade that is being used in the system.
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	9. Scan electrically controlled servo valves with an infraredthermometer. High valve and solenoid temperatures(over 150ºF) usually indicate the valve is sticking.		9. Scan electrically controlled servo valves with an infraredthermometer. High valve and solenoid temperatures(over 150ºF) usually indicate the valve is sticking.
	10. Scan the electric drive motor with for housing hot spots and rotor bearing temperatures using an infrared thermometer.		10. Scan the electric drive motor with for housing hot spots and rotor bearing temperatures using an infrared thermometer.

			====Change The Fluid====
			1. Drain the system while the fluid is hot to keep contaminants in suspension.
			2. Empty fluid from cylinders, accumulators and lines that might not drain properly.
			3. Mop, siphon, or pump out oil left in the reservoir.
			4. Wipe reservoir clean with lint free rags and remove rust and free paint.
			5. Replace or clean filter elements and strainers and clean filter housings.
			6. Refill the system with new fluid making sure to vent high points.
			7. Restart and check system for proper operation.

	==Mechanical System Maintenance==		==Mechanical System Maintenance==

Matt Maier at 05:00, 20 December 2011

2011-12-20T05:00:58Z

Matt Maier at 04:57, 20 December 2011

2011-12-20T04:57:31Z

@@ Line 38: / Line 38: @@
 ===Fluid Maintenance===<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>
 * Control the temperature
 * Keep the area clean
 * Keep the fluid clean
 * Follow an oil analysis program
 ==Mechanical System Maintenance==

Matt Maier at 04:41, 20 December 2011

2011-12-20T04:41:36Z

← Older revision		Revision as of 04:41, 20 December 2011
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	* each measuring device must be calibrated (don't underestimate the importance of this)		* each measuring device must be calibrated (don't underestimate the importance of this)

	===Fluid Maintenance===<ref>Hydraulic System Care & Maintenance, Mobil</ref>		===Fluid Maintenance===<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>
	* Control the temperature		* Control the temperature
	* Keep the area clean		* Keep the area clean

Matt Maier at 04:38, 20 December 2011

2011-12-20T04:38:37Z

← Older revision		Revision as of 04:38, 20 December 2011
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	[http://www.briggsandstratton.com/engines/support/maintenance-how-to/Push%20Mower%20Engines/Tune-Up%20Schedule/ schedule from Briggs & Stratton website]		[http://www.briggsandstratton.com/engines/support/maintenance-how-to/Push%20Mower%20Engines/Tune-Up%20Schedule/ schedule from Briggs & Stratton website]

			==References==
	<references />		<references />

Matt Maier at 04:38, 20 December 2011

2011-12-20T04:38:15Z

← Older revision		Revision as of 04:38, 20 December 2011
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	* Replace fuel filter: every 100 hours or every season		* Replace fuel filter: every 100 hours or every season
	[http://www.briggsandstratton.com/engines/support/maintenance-how-to/Push%20Mower%20Engines/Tune-Up%20Schedule/ schedule from Briggs & Stratton website]		[http://www.briggsandstratton.com/engines/support/maintenance-how-to/Push%20Mower%20Engines/Tune-Up%20Schedule/ schedule from Briggs & Stratton website]


			<references />

← Older revision		Revision as of 05:00, 20 December 2011
Line 36:		Line 36:
	* each measuring device must be calibrated (don't underestimate the importance of this)		* each measuring device must be calibrated (don't underestimate the importance of this)

