Tech Tips Inside Scoop Newsletter Maintenance Tips for John Deere Equipment January 2010 It’s your turn Do you have a “tech tip” to help your fellow maintenance man- agers? Maybe something you learned during your time as a field mechanic or something you’ve picked up while running the shop? Please share! Welcome to the January edition of Inside Scoop — TechTips. We want this publication to provide you with additional information regarding support and owning and operating tips and techniques for your John Deere equipment. So think about all the ways you work to keep your fleet up and running — I’ll bet we can all learn a thing or two from YOU. All the best, Mike How to fight moisture contamination Moisture contamination in lubricating oils and your hydraulic system can cause damage to the system and components such as motors and pumps, becoming an even bigger threat than its more obvious big brother, particle contamination. There are several ways that contaminants can find their way into your equip- ment, including poor oil top-up and sampling methods, poor seals, and improper handling methods. Here’s what happens in moisture contamination. Individual water molecules that get dispersed through oil are considered “dissolved.” All industrial fluids have a very small level of dissolved water which can typically be handled at levels between 200 and 600 parts per million (ppm). The fluid’s temperature does play a key role in its ability to keep water in a dissolved state. Newer motor oils can handle three times these amounts before contamination is noticeable. But at some point, individual water molecules saturate the oil and the water begins to coalesce. Some signs of this would be a cloudy appearance or the creation of microdroplets. Finally, after the emulsified water increases, it settles to the bottom of tanks and sumps as a layer of free water. 1
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TechTipsInside Scoop Newsletter
Maintenance Tips for John Deere EquipmentJanuary 2010
It’s your turnDo you have a “tech tip” to help your fellow maintenance man-agers? Maybe something you learned during your time as a field mechanic or something you’ve picked up while running the shop? Please share!
Welcome to the January edition of Inside Scoop — TechTips. We want this publication to provide you with additional information regarding support and owning and operating tips and techniques for your John Deere equipment.
So think about all the ways you work to keep your fleet up and running — I’ll bet we can all learn a thing or two from YOU.
All the best,Mike
How to fight moisture contaminationMoisture contamination in lubricating oils and your hydraulic system can cause damage to the system and components such as motors and pumps, becoming an even bigger threat than its more obvious big brother, particle contamination.
There are several ways that contaminants can find their way into your equip-ment, including poor oil top-up and sampling methods, poor seals, and improper handling methods.
Here’s what happens in moisture contamination. Individual water molecules that get dispersed through oil are considered “dissolved.” All industrial fluids have a very small level of dissolved water which can typically be handled at levels between 200 and 600 parts per million (ppm). The fluid’s temperature does play a key role in its ability to keep water in a dissolved state. Newer motor oils can handle three times these amounts before contamination is noticeable.
But at some point, individual water molecules saturate the oil and the water begins to coalesce. Some signs of this would be a cloudy appearance or the creation of microdroplets. Finally, after the emulsified water increases, it settles to the bottom of tanks and sumps as a layer of free water.
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Some things to keep in mind when selecting desiccant breathers:
When choosing a desiccant breather size, be sure to consider the amount of air exchanged (cubic ft./min.) for each application. Airflow capacity must match or surpass the tank’s fill and drawdown rate. Breather size should increase as the flow rates increase.
Choose a steel or plastic breather housing, depending on your operating environment. Steel is a better choice if you’re dealing with hot, dusty environments.
Pay attention to the color of the silica gel as an indicator of when to change breathers, as most breather manufacturers put dyes in the silica gel to facilitate a color change when the gel becomes saturated.
If you operate in a damp and dirty environment with minimal air- volume changes, newer expansion-type breathers can better control the breathing action and permit expansion and contraction of the airspace.
Consider more specific applications for desiccant breather filters than mobile hydraulic systems, such as switch gears, gearboxes, turbines, feed pumps, oil-cooled transformers, and diesel-fuel storage tanks.
Settlement isn’t your only problem. Once water mixes with oil, chemical reactions occur. These reactions, called hydrolysis, involve not only the water and base oil, but also various additives, including extreme pressure- and wear-resistance agents, rust and oxidation inhibitors, and viscosity improvers.
The result? Oil’s aging can accelerate tenfold. And you’ll experience sludge, varnish, various acids, surface deposits (rust), and polymerization. What’s more, a mere one-percent contamination can reduce component life by up to 90 percent.
What can you do?One way to combat moisture contamination is through the use of desiccant breather filters.
Finding the right breather will help the systems in your equipment last longer and prevent unnecessary downtime and oil replacement. Desiccant breathers are especially useful in environments that contain high dust and humidity levels.
Desiccant breathers are comprised of a silica gel that attracts and retains up to 40 percent of its weight in water. Together with a synthetic filter media, they prevent moisture and particle contamination from getting into your reservoirs as pressure fluctuations occur through thermal expansion and contraction of the fluid and the level changes produced by the filling and emptying of the reservoirs.
When carbon is added to the silica gel, the breathers can capture oil mist and evenly disperse incoming air so that the synthetic filter and silica gel combination works more effectively. The more the air passes through both, the cleaner it becomes.
If a breather is designed with more vent holes to allow variable airflow patterns, it increases the filtration media and desiccant drying capabilities.
Talk to your nearest John Deere dealer to learn more about desiccant breather filters and how they can help you fight moisture.
As the air passes through a desiccant breather, moisture and contaminants are absorbed into its silica gel and synthetic filter media.
