Fluids and Filtration

Transmission Design Elements

Sauer-Danfoss
Hydraulic
Unit Design
Pressure
and Speed
Ratings
Component
Sizing
Customer
Macine
Design
Fluid
!uality
Circuit
Design
Transmission
Design
Hydraulic Fluid Roles
Remo"e#Deal $it Contamination
Lubricate (separate moving parts)
Transfer Heat
Prevent Corrosion
Types of Contaminants
Water / other fluid
Air
olid particles
$ater#Fluid Contamination
Water or other fluids in a s!stem ma! result in"
# corrosion
# cavitation
# altered fluid viscosit!
Water can react $ith some fluids
# create harmful chemical b!%products
# destro! important additives
&ood h!drol!tic stabilit!
'luid compatabilit!
AT( )%*+,- and .)/ 01
%ir Contamination
Air increases the compressibilit! of the fluid
# creates a 2spong!3 s!stem that is less responsive
Air creates a loss of efficienc!
# Higher operating temperatures
# 4ncreased noise levels
# Loss of lubricit!
# 4ncreases o5idation
&ood anti%foam and resist dissolved air
Particle Contamination
olid Particles increase $ear in !our s!stem
olid Particles can stic6 valves / plug orifices
i7e 8 9uantit! of these particles
Allo$able contamination is determined b! the
4:11;+ standard
&S' Solid
Contaminant Code
<ach level describes
the amount of particles
for a given particle
si7e
<5ample" **/,0/,=
# ** is number of
particles larger than
1mm
# ,0 is number of
particles larger than
+mm
# ,= is number of
particles larger than
,1mm
Cleanliness (e"els
4mportant notes"
:ld standard onl! used t$o numbers
# <5maple ,0/,= $as ,0 for >mm particles and ,= for
,>mm particles
**/,0/,1 fluid has TW4C< as man! particles of
the ,1mm si7e as **/,0/,= fluid

Hydraulic Fluid Roles
?emove/)eal With Contamination
(u)ricate *separate mo"ing parts+
Transfer Heat
Prevent Corrosion
(u)ricate
H!drod!namic Lubrication (@iscosit!)
<P (<5treme Pressure additives)
@iscosit!
,iscosity Re-uirements
'luid must have high enough viscosit! to
maintain oil film bet$een sliding surfaces
# 'luid that is too thin $ill result in e5cessive lea6age
and adhesive $ear
@iscosit! and temperature limits must be met
simultaneousl!
@iscosit! depends on fluid selection
?emember lo$ temperature viscosit! during
selection
,iscosity
@iscosit! 4nde5 (@4) improved fluids
# Higher @4A usuall! more susceptible to sheardo$n
heardo$n ma! lo$er operating viscosit! belo$
the originall! specified value
,iscosity
Piston Units Gear Units
Recommended
Operating Range
12-60 cSt
70-278 SUS
25-50 cSt
164-220 SUS
Intermittent 7 cSt
49 SUS
7 cSt
49 SUS
Minimum
Startup
1600 (1000*) cSt
7500 (4600*) SUS
1000 cSt
4600 SUS


