WEAR GENERATES

WEAR 

 

  Clean your oil with our ultra-fine filtration systems, protect your machine

CONSTRUCTION MACHINES HYDRAULIC OIL FILTRATION SYSTEMS

- Hydraulic Oil Filtration

- Engine Oil Filtration

- Differential-Hub Oil Filtration

- Fuel Filtration Systems

 

 

Construction machines are off-road equipment that operate in dusty environment, under very high pressures. Pumps, valves and cylinders are critical equipment that are vulnerable to fine dust particles.

As they are mobile machines, oil reservoirs are limited capacity (min appr. 200 liters) compared to flow rates (450 liters/min) they are subject to. Therefore filtration system must cope with rate of contamination. To cope with high flow rates, filters can not be finer than 10 microns.

On the other hand, particle contamination is analysed by considering particles at the ranges of 4-5-14 microns (ISO4406) and 5-15 microns, 15-25 micron ranges (NAS1638-Later AS4059).

As OEM filters collect particles over 10 micron, oil analysis for particles under 10 microns will give high contamination level which determines oil contamination level. These levels exceed limit values specified by equipment manufacturers (pump-valve etc).

So, oil is to be drained earlier than the oil can withstand; i.e. before its service life is totally depleted. Otherwise, fine particles under 10 micron will penetrate narrrow clearances and cause wear and failure.

Hydraulic oil on railways rail maintenance machine; same oil filtered on our ultra fine filters. PArticles under 10 micron are not visible to human eye.
 

IMPORTANT: 

1- New Oil IS NOT Clean; New oil from drum is generally dirty at NAS 9-10 (at pump and valve contamination limit). Manufacturers and hydraulic experts advise their customers/end users to filter oil with a 2-3 micron filter before filling the system. Dirty oil beyond manufacturers' reccommendations will terminate product warranty

2- You can not drain all the oil from system: In hydraulic systems, considerable part of the oil will stay in the system (cylinders, hoses and tubing). Remaining dirty oil will mix with new oil which is not already as clean as specified.

 

  YOUR ADVANTAGES  

- Hydraulic oil life  will be extender (because the oil is usually drained due to contamination before it is depleted chemically/physically)

- OEM filter element life will be increased 3-4 times (fine filters will keep the oil ultra clean all the time which will reduce contaminant load of the OEM filters.

- Hydraulic system failures will be drastically reduced (80% of the system/pump failures are due to contamination)

- Wear on bearings, pumps, valves and cylinders will be minimised.

Oil sample on the left is used oil that was analysed and found NAS10 dirty; same oil filtered give NAS8 value, 75% cleaner. Oil that is clear in appearance may be dirty and unacceptable to equipment manufacturers.
 

 

 

 

HYDRAULIC OIL FILTRATION SYSTEM APPLICATIONS IN CONSTRUCTION MACHINES

         
On-Board By-Pass Application Filtration Buggy

Filtration buggies can be used to clean the oil while it is in the machine's tank; it is used as a flushing filter when any problem occurs in hydraulic system. 

This application is also necesary when filling new oil into the tank.

Unit can also be used to clean drained or spilled ois after any hydraulic system failure. Unit can be equipped with a water separator filter to dry emulsified oil.

Left sample: Oil on 1400 hours on a JCB excavator;  sample on the right shows oil on 5000 hours on an HMK220LC excavator with 2 micron by-pass filter installed on-board. Oil analysis on HMK220 showed oil to be maintained at NAS7 level clean even after 5000 hours. TAN and viscosity wee within usable limits. OEM filter were NOT CHANGED and by-pass filters were changed every 1000 hours.

On the left, oil sample on 250 hours on an HKM220LC excavator working as a breaker in a tunnel. 3 of these machines had piston pump failure and had to be replaced. 2 micron by-pass filters were installed on 3 of them and oil sample was as seen on the top right after 2 weeks. The oil is already cleaner than new oil just by judging from clarity.

 Filterin hydraulic oil in the oil tank: As the oil is delivered into the same tank after filter, you need to run the oil through the filter untill at least 7 times the oil capacity has been passed thru the filter. FOR EXAMPLE: For a machine with 200 liters oil capacity, you must filter the oil until 1400 liters of oil has been filtered, to assure that all of the oil has been cleaned at least once.

REMEMBER: 25-35% of the oil remains in the system, this oil will remain unfiltered. You can operate the hydraulic system for a while when you perform filtration with the buggy.

ON-LINE application will guaranty oil cleanliness at all times since the oil will be finely filtered as long as the machine is operating. This will assure thorough cleaning of the hydraulic system and components elimiating any risk of system falure and wear.

ADVATAGES OF ON-BOARD BY-PASS APPLICATION

- Oil life will be extended up to at least 5000 hours. Oil will withstand at least 6000-8000 hours according to oil producers' type test results. You have to drain oil because on-boear OEM filters are 10 micron or coarser. Particles at sizes under under 10 micron (4-6-14 micron for ISO4406 and 5-15-25 micron for NAS1638 Standards) increase contamination and finally cause the oil to become dirty over equipment manufacturers's specifications which affects product waranty.

 - OEM filtre element life will be 3-4 times longer as the fine by-pass filter elements pick up contaminants. By-pass filter elements can be changed every 1000-1500 hours, OEM filters can be replaced when draining oil.

- Hydraulic system/pumps failures and wear wil be minimised. Field surveys show that 75-80% of the hydraulic system/pump failures are due to particle contamination.

- Machine down-times will be reduced since oil drain periods are extended and failures are minimised. Waste and maintenance expenses, labor expenses will be minimised.

CONSTRUCTION MACHINES: DIFFERENTIAL AND HUB OIL FILTRATION

Gears are in metal to metal contact to transfer loads. Oil cleanliness is crusial since wear-out metal and dust particles accelerate wear. Contamination in gear oil consists of very fine particles which requires filtration with ultra fine filters. 

It is advisable to filter the oil while it is warm, or you may need to preheat the oil.

Our filtration buggies can be equipped with water separator and heater as well as fine filters.

 

CONSTRUCTION MACHINES: ENGINE OIL FILTRATION

Construction machines work in dusty areas ans oil and fuel systems are exposed to fine dust particles.

Wear-out metals and ambient dust in engine oil accelerates wear on cylinder rings and liners, and crank-shaft and cam-shaft bearings. As the engine wear out, oil gets thicker and gets hot, it forms more soot and oil deterioration accelerates (low TBN value).