BLOG: On The Level

[#1]

The tight tolerances of today’s machines mean even the smallest particles can cause big problems with internal wear and tear. Cleanliness really does pay, because it prevents unnecessary failures and increases uptime. Follow these tips to help control contamination around your shop and when working on equipment:

1. Keep work areas neat and clean.
   Dirty floors and cluttered work areas breed contamination. Sweep the floor at least once a day.

1. Clean up spills promptly.
   Use absorbent pads if possible since granular cleaning methods may pollute the air with contaminants.

1. Cap or plug hoses properly.
   Cutting hoses creates a significant amount of debris. After properly cleaning assembled hoses with a high-pressure device like a hose cleaner, seal the ends with correct-sized caps or plugs.

1. Protect your parts.
   Parts in storage are sitting targets for airborne contaminants. Keep parts in their original packaging until it’s time for installation.

1. Check components before installation.
   Installing dirty parts is a sure way to contaminate a system. Use filtered parts washers and proper methods to clean components.

1. Store fluids properly.
   Keep oil barrels inside and use tight-fitting covers to protect the barrel tops from dirt and moisture.
   
   Watch this video with Caterpillar Preventive Maintenance Instructor, Jeff Payne, for more tips on proper bulk storage.

1. Filter new fluids.
   Even fluids fresh from the barrel can contain microscopic particles. Always filter new fluids before using to meet cleanliness targets.

1. Protect machine openings.
   Use covers, tape or plastic to seal openings and protect the inner workings.

1. Use advanced high-efficiency filters.
   Good filters are cheap insurance to keep fuels and other fluids clean.

1. Protect “works in progress.”
   When work is interrupted, cover components to keep them clean until work is resumed.

1. Count particles.
   Conduct regular fluid sampling and analysis to monitor the cleanliness of the fluids and record the results to track ongoing changes to the condition.

1. Put someone in charge.
   Make ongoing contamination control an assigned responsibility. Choose someone with authority, and hold that person accountable for results.

What did I miss? Do you take additional precautions to prevent fluid contamination? Please share your comments below.

[#2]

Another thing to keep in mind is that o-rings that have been sitting out in the elements can contaminate as well, so I would recommend buying some small sealable, zip lock bags to store them in.  Also, Greg mentioned capping and pluging hoses, but you should also cap and plug any hydraulic fittings you have as they will get dirt and dust in them fairly quickly especially if you install temporarily and remove them for specific applications.....this is to include re-usable hose couplings, hydraulic adapters, etc.  I know this may seem like common sense stuff, but sometimes I find the most obvious things are the ones we miss the most.

[#3]

Three points of the tips I would like to comment on.  I agree with some of the 12 Tips but ask you self this question?  How often would you want your operator/on site mechanic to open up your hydraulic systems and take the risk of contamination from this?

1.  What is the purpose of the filters in this system.?  Is it not to filter the dirt out of the oil?  I think the manufactures of pumps, valves and cylinders need to use better metalurgical materials to withstand some contamination.  The foriegn manufactueres do not understand metalurgical engineering very well. 

2.  Have you heard about Eaton's smart hoses?  They detect when hydraulic lines are about to burst.  This is a significant improvement that was designed from Purdue University's Ag Engineering Dept and Prof Kurtz.  Your Cat Engineers are just now checking out this new design. 

3The industry should ship barrels of oil with spouts on them.  They are making too much off the high price of oil