as on July, 2012 - til india

Vol. - 7, Issue - 1, 2012TECHNICAL UPDATE ON CONSTRUCTION, MINING & POWER SOLUTIONSContentsPageThe Diesel Bug 4The Unsung Hero 6Extended Life Program 10Use Maintenance Management 12CAT

VISIBLYBETTERCAT® FLUIDS & FILTERS HELP YOU PROPERLY MAINTAINYOUR EQUIPMENTTIPL h<strong>as</strong> all the Cat® fluids, filters and preventive maintenance products you needto take care of your equipment. Cat Filters are manufactured to meet the most demandingengineering specs for filters — those specified by Caterpillar.Only Cat Filters provide the protection needed to give you the lowest owning and operatingcosts.Choose Cat Filters, get peace of mind.Call us to find out all the ways we can help you get themost from your equipment.Contact : Mr. Pankaj Kumar +91 98310 28004Tollfree No. : 1800 345 3356, 1800 345 3355www.tiplindia.inCAT

Dear Reader,TIPL is focused on ways to help customers’ profit grow: by providing hi-tech products from Caterpillar® deliveringquality service and helping bring every project to success. To this end, TechTrak remains another example of addingvalue to your business by recommending best practices that maximize equipment <strong>as</strong>set-life <strong>as</strong> well <strong>as</strong> profits.This issue of Techtrak covers real life stories and articles that help you derive maximum value out of your machines.The Diesel Bug story reveals interesting <strong>as</strong>pects of microbial contamination in diesel engines – its harmful impacts ofcontamination and the possible solutions. We also continue in this issue the second part of the Motor Grader storytheUnsung Hero. If properly understood, operated and used, this machine can give you maximum cost saving.Through the article on Extended Life Program (ELP)–the program TIPL recently introduced, we have offered suggestionson getting the best value out of a product and various repair options offered by us. Customers can leverage theexcellent facility of TIPL‘s 5 Star Component Rebuild Center [CRC] at Asansol with contamination free repair and<strong>as</strong>sembly workshop. The workshop maintains highest standards of quality set by Caterpillar for a trouble free reliableperformance.Also the article on Maintenance Management is a useful read. Equipment Management h<strong>as</strong> positive impacts and isthe only way you can run your machines at peak performance.I hope you find the articles helpful to guide you on machine operations and management to get the intended benefits.TECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONSWe are keen to have your feedback.G SivaramakrishnanVice President - Center of Excellence

The Diesel BugMicrobial Growth in DieselMicrobial contamination and biodegradation pose <strong>as</strong>a major problem in diesel engines which require cleanuncontaminated diesel, free from water andsuspended impurities. High pressure fuel injectionsystems in modern engines are vulnerable to fuelquality issues and hence require added protection.Wherever fuel and water come into contact in <strong>as</strong>torage or distribution system, microbialcontamination is likely to occur. No matter how wellmaintained a storage system is, a water-bottom isalmost invariably present.This results from a number of sources:l Freshly refined fuel contains some water. Thisseparates out <strong>as</strong> the fuel cools down.lAtmospheric condensation: Humidity in the air instorage tank condenses and adds to the waterbottom.Typical Microbial GrowthlRain or snow may enter the tank via sampling ports, breather vents or ill-fitting seal on floating roofs.4Water from all of these sources accumulate in the storage tank to form the water-bottom. Consequently <strong>as</strong> the water-bottomdevelops a microbial population builds up in it. Liquid hydrocarbon fuels act <strong>as</strong> an excellent nutrient source resulting in a populationexplosion: the microorganisms proliferate at the fuel/water interface, surviving in the water ph<strong>as</strong>e whilst feeding on the fuel.This gradually leads to development of sulphate reducing anaerobic organisms which inturn form corrosive w<strong>as</strong>te products such<strong>as</strong> hydrogen sulphide.Microbial Growth & its ConsequencesOnce a microbial population becomes established, fuel quality rapidly deteriorates. Problems such <strong>as</strong> Haziness, Failure to meetspecifications, Corrosion, Filter plugging and Additive degradation can occur. All of these problems are related directly to thepresence of microorganisms or their <strong>as</strong>sociated by-products.Fuel HazinessThis is a clear indication that fuel is out ofspecification. The primary cause of hazinessis an incre<strong>as</strong>e in the water content of thefuel resulting from the production ofbiosurfactants. These are by-products ofmicrobial growth and alter the surface tensionat the fuel/water interface. As a consequencethe solubility of water in the fuel is incre<strong>as</strong>ed,Samples of Contaminated & Clean Diesel Showing Fuel Hazinessthus causing diesel contamination.