	===Fluid Maintenance===<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>		===Fluid Maintenance===
			<ref>[http://www.mobil.com/IND/English/Files/tt-hydraulic-system-care-and-maintenance.pdf Hydraulic System Care & Maintenance, Mobil]</ref>
	* Control the temperature		* Control the temperature
	Excessive temperatures will oxidize the oil and can lead to varnish and sludge deposits		Excessive temperatures will oxidize the oil and can lead to varnish and sludge deposits
Line 67:		Line 68:
	===10 Point Check===		===10 Point Check===
	'''Perform weekly'''		'''Perform weekly'''
	1. Check fluid levels. Add oil (if needed) via portable filtration(if available). DO NOT MIX OILS! Use the same oil brand andviscosity grade that is being used in the system.		1. Check fluid levels. Add oil (if needed) via portable filtration(if available). DO NOT MIX OILS! Use the same oil brand andviscosity grade that is being used in the system.
	2. Inspect breather caps, breather filters and fill screens — DO NOT punch holes in screens in order to expedite adding oil.		2. Inspect breather caps, breather filters and fill screens — DO NOT punch holes in screens in order to expedite adding oil.
	3. Check filter indicators and/or pressure differential gages.		3. Check filter indicators and/or pressure differential gages.
	4. Visually inspect all system hoses, pipes, pipe connections for leaks and frays. Hydraulic fluid leakage is a common problem for industrial systems. Excessive leakage is an environmental and safety hazard, increases waste streams and oil consumption, and, if ignored, canreduce the system capacity enough to overheat the system.		4. Visually inspect all system hoses, pipes, pipe connections for leaks and frays. Hydraulic fluid leakage is a common problem for industrial systems. Excessive leakage is an environmental and safety hazard, increases waste streams and oil consumption, and, if ignored, canreduce the system capacity enough to overheat the system.
	5. Check system temperature via built-in thermometers or hand-held infrared detectors. Normal temperature range for most systems is110-140ºF. If temperatures are high, check cooler operation andrelief valve settings.		5. Check system temperature via built-in thermometers or hand-held infrared detectors. Normal temperature range for most systems is110-140ºF. If temperatures are high, check cooler operation andrelief valve settings.
	6. Visually inspect the inside of the reservoir for signs of aeration (via the fill hole using a flashlight). Aeration is a condition in which discrete bubbles of air are carried along in the stream of oil as it enters the pump. Visual signs of aeration in the reservoir are generally foaming and/or little whirlpools taking small gulps of air ~~intothe~~ suction strainer. Causes of aeration include: low fluid levels; airleaks in the suction line; low fluid temperature; fluid is too viscous to release air or maintain suction at the pump; or faulty shaft seals.When air leaks are suspected on the suction line, smotheringthesepoints with oil will usually pinpoint the leaks by creating a markedchange in pump noise. A pump ingesting air sounds as if it weregargling marbles.		6. Visually inspect the inside of the reservoir for signs of aeration (via the fill hole using a flashlight). Aeration is a condition in which discrete bubbles of air are carried along in the stream of oil as it enters the pump. Visual signs of aeration in the reservoir are generally foaming and/or little whirlpools taking small gulps of air into the suction strainer. Causes of aeration include: low fluid levels; airleaks in the suction line; low fluid temperature; fluid is too viscous to release air or maintain suction at the pump; or faulty shaft seals.When air leaks are suspected on the suction line, smotheringthesepoints with oil will usually pinpoint the leaks by creating a markedchange in pump noise. A pump ingesting air sounds as if it weregargling marbles.
	7. Listen to the pump for the signs of cavitation. Cavitation is slightly more complicated than aeration, but bares somesimilarities. Cavitation occurs when air is released from ~~thehydraulic~~ oil during momentary depressurization at the pumpsuction and then imploded onto metal surfaces upon discharge.These implosions are extremely destructive to pump surfaces. A cavitating pump will emit a high-pitched whine or scream. Causes of cavitation are the same as those of aeration with the exception of suction side air leaks. How do you discern aeration from cavitation? One way is to install a vacuum gage on the suction side and make sure the pressure is equal too or greater than that prescribed by the pump manufacturer. Foaming in the reservoir is usually the telltale sign of aeration.		7. Listen to the pump for the signs of cavitation. Cavitation is slightly more complicated than aeration, but bares somesimilarities. Cavitation occurs when air is released from the hydraulic oil during momentary depressurization at the pumpsuction and then imploded onto metal surfaces upon discharge.These implosions are extremely destructive to pump surfaces. A cavitating pump will emit a high-pitched whine or scream. Causes of cavitation are the same as those of aeration with the exception of suction side air leaks. How do you discern aeration from cavitation? One way is to install a vacuum gage on the suction side and make sure the pressure is equal too or greater than that prescribed by the pump manufacturer. Foaming in the reservoir is usually the telltale sign of aeration.
	8. Inspect a small sample of fluid for color, signs ofcontamination and odor. Keep in mind that visual inspectionis limited in that it will only detect signs of excess contamination.		8. Inspect a small sample of fluid for color, signs ofcontamination and odor. Keep in mind that visual inspectionis limited in that it will only detect signs of excess contamination.
	9. Scan electrically controlled servo valves with an infraredthermometer. High valve and solenoid temperatures(over 150ºF) usually indicate the valve is sticking.		9. Scan electrically controlled servo valves with an infraredthermometer. High valve and solenoid temperatures(over 150ºF) usually indicate the valve is sticking.
	10. Scan the electric drive motor with for housing hot spots and rotor bearing temperatures using an infrared thermometer.		10. Scan the electric drive motor with for housing hot spots and rotor bearing temperatures using an infrared thermometer.

	==Mechanical System Maintenance==		==Mechanical System Maintenance==