EP %dditi"es
When viscosit! Bust isnCt enough
# Phospherous
# Dinc Phosphates (D))P)
# (ol!bdenum
# Pol!mers
Hydraulic Fluid Roles
?emove/)eal With Contamination
Lubricate (separate moving parts)
Transfer Heat
Prevent Corrosion
Effects of Hig Temperature
Affects viscosit! (lubricit!A film thic6ness)
Limits life of rubber seals
# high temperatures cause rubber to hardenA
crac6
'luid brea6s do$n
# sheardo$n occurs easier at higher
temperatures
# thermal stabilit! is critical
Could mean air in s!stem
# cavitation possible
Temperature Re-uirements
i7e heat e5changers to 6eep fluid $ithin
recommended temperature limits
elect $orst continuous operating conditions
# 'or most machinesA this occurs at highest
transmission output speed obtainable
hould test to verif! these temperature limits
are maintained
<5cessive heat ma! be generated b! other
circuit components
Temperature Re-uirements
Circuit designs should avoid depending on high
pressure relief valves as part of the control
s!stem
're9uent operation of these relief valves $ill
generate intolerable heat
Circuit components $ith high internal lea6age
also contribute to heat problems
Circuits containing flo$ control valves such as
flo$ dividers are susceptible to heat generation
since the! function b! restricting oil flo$ $ith a
pressure drop
Temperature (imits
Sources of Heat
Component malfunction or circuit design
High psi relief operation
4nherent internal lea6age
'lo$ dividersA throttling devices
Long po$er loop lines
<5tended roading
Hydraulic Fluid Roles
?emove/)eal With Contamination
Lubricate (separate moving parts)
Transfer Heat
Pre"ent Corrosion
# Fluid compati)ility .it metals
Fluid !uality
Fluid !uality
!stem Life depends on 'luid /ualit!
# 0> to -;E of all service problems are fluid relatedF
Poor 'luid affects H!draulic !stems
# )oes not necessaril! brea6 components
# Causes loss of <fficienc!
?educed peed
?educed Po$er
'luid selection can lessen the impact of unusual
environmental factors
4f !ou are getting good results $ith !our current
fluidA change $ith CAGT4:HF
Fluid !uality
Loss of <fficienc! is caused b!"
# mearing" Parts rubbingA material transfer
Caused b! lo$ fluid viscosit!A lac6 of lube film
# Cavitation" 'luid implosionA material removal
Caused b! air in fluid
# <tching" Chemical corrosionA material removal
'luid becomes acidic due to presence of $ater and/or e5cessive
temperature
# coring" &rooves in partsA material removal/transfer
Caused b! particles of abrasive material in fluid
Fluid Recommendations
Ho set rules for choosing fluid
4s a fluid is acceptableI Ho$ to get it approved
# 'luid producer should provide primar! data including
proof the fluid does $or6 on piston e9uipment
Approvals not published b! pump mfgsJ
# pump mfgs do not produce fluids
# pump mfgs do not control changes in fluid chemistr!
4f the current fluid is $or6ingA change $ith
caution
Tal6 to !our fluid peopleF
Tal6 to !our filter peopleF
Successful E/perience
Premium grade anti$ear mineral%based
h!draulic fluids
# Premium turbine oils (e5cept >,)
# AP4 C) engine oils % A< .,0=
# T!pe ' automatic transmission fluid %(*C=='
# Po$er shift fluids (Allison C%1A CAT T:%*)
Successful E/perience
# Tractor fluids (4H H!tranA etc) %% e5cept some have
sho$n etching of !ello$ metals
# AT' e5cept some )e5ron 444 %% has sho$n etching of
!ello$ metals
# 'ire resistant fluids (at modified conditions)
# <nvironmentall! acceptable (biodegradable) fluids
En"ironmentally Friendly
En"ironmentally Friendly Fluids
When !our customer $ants"
this
instead of this
Some 0ey Terms
?eadil! Kiodegradable
# +;E brea6do$n $ithin *0 da!s
4nherentl! Kiodegradable
# +;E brea6do$n $ithin -; da!s
Ashless
# t!picall! contains no 7inc or other heav! metals
Types
@egetable Kased
# H<T& # ?ape eedA traditionall!
(ineral :il Kased
# no recogni7ed 4: classification
!nthetic
# H<P& # Pol!gl!col
# H<< # !nthetic <ster
# H<P? % Pol!alphaolefins
# (an! ne$ proprietar! t!pes
Considerations
Temperature
Pressure
peed
Long term fluid 9ualit!
4ncreased maintenance interval
pecial filtration
Fire Resistant
Fire Resistant Fluids
Phosphate ester or ester $ith oil
Pol!olester
4nvert emulsion
Water gl!col
HWC' (define)
Fire Resistant Fluids
?e9uire special s!stem considerations
# eals ($ith 6!drol)
# 4nlet plumbing
# ?eservoir si7e
# 'ilter si7e
# (odified operating parameters
# 4ncrease maintenance fre9uenc!
# 'luid monitoring (bacterial gro$thA brea6do$nA etc)
Fire Resistant Fluids
FLUID TYPE Speed
(% ata!og"
Pressure
(% ata!og"
Ma#imum
Temp$
P%osp%ate
Ester
100% 100% 180
o
F
82
o
C
Po!&o!ester 85% 85% 150
o
F
66
o
C
In'ert Emu!sion
(() oi!*+),ater"
65% 70% 140
o
F
60
o
C
-ater G!&co!
(() * +)"
65% 60% 140
o
F
60
o
C
.-F
(/0 ,ater*0 oi!"
65% 40% 122
o
F
50
o
C


Filtration
Filters
'ilters clean the oil at start%up 8 maintain
acceptable levels of contamination as particles
are ingested during s!stem operation
'iltration %% controlling particle si7es and
9uantities to meet appropriate levels
'luid cleanliness can onl! be maintained b!
selecting a filter capable of removing
contaminants from the s!stem
Filter Selection
)ependent on circuit design
'luid cleanliness re9uirement
Particle ingression rate
(aintenance interval
# )irt holding capacit!
Kuilt%in dirt
Clean%up rate
Filter Selection
'ilters are selected to meet the previous
re9uirements using rating parameters of filter
efficienc! and capacit!
'ilter efficienc! %% ho$ $ell the filter removes
contaminants from the fluid
'ilter capacit! %% ho$ much contaminant the
filter is capable of removing before a filter
replacement is needed
Filter Selection
Filter Efficiency dei!n"ted #y $et" %"tio
$et" () %"tio & U'tre"( '"rticle
)o*ntre"( '"rticle

+
& 10 & 10 or 90% efficient
1
+ & '"rticle i,e in (icron

10
& 10- (e"n t."t 90% of "ll '"rticle 10 (icron "nd
l"r!er "re filtered o/t0
Filter Testing
4: ,+00- (ulti%Pass Test
# Pressure drop/flo$A
# @ariation in particle removal abilities (Keta ratio) $ith si7eA
# @ariation in performance $ith time and differential pressureA
# Weight of test contaminant retained b! the filterA
# 'iltration ratings over a $ide si7e rangeA and
# 'iltration performance over a $ide range of particle si7esJ
What does an LAbsoluteC rating on a filter meanI
# LAbsolutel!C donCt believe a $ord the! sa!J
(iterature
>*;L;1+= >*;L;1+>
(iterature
>*;L;1++ >*;L;1+M
Ca"itation