Degradation of AdditivesCertain additives, especially those rich in nitrogen and/or phosphorous, encourage microbial growth. In the process theadditives are degraded and consequently their effect is lost.Microbially Induced CorrosionHydrogen sulphide is produced by sulphate reducing bacteria. Thisenters the solution and is highly corrosive, causing severe damagesto the fuel system parts and fuel injectors.Sludge FormationMicrobial debris is deposited on the tank bottom where it forms alayer of sludge. This sludge creates an environment which favorsmicrobially induced corrosion. It may also become contaminated withviable microorganisms and unless removed will act <strong>as</strong> a reservoir ofinfection every time the tank is used.Filter PluggingMicrobial Debris Forming SludgeBiopolymers are formed during microbial growth. These are gummy products, which, along with microbial and other debris,are deposited on filters and pipes leading to reduced flow rates and blockages. For an end user, this can have seriousconsequences causing engine damage and in extreme c<strong>as</strong>es complete failure.TECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONSControl of Microbial ContaminationFiltration systems are available for water separation and suspended solid particles along with a diesel conditioner that preventand control biodegradation of diesel. This system effectively controls fuel contamination and degradation problems and willnot replace the secondary filtration of engines, but will enhance its performance in all operating environment and varyingfuel quality.Bottle 1 (left): unprotected diesel from an engine fitted withstandard filtrationBottle 2 (right): Diesel protected with advanced pre filtrationand conditioning systemBenefits of diesel purification and conditioning systemllllllllllllLonger service life for fuel injection pump and injectorsHigh efficiency water and particulate removalPrevents frequently filter plugging and tank cleaningWater and particulates separate e<strong>as</strong>ily and drained offBack flushing feature for extended service lifePrevents and controls biodegradation of dieselLow flow restrictionEnhances fine filter efficiencyClean diesel enhances combustion and reduces fuel w<strong>as</strong>tageEngines run better with less smokeIncre<strong>as</strong>ed safety and reliabilitySimple maintenanceTo know more contactDr. Deb<strong>as</strong>ish Mukherjeedeb<strong>as</strong>ish.mukherjee@tiplindia.comContributed byG SivaramakrishnanVice President-Center of Excellence

