Has anyone got generic recommendations when starting up New gearboxes & hydraulic systems
eg - sampling, changing the oil, flushing run-in periods etc etc

Do you have the OEM manuals for this info?

OEM data is not that good for small to medium systems and we want to have some generic guidelines that can be used in conjunction with any OEM data.

Making a comparision to the run-in period of a new car, after a month flushing the system to get any metal burrs out...

Glenn,

Generic recommendations for new equipment.
1. Determine the most contamination sensitive component. Obviously, this will be different for a hydraulic system than a Gear Drive. Set your cleanliness expectations based on this component. (Piston pump = 16/14/12; Gear Pump = 19/17/14; Servo valves = 15/12/10; Gear Drives = 17/15/14)
2. During machine installation, fit the system with a permanently installed (or portable system fitted through QC's if you cannot justify the additional investment)filtration systems. These should be low-flow, low pressure, and have a turnover that will cycle the system at a minimum of 10 times per hour.
3. Set the by-pass filter system to operate on separate motor controls. Charge the system and let the by-pass filter run until 20 times the volume of the sump has passed through the filter (minimum). You cannot over-filter a new machine.
4. Upon early commision and operation of the new system, plan to leave the by-pass filter sytem running any time the machine is running.
5. For the gear drive, there will be fines generated, but these finds do not justify an oil change for a given operating cycle IF you are removing the fines along the way. Target to acheive and maintain an 17/15/14 ISO code value to limit seal wear, bearing wear and leakage. You should not require an oil change if you will do this.
6. Collect your samples from a fixed sample port in front of the element on the by-pass system. Take samples weekly, then monthly until you are satisfied that you have reached a static contaminant and wear metal condition. That is your trending baseline.

Keep in mind, hydraulic systems with high pressure must have cleaner oil to operate effectively than those with lower pressure. You OEM ISO cleanliness code values would be a minimum starting point.



Regards,
Mike Johnson, CMRP
mjohnson@amrri.com