Aerospace Hydraulic GSE: Maintenance and Troubleshooting - Part 1 -Types of Contamination

Aerospace aircraft are serviced and maintained by ground service equipment (GSE), with service carts that connect to the aircraft on the ground to support maintenance requirements, repair or replace components. Aerospace GSE supports many intricate systems with service repair carts equipped with hydraulic test stands, compressors, nitrogen, cooling air and various components such as hydraulic quick couplings. Hydraulic aircraft GSE must be properly maintained according to the OEM operations manual to provide trouble-free service and to prevent catastrophic and costly problems.

Aircraft Hydraulic GSE and the Need for Preventive Maintenance

Maintaining aerospace GSE extends equipment life, reduces the frequency of unscheduled maintenance, and reduces overall lifecycle costs. Hydraulic GSE equipment that interfaces with the aircraft could contaminate and damage sensitive aircraft hydraulic components if not properly maintained. Checking for hose and seal integrity, checking fluid levels, checking for leaks, and preventing contamination are some of the tasks performed during regular maintenance of hydraulic GSE equipment.

Many aircraft GSE systems include hydraulics such as:

●       Hydraulic Power Units

●       Reservoir Service Units (Engine Oil and Hydraulic Oil)

●       Hydraulic Jacks

●       Hydraulic Test Units

●       Towbars with Hydraulic Height Adjustment

●       Hydraulic Cranes

●       Hydraulic Maintenance Platforms

●       Ground Test Units of Emergency Power Systems

●       Hydraulic Wheel and Brake Dollies

●       Hydraulic Tire Bead Breakers

Preventing Contamination in Hydraulic GSE Is Critical

Preventing contamination should be the foundation of any preventive maintenance plan for hydraulic GSE. In-depth training for all personnel involved is a mandatory part of any contamination prevention program and can be performed by the equipment manufacturer, the School of Engineering or the Fluid Power Training Institute.  All hydraulic GSE equipment should have a baseline fluid sample with testing performed from an independent laboratory or with a contamination monitor. Fluid testing should be performed at specific intervals along with regular filter replacement to help prevent contamination in hydraulic GSE.  Not all systems interface with the aircraft, closed systems still require inspection and maintenance such as checking for fluid leaks, checking fluid levels and obtaining fluid analysis at predetermined frequencies unless troubleshooting.

Contamination Problems in Hydraulic GSE Fluid

When aircraft GSE experiences hydraulic fluid contamination, it is either from one of four major categories:

 

1. Particles, solid foreign material in the fluid
2. Water, free water or in a solution
3. Chemical, from a foreign source or fluid deterioration
4. Air, either entrained or dissolved

 Particles

Particle contamination in hydraulic fluid can cause accelerated system wear or complete component failure. Foreign particles can cause abrasive wear on moving components and deteriorate surfaces. Solid particles can plug systems with tight operating clearance and cost unintended equipment shutdown.

Water

Moisture causes chemical reactions with hydraulic fluid and can lead to interference of performance and increased system wear.  Water contamination of hydraulic fluids may cause a galvanic action promoting rust and corrosion; this corrosive action causes surface degradation and fatigue.

Chemical

There are many potential causes to chemical reaction in hydraulic systems such as mixing up hoses and introducing incompatible fluids, a chemical reaction with fluids and components, thermal damage caused from excessive heat, deterioration from additives, excessive mechanical shear, a breakdown of fluid additives or variances in viscosity are some examples.

Air

Air contamination of hydraulic GSE equipment can produce excessive heat with pressure changes that compress the air, this causes premature wear and decreased operating efficiency. Air contamination causes oxidation of metal parts which increases noise level, operating temperature and reduces transmitted power.

These are some of the various methods of contamination that can occur in hydraulic fluid systems in aerospace ground service equipment.

Solutions to Prevent Contamination in Hydraulic GSE Equipment

Using the right hydraulic quick couplers for your aircraft hydraulic GSE equipment is critical to prevent contamination.  Stucchi is a leading supplier of hydraulic solutions and quick couplings designed for a variety of challenging, heavy duty applications. Our quick couplings for aerospace GSE include threaded couplings, flat face quick disconnect (QD) and multi-coupling plates. Our hydraulic specialists help you choose the best quick couplers for your hydraulic GSE equipment as we customize your solutions to meet your specifications with optimal performance.

Stucchi’s design of the flat face quick coupler that the ISO 16028 standard, as a leader in delivering leak-free quick connect solutions. Our flat face quick couplers eliminate contamination in hydraulic circuits, with a no-spill design that prevents fluid loss on quick connect and quick disconnect. Threaded, flat face quick couplers by Stucchi hold up to heavy-duty, pressurized applications with a thread to connect design that prevents unwanted disconnection.

Multi-coupling plates prevent cross connection and chemical fluid contamination, with easy and reliable quick connect and quick release of multiple lines at once.  We offer multi-coupling plates to support the same or different size couplers and the same or different media such as hydraulic fluid, electrical or pneumatic lines.

Stucchi is a recognized industry leader in providing hydraulic solutions to many industries including heavy duty and challenging configurations. We offer a wide selection of hydraulic quick couplers and multi-coupling plates to improve efficiency, safety, prevent leaks and contamination. Contact us to learn more about our hydraulic quick couplers for aerospace hydraulic GSE equipment. 