The Unsung HeroCat ® Motor Grader - Part IIMotor Graders are very versatile and mostly used in building roads from start tofinish, from close tolerance to finish grading. A high percentage of Motor Gradersare used in road maintenance, repair and rebuilding work on provincial and townshiproads. In our previous issue we discussed about the relevant terms and modes ofoperation that are commonly used while operating a Motor Grader. In this article,we will share the best practices for maintenance, clearing, building city townshiptype roads. This includes smoothing, shaping the travel surface, and providingdrainage to prevent road deterioration in inclement weather.6Road Maintenance TipsThe best time to dress a road is when moisture is present:after a rain or after the road h<strong>as</strong> been sprayed by a waterwagon. Maintain straight cutting edges by trimming themwith a torch or, if wear is not severe, by dragging thecutting edges on a smooth concrete surface. Replace edgesbefore wear occurs on the bottom of the moldboard andreduces cutting edge support. Drag the surface when hardand dry, with the cutting edge near 90 degrees to thesurface. Cut to the depth of major potholes and don't fillthese holes with loose dry material, because traffic willquickly displace the loose material and the holes will reappear.Maintenance work is normally done with the centershiftlock pin in the center position, and the drawbar and circlecentered under the mainframe. For maximum machinestability, the mainframe should be straight or articulatedslightly. Articulating the rear frame toward the toe of themoldboard approximately 2 to 5 degrees (1 to 1.5 timesthe width of the tire) will frequently help reduce themachine's tendency to bounce. Start with the moldboardtop 2 inches (5.1 centimeters) ahead of the cutting edge.Then adjust to the material and conditions. Use of full reartip could cause material penetration problems and damagethe moldboard bottom or pivot area, especially if the cuttingedges are worn.Use only enough down pressure to accomplish the t<strong>as</strong>k.Excessive down pressure on a hard dry surface causesrapid cutting edge wear, requires more horsepower andfuel and reduces productivity. Sliding and tire spinningincre<strong>as</strong>e front and rear tire wear. In extreme c<strong>as</strong>es,excessive down pressure may cause the cutting edges tosplinter causing tire damage.In road maintenance, cutting edges will wear quicker inthe center than at the ends. Three section edges aresometimes used: carbide edges in the center, hardenededges at the ends. Check edge wear frequently to preventmoldboard damage..To Extend Cutting Edge Life in RoadMaintenance, Maintain a Constant TipPositionSide View of moldboard cutting edge1. FootprintThe cutting edge tip angle can affect cutting edge lifewhen maintaining roads. The tip angle should position thecutting edge at 90 degrees to the road surface. In thisposition, down pressure on the moldboard places less stresson the cutting edge and retaining bolts. The edges willhave a tendency to ride over objects possibly preventingmachine damage.The fixed tip angle presents a constant edge thickness tothe wear surface for longer life. If you change the tip angleoften in this application, the sharpened edge will wearquickly, shortening its life.

Cross section of moldboard cutting edge1. M Section Reinforcement 2. Slide Rails 3. Cutting EdgeNew moldboards are designed to give support to cuttingedges. To maintain this support, the edges must be replacedbefore wear occurs on the bottom edge of the moldboard(shown in grey at bottom of above illustration). Wear in thisarea reduces cutting edge support. Bent ends of themoldboard also reduce edge support. Repair damage beforeinstalling new edges. Cutting edges have good support in theforward direction, but use caution when back-draggingmaterial or backing up with the moldboard close to the ground.For long life in road maintenance, use the thickest edges thatallow you to do the job. In hard material if you use excessivedown pressure, the machine's front end appears light. Ifpenetration is a problem use thinner cutting edges, a serratededge or a scarifier to loosen the material.Cutting edges with carbide tipped replaceable teeth areoffered by several manufacturers. They generally give longerlife than standard hardened edges. The Cat GraderBitsSystem provides four types of tips: Standard, Wide,Penetration and Sharp. The teeth can be individually replacedor repositioned for wear. They can be placed in a solid orserrated configuration depending on job needs.Wide bitStandard bits are used on larger units where penetrationis not a problem but the material is abr<strong>as</strong>ive.Wide bits are used on each end of the standard arrangement.Use of all wide bits supplies a continuous edge. (Note widebit in photo.)Penetration bits are used on mid sized Graders and wherepenetration is a problem.Sharp bits are used on smaller Motor Graders and wherepenetration is a problem. Bit types can be mixed to customizethe edge to material or conditions. Cutting edge condition isvery important for keeping the proper road profile. Cuttingedges constitute major expense in this application, so checktheir condition frequently.Know Your Job’s Cutting EdgeRequirements and Select the ProperType for Your ConditionsFor the best machine stability in road maintenance, use thewidest possible p<strong>as</strong>s width. Keep the moldboard angle <strong>as</strong>square to the frame <strong>as</strong> possible. If material starts to flowaround the leading end of the moldboard, incre<strong>as</strong>e the bladeangle. Keep machine travel speed <strong>as</strong> high <strong>as</strong> possible formaximum productivity but low enough to prevent machinebounce. The cutting width of a p<strong>as</strong>s will depend on the lengthof the moldboard and the moldboard angle used. The chartbelow shows the width of coverage for different lengthmoldboards and several blade angles.TECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONSMOLDBOARD LENGTH12Feet 14 Feet 16 Feet3.7 meters 4.3 meters 4.9 meters30o blade angle 10.3 ft 12.25 ft 13.7 ft3.1 m 3.7 m 4.2 m45o blade angle 8.5 ft 9.9 ft 11.3 ft2.6 m 3 m 3.4 m

