Hydraulic systems of industrial equipment
Hydraulic systems of industrial equipment, vehicles and special-purpose machinery are subject to treatment. The purpose is to restore and protect hydraulic drive components against wear without replacing the working fluid and without disassembly.
Procedure for treating hydraulic systems of industrial equipment with XADO revitalizant gel
What is treated
- Hydraulic systems of industrial equipment, vehicles and special-purpose machinery that have no assemblies or mechanisms with ultimate mechanical wear or macromechanical damage.
- New hydraulic machines or hydraulic machines with initial wear (up to 10%) — treatment is carried out according to this same procedure in 4 stages at the same consumption rate of XADO revitalizant gel.
When treatment is not performed
- Hydraulic systems having assemblies and mechanisms with ultimate mechanical wear and macromechanical damage are not subject to treatment.
Preparation
- Before starting the treatment, eliminate working fluid leaks.
- Before starting the treatment, take measurements of the main operating parameters of the hydraulic system (clause 7.3).
- Prepare the revitalizant gel in the amount required for one treatment stage.
- Pour the hydraulic system working fluid, heated to 40 - 60°C, into a separate container at a ratio of 1 part of the gel being dissolved to 5 - 10 parts of oil.
- Mix the composition thoroughly until a homogeneous mixture is obtained and add it into the working fluid tank.
What is measured before and after
| Parameter | Instrument | How and when |
|---|---|---|
| Pressure in the hydraulic system | Pressure gauge calibrated under the State Standard system | At a fixed working fluid temperature; before the start of the treatment and after completion of the full cycle. |
| Operating temperature of the oil (hydraulic fluid) in the hydraulic system | Liquid-in-glass thermometer, infrared pyrometer or other standard temperature measuring instrument | Before the start of the treatment and after completion of the full treatment cycle. |
| Output (delivery) of the hydraulic pumps | Flow meters | At a fixed pressure and working fluid temperature. |
| Volume of working fluid leakage during hydraulic motor operation over a fixed period of time | Measuring vessel with a graduated scale | At a fixed pressure and constant working fluid temperature at the hydraulic motor outlet. |
| Vibration level of the hydraulic machine | Vibration meter | At specified points under fixed hydraulic system operating modes. |
| Output of the hydraulic pumps of power hydraulic systems (indirectly — from the actuation speed of the power mechanism) | Measurement of the time of fixed travel of the power hydraulic cylinders | At constant pressure and operating oil temperature. |
| Hydraulic tightness of the directional control valves (indirectly) | Comparison of the amount of travel of a loaded serviceable power hydraulic cylinder | With the directional control valve spool in the neutral position and the valves in the hydraulic system in serviceable condition. |
| Other characteristics of the hydraulic drive | — | Measured as required. |
Dosage rates
| Compound | Rate | How and when |
|---|---|---|
| XADO revitalizant gel for power steering (industrial) | 0.6 ml of gel per 1 litre of working fluid | Per one treatment stage; 6 stages in total without oil replacement. |
| Hydraulic system working fluid for preliminary dilution of the gel | 1 part of the gel being dissolved to 5 - 10 parts of oil | Heat the fluid to 40 - 60°C. |
Treatment stages
- Prepare the gel at a rate of 0.6 ml per 1 litre of working fluid, dilute it in working fluid heated to 40 - 60°C (1 part of gel to 5 - 10 parts of oil), mix until homogeneous and add into the tank. Switch on the hydraulic system and provide a pressure load of up to 50% of the maximum permissible value.1 - 2 hours at a load of up to 50% of the maximum permissible value, then operation at rated load in the standard mode
- Adding the next portion of gel in the same way as in the first stage, at the standard load of the hydraulic drive.After 8-12 hours of total hydraulic system operation following the previous stage
- Adding the next portion of gel in the same way as in the first stage, at the standard load of the hydraulic drive.After 8-12 hours of total hydraulic system operation following the previous stage
- Adding the next portion of gel in the same way as in the first stage, at the standard load of the hydraulic drive.After 8-12 hours of total hydraulic system operation following the previous stage
- Adding the next portion of gel in the same way as in the first stage, at the standard load of the hydraulic drive.After 8-12 hours of total hydraulic system operation following the previous stage
- Adding the next portion of gel in the same way as in the first stage, at the standard load of the hydraulic drive.After 8-12 hours of total hydraulic system operation following the previous stage; the full treatment cycle is 550 hours of total operating time
After treatment
- After completion of the full treatment cycle, take measurements of the main operating parameters of the hydraulic system in accordance with clause 7.3 and compare them with the initial values to determine the effectiveness of the XADO compositions.
- The following are recorded: pressure in the hydraulic system, operating temperature of the oil (hydraulic fluid), output (delivery) of the hydraulic pumps, volume of working fluid leakage during hydraulic motor operation, vibration level of the hydraulic machine, time of fixed travel of the power hydraulic cylinders, hydraulic tightness of the directional control valves.
Points to watch
- Before starting the treatment, working fluid leaks must be eliminated.
- The treatment is carried out without oil replacement.
- To reduce the cost of treating positive-displacement hydraulic machines operating with large volumes of hydraulic fluid, it is recommended that individual components of the hydraulic system (hydraulic pumps, hydraulic motors, directional control valves) be treated individually on a special test bench according to a separate procedure (Annex 2 to these instructions).
- At the first stage the pressure load is up to 50% of the maximum permissible value.
Instruction appendices
Compounds for these units
- Revitalizant gel for hydraulic systemsHydraulic systems of industrial and special equipment, pumps, motors and valves; gearboxes with oil filtration.
Source: Instructions for the use of XADO revitalizant gels IE-24.6-25612000-005-2008, pages 14–16.