Proven ways to keep your equipment
running longer, smoother, safer.
Preventative Maintenance Programs are designed to eliminate costly
EMERGENCY Breakdowns, improving reliability and lowering maintenance
costs. Reliability Programs are pre-scheduled, routine maintenance.
The needed maintenance work is accomplished during normal equipment
down time (weekends, holidays, swing shifts, etc.)
Stuart M. Davis, Inc. can immediately start your Preventative Maintenance
Program, plus with an “in-house”, staff Tribologist,
your lubricants can be quickly and accurately analyzed.
Get started NOW! Call or email us now. (Click here for our contact
page).
The following 3, 6, 12, 18 and 24 month Preventative Maintenance
Program is specifically designed for critical hydraulic systems,
however the overall objective can be achieved with electrical and
pneumatically powered equipment also.
THREE (3) MONTH INTERVAL
1. Fluid Sampling
1.1. Install fluid sampling valve in the return
line, upstream of the return line filter.
1.2. Fluid sampling:
(link to Oil Analysis Page) use a trending analysis approach
(link here to the Fluid Analysis Page)
1.2.1. Take a sample of
new, clean oil
1.2.2. Use this report as your oil “baseline”
1.2.2.1.
Select your “go – no go” levels of:
Silica
Water
T.A.N (acid)
Additives
Metals
I.S.O. Cleanliness Levels
1.3. Check filter placement and
sizing. (link to Filtration Page) Filters should provide a minimum
of 800 hours
operation under
normal conditions. This is assuming the system
was flushed prior to start-up,
Beta 3 > 200 inline filter elements have been
used, and an effective Beta 1 > 200 air breather
is used. Once the oil is clean, except for maintenance,
contamination levels should remain consistent.
2. Clean the equipment, put it into full
service and check for leaks.
2.1. Look for such things as broken
fittings, loose connections,
blocked oil passages in motors, and broken gauges. Repair as
needed.
2.2. List location of leaks, damaged or broken parts and the
general operating condition of the equipment.
2.3. Check the
condition and settings of the pressure and temperature gauges.
This is important for troubleshooting,
to insure the hydraulic
system is operating properly.
2.4. Check the cooling fan
assemblies in the electric motor
2.5. Check the control valves
for leaks at the sealing joints, including subplates and end
caps where control shafts connect
to valve bodies.
2.6. Note anything unusual, listen for
strange noises and locate their source.
2.7. In general, see if
the equipment is operating at its design specifications.
3. Hose, Tubing and Fittings.
3.1. Look for cracking or signs of
aging like brittleness. This is a sign that the hose has been
in service too long or the area near
the hose is too hot. If the operating temperatures of the equipment
/ environment is too high, an upgraded class of hoses should
be considered.
3.2. Check the hose fittings for damage and leaks
3.3. In case
of metal tubing, look for crimping or other mechanical damage.
3.4.
Make sure that the tubing and hose runs follow standard installation
practices.
3.5. For hoses, tubing and fittings, make sure that
they have enough clearance to prevent chaffing on other parts.
3.6.
For repairing or replacing the damaged hoses, tubing and fittings,
check if they can be protected by rerouting
or moving
out of the
way.
3.6.1. Many leaks occur because clearance problems
allow them to hit or rub against something else.
SIX (6) MONTH INTERVALS (in addition to the
3-month interval inspection above):
1. Motors, pumps, coupling condition and alignment:
1.1. Make
alignment and electrical checks. Observe coupling condition and
measure alignment per manufacturers recommendations.
1.2. Check the hold-down bolts and the feet of the motor to make
certain they are in good condition and free of cracks.
1.2.1.
The bolts should be in place and properly torqued.
TWELVE (12) MONTH INTERVALS (in addition to the 3 & 6-month
interval inspections above):
1. Reservoir Maintenance:
1.1. Completely clean fluid, wipe
out with lint free rags.
1.2. Inspect internal baffles and repair
if needed.
1.3. Inspect, clean, and repair or replace everything
inside the tanks before reinstalling the tank lids.
1.4. Clean the
sealing surfaces and replace the seals or gaskets around the lids.
1.5.
Avoid reintroducing new dirt into the reservoir before closing
it up.
1.6. Drain and clean connecting equipment, hoses, lines
and fittings.
1.7. Perform a pressure and flow test
on the water-cooled heat exchanger to check for tube fouling.
1.7.1.
Send out for repairs if needed
1.7.2. Air / Oil Cooler? Back blow
all baffles as needed.
Get started NOW! Call or email us now. (Click here for our contact
page).
TWENTY FOUR (24) MONTH INTERVALS (in addition to the 3, 6 & 12
month interval inspections above):
1. Major component maintenance:
1.1. Pump maintenance
- Check the pump(s) for leaks, broken and
/ or damaged fittings.
- The pump rotating group can be rebuilt
in place and may of the seals can be replaced without removing
the unit from its mounting.
- However, the 24-month overhaul is best
completed upon a bench, with a complete new seal kit.
1.2. Valve
maintenance
- Dirty oil is the most common cause of valve failure.
- After
disassembling the valve, clean and inspect it.
- Replace wear parts,
which include springs, seals and those parts recommended
by the manufacturer.
1.3. Actuator maintenance
- Look for leaks, broken or damaged fittings,
damaged body parts, misalignment and chaffing.
- Leaks usually
occur at shaft seals and sealing surfaces.
- Many seal leaks are
caused by dried out seals or seals damaged by a dirty work
environment.
1.4.
Electric Motor maintenance
- Checking should include visual inspection,
vibration analysis, current measurement and temperature
monitoring on the frame and
bearings.
- Since the majority of electrical failures are mechanical,
it is important that the fits of the bearing journals
and housing should
be measured.
- The frame and shaft should be free of cracks or
areas weakened by corrosion.
- The straightness of the shaft and
balance of the rotor also affect performance.
- Electrical tests
should be carried out by an electrical apparatus service
center.
- Tests should include winding inspection, ground inspection,
condition of winding coils, and squirrel cage rotor inspection.
- The current
in an AC motor increases with load, but the no-load point
varies from 20 to 70% of full load current
in different
motor designs; slow speed and low HP motors
have higher no-load current.
- It is important to obtain the manufacturer’s
values before attempting measurements.
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