Four p<strong>as</strong>ses are normally required to maintain a 28-ft. (8.5-meters) wide road (24-ft. [7.3 meters] wide traffic laneswith 2-ft. [0.6 meters] shoulders). In this application, onwider roads, blade extensions are frequently used on oneor both ends of the moldboard to incre<strong>as</strong>e p<strong>as</strong>s width andreduce the number of machine p<strong>as</strong>ses required. Theseextensions are of lighter construction than the parentmoldboard.8Moldboard fitted with blade extensionsWhen backsloping, the extension must be installed on thetoe to obtain the heel clearance required.CAUTION: Using it on the leading end in tough or rockymaterial may damage the extension.When two extensions are installed, they should be used onlyin light maintenance work and will need to be removed forsome jobs, <strong>as</strong> their length restricts blade positioning. Inrocky are<strong>as</strong> where control of the moldboard is desirable butthere is a need to reduce vertical stress into the drawbar,circle and main frame, use a blade cushion arrangement forreduced maintenance and longer circle and drawbarcomponent life. An important feature in snow plowing orother high impact are<strong>as</strong> is the circle slip clutch. It will relievehorizontal impacts on the moldboard and circle and canreduce maintenance costs.Maintaining Road and Existing Ditchesand ShouldersFor maximum machine stability when maintaining the travelsurface, the Motor Grader's main frame should be straightwith the drawbar and circle centered under the frame. Forthe widest possible p<strong>as</strong>s width on the travel surface, keepthe moldboard angle <strong>as</strong> square to the frame <strong>as</strong> possible. Ifmaterial starts to flow around the leading end of themoldboard, or the rolling action dies, incre<strong>as</strong>e the bladeangle. Keep machine travel speed <strong>as</strong> high <strong>as</strong> possible formaximum productivity but low enough to prevent machinebounce (4-7 mph [6-11 km/h]). On straight sections, steerthe machine <strong>as</strong> straight <strong>as</strong> possible to maintain a straightshoulder and uniform crown to the road.Aerial view of articulating rear frame toward toe of moldboardArticulating the rear frame toward the toe of the moldboard2 to 5 degrees frequently reduces the machine's tendencyto bounce. This crab mode is extremely effective whencutting w<strong>as</strong>hboards from the travel surface with themoldboard. When the Motor Grader is in the crab mode, thefront axle is no longer running perpendicular to the directionof travel. This places one front tire slightly ahead of theother and allows one tire to be on top of a corrugation whilethe other is at the bottom. As the tires roll up and downthrough the w<strong>as</strong>hboard, the front axle will pivot up anddown keeping the front mainframe stable. The degree ofarticulation required to make this technique work effectivelywill vary with the space between corrugations.CAUTION: Do not use the crab mode when scarifyingw<strong>as</strong>hboarded are<strong>as</strong>. Crab mode could bend the scarifiershanks and/or linkage.Regular traffic forces the shoulders to mushroom aroundwhen roads are soft, widening the road. Ditches may requirecleaning to restore drainage <strong>as</strong> gravels fall off the road onto road shoulder and ditch slope. Spring road maintenancenormally includes repairing these problems.Use straight or articulated frame for this work.Cleaning Ditches using Linkbar & Drawbar Operations

