Embracing Water Hydraulics
Even the most expensive water additives become economically viable when considering that one gallon of concentrate can yield 20 gallons of usable fluid. Hence, the focus on water-based fluids often revolves around their cost-saving potential. However, designers must recognize that transitioning from oil to water cannot be done without implementing significant changes to their systems.
What may be seen as disadvantages are simply different rules applicable to Automotive Lift Repair Orlando water-based hydraulic systems. Designers might be reluctant to delve into water-based hydraulics due to the perceived complexity involved in designing new systems or retrofitting existing ones. By ignoring this alternative technology, they risk overlooking the additional advantages water-based fluids can provide, especially in light of growing environmental concerns that increase disposal costs for hydraulic fluids.
Confronting Freezing Issues
Automotive Lift Repair Orlando Water-based hydraulic systems have their limitations, with freezing being a significant concern, particularly in mobile equipment applications. Longwall mining represents the largest sector benefiting from water-based systems, as underground temperatures rarely approach freezing, and fire resistance is crucial. Although mobile and marine equipment in temperate regions could leverage the advantages of water-based systems, their use in consistently above-freezing temperatures is not guaranteed.
Reservoir Design
Most Automotive Lift Repair Orlando hydraulic systems are best served by a pressurized cylindrical reservoir, which is not widely utilized due to additional costs. A cylindrical design facilitates condensation from the top running down into the sump and allows solid contaminants to settle at the lowest point for easy removal. This shape withstands internal pressure without needing struts and stiffeners that can trap contaminants, as seen in rectangular reservoirs.
A sealed reservoir must accommodate fluctuations in fluid level while preventing air from entering and exiting repeatedly. One simple and cost-effective solution involves using a breather and two check valves with different spring rates.
In a sealed system, the fluid level rises at startup before fluid circulation occurs. As fluid exits the reservoir, air enters through the breather. After fluid returns, air cannot exit through the breather, creating a pressurized air pocket. When the fluid level rises, the air pressure can reach 3 to 5 psi, prompting air to exit through a check valve to prevent overpressure.
This pressure also serves to precharge the main pump, helping to prevent cavitation. When the fluid level decreases, the air pocket expands without drawing in additional air, leading to minimal air in the system over time.
Key Considerations for Water Hydraulics
Water-based hydraulic systems require careful design to mitigate pump cavitation risks. Important considerations include:
- Porting and Passageways: Ensure fluid velocities remain below 20 ft/sec, ideally under 15 ft/sec in pressure lines, 2 to 3 ft/sec in suction lines, and less than 5 to 10 ft/sec in return lines to avoid foaming.
Replacing a pump in an Automotive Lift Repair Orlando hydraulic system seems straightforward, right? Just unbox the pump, install it in the machine, fill the case with oil, connect the lines, and switch it on. It may sound simple, but a poorly installed hydraulic pump could lead to your customer needing a replacement before the shift ends. Most pump failures stem from external issues. Here are three critical checks to perform when commissioning a pump in a hydraulic system.
Check 1: Hydraulic Oil
Oil is essential for the hydraulic system, transmitting power, providing lubrication, cooling, and removing contaminants. Clean oil is vital to prevent breakdowns and minimize wear. Keeping track of oil service records is crucial for machine maintenance. Here are key considerations for servicing hydraulic oil:
– Inspect the filters
Changing the Automotive Lift Repair Orlando filters should be standard practice when replacing a pump. Examine both the pressure and return filters, ensuring they are replaced with appropriately rated ones. Using a filter cutter to analyze the element can help identify the types of contaminants captured and their possible sources.
– Check for water contamination
Water is detrimental to hydraulic systems, causing corrosion, accelerating wear, increasing oxidation rates, and leading to faster oil degradation. Conduct a visual inspection and examine a sample of the oil; it should be clear and not cloudy or milky. Many hydraulic systems feature a water drain at the bottom of the reservoir for removing settled water. The best method to detect water in the oil is to send a sample to an oil testing facility for analysis, or use the hot plate method: set a hot plate to 250 degrees and place a drop of oil on it. If it crackles and sputters, water is present.
– Refer to ISO cleanliness charts
Oil contamination can be assessed using ISO guidelines, which provide a series of three numbers for the oil sample that can be compared with machine records and contamination limits. This helps determine whether the oil is truly clean or just appears so. Most contaminants are invisible, so even if the oil looks clean, it could still contain harmful substances that could lead to premature pump failure.
Check 2: Pump Connections
When installing a new pump, it’s crucial to check the connections between the pump and the machine. Here are essential aspects to review:
– Mounting bracket and drive coupling
This is where the prime mover transmits mechanical power to the Automotive Lift Repair Orlando pump, converting it to hydraulic power. Inspect the mounting surface for dents, burrs, or uneven areas, as these can misalign the pump, causing uneven force and vibrations that may lead to premature bearing failure. Also, examine the coupling set on both the prime mover and pump for wear, corrosion, or damage, and replace it if necessary.
– Fittings and flanges
While replacing a pump, check the conductor connections. Replace O-rings on fittings and flanges to prevent leaks. Ensure that the inlet lines, which typically use low-pressure hoses, are free from collapse, deterioration, or leaks that can cause aeration.
– Hydraulic lines
Sometimes, mechanics use rags or plugs to prevent leakage during pump removal and replacement. Before connecting the new pump, inspect the lines for any rags, plugs, or debris that might obstruct pump flow.
– Case drain line
The Automotive Lift Repair Orlando case drain line is crucial for pumps requiring one. Any obstruction can lead to high case pressure, resulting in severe pump damage. Visually inspect the case drain line, especially if the previous pump experienced catastrophic failure. Debris can become lodged in fittings and conductors, restricting flow and causing pressure buildup. Avoid using compressed air for checking for obstructions.