This article was previously published at:  https://www.stucchiusa.com/blog/aerospace-hydraulic-gse-maintenance-and-troubleshooting-part-1/

 

 

 

Prevent Overheating with Best Practices for Mini Excavator

 

Operating equipment like skid steers, compact track loaders and mini excavators effectively requires best practices in maintenance and a good understanding of the hydraulic system.  Compact excavators pack a powerful punch and some mini excavator attachments can push your equipment to the limit, causing overheating issues or serious equipment damage.  Understanding how to keep your equipment running smoothly, without damage or safety risks is key to efficient operation.

Best Practices for Mini Excavator Attachment Operation

No matter what mini excavator attachments your compact machine is operating, following some regular inspections, and analyzing your auxiliary hydraulic flow for each tool and task should be mandatory. The following checklist includes some of the best practices to get the most from your mini excavator :

✔ Inspect Your Cooling System

 

✔ Know the Auxiliary Flow of Your Machine and Attachments

 

✔ Inspect Hoses for Cracking or Damage

 

✔ Inspect for Dirt and Debris

 Inspect Your Cooling System

 Compact excavators and attachments provide exceptional versatility to many earthmoving applications, although some tools and tasks put a heavier burden on your machine than others.  Several factors may contribute to a machine overheating including the ambient temperature. Operating a heavy duty tool in high heat is asking for trouble if you haven’t inspected your cooling system. 

Many engine failures are related to the coolant, which means many overheating issues can be prevented with proper maintenance. Bobcat recommends coolant changes every 1000 hours or every two years, you should follow your manufacturer recommendations for maintaining your cooling system when running Kubota mini excavator attachments or other OEM equipment. Flushing should be done if the fluid looks questionable and be sure to never mix two or more types of coolants. 

Bobcat and many other compact machines use propylene glycol instead of ethylene glycol coolants. If these two are accidentally mixed it causes a “gelling” type of reaction which will certainly cause radiator damage and risk damaging the entire engine. Propylene coolant can come in various colors although ethylene glycol is always green. Bobcat makes their propylene coolant and a unique purple color and the hydraulic fluid is always orange to help prevent maintenance techs from accidentally mixing fluids. Once you decide which type of coolant to use whether one that is mixed with distilled water or an extended life type of coolant you should stick with it and never mix the two.

Know the Auxiliary Flow of Your Machine and Attachments

It is important to make sure the auxiliary flow of your machine is within range for the tools you plan to use and supports the application. Operating mini excavator buckets or mini excavator grapples will most likely not cause the machine to overheat.  Operating high capacity John Deere mini excavator attachments like a mulcher, however, on something like a 333G track loader is fine as long as your machine is equipped with the right high capacity hydraulic couplings.

Operating hydraulic attachments like a mini excavator forestry mulcher, tree grinders and fixed tooth mulchers requires a lot of hydraulic capacity and flow. Without the right auxiliary hydraulic quick couplings, applications with these tools in high ambient temperatures can easily result in overheating. Some machines provide an audible alarm to let you know your equipment is close to dangerously overheating. If this warning is not heeded, built-in protections automatically shut down equipment resulting in lost productivity and possible equipment damage.

Inspect Hoses for Cracking or Damage

Any hydraulic oil spills should be cleaned up right away as hydraulic oil can damage coolant hoses. Hydraulic oil tends to weaken and soften hoses, which can lead to a leaking or burst hose over time. Stucchi’s threaded, flat face quick couplers eliminate leaks to protect your equipment and the environment. Stucchi’s VEPHD threaded flat face couplers provide quick-connect without premature wear during heavy duty applications with a flat face design that eliminates leaks on quick release.

Inspect for Dirt and Debris

One of the most common causes of skid loaders or mini excavators overheating is when dirt and debris clogs cooling radiators. Depending on the application and the environment, something like mulching which is continually throwing around dirt, leaves and mud has a high potential to allow contamination into sensitive systems. Mini excavator stump grinders can throw up a lot of sawdust which can quickly clog a radiator. When a radiator gets clogged, it can actually explode and blow right off of the machine.  Debris in hydraulic oil can act like a fire starter and poses serious safety risks to operators and the environment. 

Blowing off your coolers should be done regularly, every day or multiple times a day when operating in extreme high heat.  Evaluating your auxiliary hydraulic flow requirements and using the right auxiliary hydraulic quick couplings will provide the most efficient and productive operation while helping to prevent overheating, machine downtime or damage.

Hydraulic Solutions to Make Your Mini Excavator a Big Tool Carrier

Not every compact machine is equipped with high-capacity auxiliary flow necessary to power some attachments. Stucchi offers a solution with auxiliary hydraulic kits to accommodate high-capacity mini excavator attachments.  Make your mini excavator a big tool carrier with our auxiliary hydraulic kit that includes:

●       APM Flat Face Couplings

 

●       A-HD Flat Face Couplings

 

●       Hydraulic Adapters

 

●       Ball Valve

●       Mounting bracket

Stucchi offers a variety of auxiliary kits and will customize the best solution for your equipment and your application.  We offer solutions with hydraulic adapters to your skid steer, compact track loader or mini excavator to get the most out of your equipment safely and efficiently. Helping to prevent equipment overheating improves your productivity and your profits, by eliminating unplanned downtime and costly equipment damage.

Stucchi has been providing a constant flow solutions for more than 60 years, with a hydraulic specialist dedicated to providing the best hydraulic solution to meet your needs. We offer custom solutions with technical expertise in hydraulic specialists experienced in many market segments. Contact us to learn more about improving your land management applications with hydraulic adapters and auxiliary kits to meet the demands of high-capacity mini excavator attachments.

This article was previously published at: https://www.stucchiusa.com/blog/prevent-overheating-with-best-practices-for-mini-excavator-attachments/