Two modes of operations are:1. Move the linkbar to its maximum position toward theditch. Side shift the drawbar to its maximum position.With the frame in straight mode, position the Motor Graderon the road shoulder. Circle the moldboard and side shiftit to obtain the desired blade angle and desired reach intothe ditch. Raise the heel of the moldboard to match theditch slope angle. Move the material up onto the roadshoulder or onto the ditch slope <strong>as</strong> desired. When theshoulders are soft, using articulation to offset the heavyrear frame away from the shoulder will prevent ruttingand trap water that cause shoulder damage.Re-opening culvert with Crab SteerMove slowly forward to remove the blocking material,then rotate the circle to pull the material up onto the roadshoulder. Several short forward-reverse p<strong>as</strong>ses may berequired to reach the bottom of the culvert. Continue onusing one of the ditch cleaning techniques describedpreviously. In shallow ditches, this operation can also beaccomplished with the machine on the road travel surfaceand the frame straight. It is very important to maintainthe proper road crown for drainage. In many c<strong>as</strong>es whilemaintaining the road surface, operators will cut below theexisting shoulders leaving a ridge on each side of the road.In other are<strong>as</strong> a windrow of material is left on the roadshoulder so material is available for the next maintainingp<strong>as</strong>s. Both of these have undesirable effects like theyblock drainage by holding water on the shoulder causingit to become soft.TECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONSCleaning Ditches using Crab Steer mode2. Using crab steer will allow running one front wheelin the road ditch or on the road shoulder slope to recovermaterial moved there by traffic or snow plowing. Use crabsteer to narrow shoulders, to maintain the desired roadwidth, and to clean wet ditches. The rear tandems canbe kept on the road travel surface away from the shoulder.Extend the blade into the ditch to open a drainage path.This reduces standing water and possible road damage.Crab steer can be used to reopen culverts blocked bymaterial. If the ditch bottom is solid, place the front wheelsin the ditch with the rear frame on the road travel surface.Shift the circle toward the toe of moldboard, with themoldboard square to the mainframe and tipped to nearlytwo-thirds of its maximum forward tip capability. Placethe moldboard cutting edge into the ditch at the blockedend of the culvert, and set the blade angle to match theshoulder slope. Be careful not to damage the end ofculvert.1. Shoulder Undercut, 2. Shoulder WindrowNOTEThe windrow of material should be processed andspread across the road evenly with only the oversizerocks or chunks of sod to kick over the slope.Source:Cat ® Motor Grader Application Guide

Extended Life Program (ELP)Earn profit from extended equipment life10The Indian Mining Industry h<strong>as</strong> traditionally used machines fora life span of 7-10 years or 30,000 hours of operation, dependingupon the machine’s capacity and the depreciation cost. Theaverage utilization across public and private sectors especiallyfor the lower capacity mining trucks have been around 40% ofthe scheduled hours. Thus the major structures of these equipmentdo not experience the stress cycles that are common to highutilization, leaving a scope for machine rebuild and extended lifefor additional periods of operation.In the present scenario, the growth in mining industry h<strong>as</strong> causeda rise in the market demand for new machines which is not beingmet due to demand supply gaps from the manufacturers. Thusmining companies in public and private sectors both face achallenge to meet up to their production plans and are exploringoptions that can keep their old machines available and productiveat minimum costs.To support the customers and their production plans, TIPL cameup with the “Extended Life Program” (ELP) to rebuild the machinesfor an additional period of 30,000 hours at a re<strong>as</strong>onable cost.Backed by years of experience, TIPL h<strong>as</strong> all the resources such<strong>as</strong> the 5 star Component Rebuild Center (CRC) at Asansol inWest Bengal to refurbish the machines ensuring quality andtimelines demanded by customers.TIPL CRC - Asansol

Once a machine for rebuild is received at the CRC, theprocess starts through cleaning of the equipment in orderto remove every bit of dirt, gre<strong>as</strong>e, sludge, oil etc. Thisprocess is then followed by complete dismantling of theimplements and checking through specialized instrumentsto <strong>as</strong>certain the reusability of parts and components. Aftera component is repaired, CRC provides the facility of testingthe performance of the component <strong>as</strong> per Cat specification.Some of the multiple values customers derive through ELP, are highlighted below:llllLower cost of repair vis-à-vis capital costAvailability and production being equitable with that of a machine rebuilt through ELP enables achievement of productiontarget <strong>as</strong> per scheduleFor specific models, the cycle of machine repair is far less than new equipment delivery lead timeExtended life of costly machine to achieve lower cost per ton of productionTECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONSTIPL’s Extended Life Program – a solution from TIPL which h<strong>as</strong> addressed the demand supply gap and customer productiongrowth enhancing customer loyalty.Contributed byBiswajit MukherjeeHead - West Bengal & Sikkim - Territory E<strong>as</strong>t - TIPL

Use Maintenance ManagementRun your machines at peak performance12Equipment management is the only wayyou can keep your machines running atpeak performance. It helps you makemaintenance decisions, reduce owningand operating costs and maximizecomponent life.As a Cat ® dealer we have beencontinuously providing value - b<strong>as</strong>edinformation to our customers. Theseinclude equipment management processthat h<strong>as</strong> positive impact and improvesoverall business profitability.An efficient equipment maintenancemanagement process will schedule theentire repair cycle of various systems andcomponents on the equipment along withthe filter and oil changes at appropriatehours. Maximizing component life wouldmean ensuring a contaminant free systemand checking the contaminants in betweenoil changes especially if the intervalsexceed 1000 hours.Scheduled Oil Sampling (S O S SM ) willl lidentify and provide early warnings ondefects arising inside major components.S O S SMis a highly essential monitoringl ltool for aligning with Repair Before Failureconcept and ensuring designed componentlife and managing <strong>as</strong>sociated coststhereof. Machine system audits atscheduled intervals will help in correctingthe minor problems before they becomemajor. It also indicates the actualcomponent change on overhaul timelinesand ensures that maintenance costs donot exceed budgets; thus controlling lifecycle costs. It also tracks individualcomponent life irrespective of machineclocked hours, b<strong>as</strong>ed on the monitoringof the component during each componentchangeout (component tracking).TIPL offers a host of such supportagreements to choose from, of whichS O S SM condition monitoring and machinel lsystem audits being critical to machineperformance at lowest costs.While walk-arounds before every shift areimportant, they don't let you see insideof your engine. Regular fluid analysis doesgive you that glimpse inside, so you notonly avoid failures but also find problemsearly to keep repair costs low. Torecognize the value of regular fluidanalysis, you need only consider two facts:l80% of hydraulic system failures aredue to contamination.l50% of engine problems are linked tocooling system faults.Cat S O S SMServices is a good idea forl lcompetitive <strong>as</strong> well <strong>as</strong> Cat machines,helping you manage downtime moreeffectively. Regular S O S SMsamplingl lindicates trends so you can schedulerepairs with a minimum loss of production.There are primarily four types of S O S ltesting and possible causes of problems.1. Wear Rate AnalysisIn EngineslSMSilicon - air induction system/filter dirtcontamination.Iron - abnormal operating temperatures,oil degradation, rust, broken rings, lackof lubrication.Chrome - blowby, oil consumption ordegradation.Lead - lack of lubrication, coolant or fuelcontamination.In HydraulicsSilicon - dirt contamination.Copper - oil degradation, contamination.In TransmissionsAluminum or Copper - abnormaloperating temperatures, lack of lubrication,rust, contamination.In Final DrivesSilicon - dirt or clay soil contamination.Iron - water entry, preload loss.When analyzing the trend, don't look at <strong>as</strong>ingle metal, observe the wear rate of acombination of metals. For example,continuous high iron and chromiumreadings along with high soot will indicateliner and ring wear with incre<strong>as</strong>e ofblowby. Sooner the problem is rectified,lesser will be the consequential damages.

2. Oil ConditionSoot - plugged air filter element,excessive idling, cool engine temperatures,blowby, rapid acceleration, longoil drain intervals.Sulfation - excess sulfur in fuel, lowTBN (Total B<strong>as</strong>e Number, whichneutralizes sulfur), machine operating inhigh humidity and temperature, long oildrain intervals.Oxidation - high operating temperatures,glycol or copper contaminants, inefficientantioxidant oil additives, long oil drainintervals.Nitration - nitrogen chemicallycombining with oil.3. Oil ContaminationWater - water p<strong>as</strong>sing through a matingsurface. You'll receive an alert whenyour sample exceeds 0.5% watercontent.Fuel Dilution - leak in transfer pump orbad fuel nozzle. You'll receive an alertwhen fuel dilution reaches 4%.ISO CodeOil viscosity is decre<strong>as</strong>ed.Glycol - leak from the cooling systemthrough the heat exchanger into the oil,leading to accelerated oil oxidation andincre<strong>as</strong>ed oil viscosity.Silicon - dirt entry.4. Oil CleanlinessParticle Count detects additional signsof abnormal wear and dirty oil that othertests may not find, such <strong>as</strong> gear androller bearing failures or nonmetallicmaterials.The chart below shows the levels of contamination identified by ISO codes in your S l O l S SM Services reportsParticles per milliliter20........................................................ 5000 - 1000019........................................................ 2500 - 500018........................................................ 1300 - 250017........................................................ 640 - 130016........................................................ 320 - 64015........................................................ 160 – 32TECHNICAL UPDATE ON CONSTRUCTION MINING & POWER SOLUTIONS

14S O S SMsamples should be taken for alll lfluids. When it’s performed regularly,coupled with expert interpretation, itwill help lower maintenance costs.Combined with S O S SM , effectivel lcontamination control reduces breakdownsand <strong>as</strong>sociated costs. Keeping machinesystem clean eliminates component wearand improves system efficiency andresponse under varying loads.Because 80% of hydraulic system failurescan be traced to contamination, here aresome tips that will help you focus oncleanliness.Types of ContaminantsllllAbr<strong>as</strong>ive particles like aluminium andsilica cause sticky valves and poorpump performance.Water in hydraulic fluid forms bubblesthat pit internal component surfaces.Air in the system causes jerky motion.Heat reduces the lubricity of hydraulicfluid, accelerating component wear.Sources of ContaminantsllllExposure to external environment viaworn seals, faulty g<strong>as</strong>kets, leakyvalves or defects in cylinder rods.Internal wear due to insufficientlubrication or improper clearances.Installing new components, like dirtyhoses.Adding fluids that were stored in dirtycontainers.Controlling ContaminantsllUse particle counter to <strong>as</strong>sess thecleanliness of the fluid before and afterfiltration.Flush a dirty system and fill it withnew fluid.Use these simple t<strong>as</strong>ks and derivesignificant impact on your hydraulic systemefficiency.Contamination control and SlOlS SM analysisare two very effective ways you canconsider to improve your machineavailability and performance. Performedat regular intervals these take minimumtime and cost but have huge returns onyour investment.lllllCheck the machine for leaksduring daily walkaround inspection.Use proper filters and change themregularly.Use proper hydraulic fluid, filtering itwhen transferred between storagelocations.Use desiccant breathers on fluidstorage containers to prevent waterand contaminant ingression inside thesystem.Remove contaminants from a dirtysystem with kidney loop mobilefiltration.Contributed byDr. Deb<strong>as</strong>ish MukherjeeIn-charge-Scheduled Oil Sampling Lab, TIPL

THE FASTEST GROWINGCONSTRUCTION EQUIPMENT COMPANY9TH CONSTRUCTION WORLD AWARDS 20111, Taratolla Road, Garden Reach, Kolkata 700 024Tel: (91) (33) 2469 3732-36, 6633 2000Fax: (91) (33) 2469 2143/3731www.tilindia.in

“We make ourcustomers moreprofitable”lA quarterly journal from TIPL l For private circulation only l Edited & Published by Corporate Communications l Printed at CDC Printers (P) Ltd. l Copyright © TIPL 2012CAT1, Taratolla Road, Garden Reach, Kolkata 700 024Tel: (91) (33) 2469 3732-36, 6633 2000, Fax: (91) (33) 2469 2143/3731Our Toll Free Nos.: 1800-345-3356 (Sales) 1800-345-3355 (Service)Visit our website: www.tiplindia.in