2 Signature Customer
Remanufactured vs.rebuilt: the process
Seems that almost anyone can rebuild a component — hundreds of businesses offer rebuilt items for equipment, often at bargain-basement prices. Trouble is, the effort that goes into rebuilt components addresses only the parts that failed. You’re still buying a lot of untouched “old stuff” within that component that can lead to repair expense and downtime later.
Remanufactured components are different because they’re completely torn down and inspected. Worn parts, not just the defective ones, are either replaced with genuine, new manufacturer’s parts or parts meticulously remanufactured to the original manu-facturer’s specs.
Here’s a brief look at how John Deere does reman along a wide breadth of components, including engines, engine and hydraulic components, drive-train, fuel injection, rotating electrical components, and A/C compressors.
First, components that come in to Deere for remanufacturing are thoroughly cleaned and bead-blasted to eliminate corrosion. They’re then disassembled and inspected — completely, not partially. Every surface, every contact point, and every moving part is scrutinized. Nothing is left to chance.
Worn or failed parts are replaced, and the component is reassembled and painted. Then it is tested under load to be sure it delivers like-new performance. It’s not just a matter of looking pretty and being repackaged in a new crate.
Contact your John Deere dealer for more details about what’s available in reman and the money it can save you. He’ll also tell you about the like-new warranty, which we’ll expand on in the next issue of TechTips.
Part two of a three-part series
Take a closer look
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With emission reduction becoming increasingly important, we know you may be looking for solutions for older equipment. If repower is on your radar, Deere has engine kits engineered to meet the standards and performance criteria of the original production design. Check out the chart below.
Keep in mind… Hour estimates are ballpark only. Actual install times will vary based on machine condition.
These kits are collaborative efforts between the factory and the John Deere Power Systems distribution network to ensure original performance standards.
A kit parts list will be provided with kit installation instructions.
The base engine warranty is two years/ 2,000 hours. Engine-related parts (such as alternators and compressors) have a one-year/unlimited-hours warranty. All other parts have the standard Deere warranty of 90 days/unlimited hours.
For more information on how to keep your fleet up and running, visit our website on Condition Based Maintenance at www.JohnDeere.com/en_US/cfd/construction/deere_const/service_support/cbm.html
(Hydraulic) hammer time!Before it cracks into that concrete, consider these helpful tips to achieve maximum performance from your hydraulic hammer:
Impure thoughts? Maybe it’s your funnelThe greatest enemy of a well-maintained engine is close at hand. It’s the funnel used to add oil to the crankcase.A dirty funnel can introduce grit into the oil, which will grind on the oil pump’s internal surfaces before it can be caught by an oil filter.
The disposable Fast Funnel® is designed for one-time use to eliminate the impurities and cross-contamination that can occur with reusing funnels.
These 9-inch-high by 4.25-inch-wide funnels are folded flat until they’re ready to use, making them both practical and easy to carry. They are made of heavy-grade paper stock and are .375 inches wide at the base for an even, precise pour of oil, diesel fuel conditioner, and more.
The Fast Funnel is available at your nearest John Deere dealer.
– DON’T cross-contaminate. If your hammer was used with other machinery, you risk contamination if the previous machines used other fluids. Remember to flush out your hammer before use on new equipment.
– DO install a breather filter. The installation is quick and inexpensive, and filtration is a must in the dusty environment in which your hammer will be operating.
– DON’T operate with worn bushings. If bushings are worn down, the tool and piston will not be properly aligned for contact, and this will damage the seals.
– DO contact your nearest John Deere dealer to find the hydraulic hammer best suited for your next project.
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Do something “green” with your yellowWhat comes in 1-, 5-, and 55-gallon containers that you can put in your equipment but won’t kill the fern in the office?
It’s no joke.
It’s Bio Hy-Gard™ II, the biodegradable lubricant alternative that protects trans-missions, final drives, and hydraulic systems — including those with wet brakes and clutches — yet is safe on the environment.
This is a way to do something green and environmentally friendly with your equipment without sacrificing performance. If you or your technicians do any lube work outside around turf, water sources, or otherwise environmentally sensitive construction sites, Bio Hy-Gard II is a great option.
Bio Hy-Gard II is formulated with canola oil, which allows grass and soil to regenerate quicker after spills or leaks with no residual effects on the environment such as contamination to soil or groundwater. And because of canola oil’s composition, it reduces friction and wear.
There’s more. It also offers improved oxidation resistance that allows your machines to operate in hotter temperatures. Bio Hy-Gard II can be substituted for standard Hy-Gard Fluid.
Talk to your nearest John Deere dealer to learn more about Bio Hy-Gard II lubricant.
6 Signature Customer
Reman now on the WebIt’s not exactly YouTube™, but it’s a whole lot more helpful.
John Deere Reman has all the information you need on remanu-factured parts and the best warranty in the business. Visit www.JohnDeere.com/Reman.
Remember, remanufactured components typically cost 60 to 70 percent of what a new component runs. Get online and see how Reman can benefit your fleet and your operation’s bottom line.
Oil analysis just got more affordable
“Expand” your arsenal against pivot wearExpander pivot pins offer a simple and permanent solution to pivot wear. The pin can be inserted directly into the worn mounting and, as its name suggests, its sleeves expand into the worn area and are securely locked on both sides.
This installation requires no welding or line boring and is backed by a 10-year warranty. With lasting protection for your machinery and peace of mind for you, expander pivot pins are a cost-effective investment for your equipment.
Expander pivot pins for John Deere excavators are available to order through your John Deere dealer.
If your guys aren’t doing oil analysis because they’re worried about expensive fluid-analysis kits, check this out: Deere now has a lower-cost fluid-analysis kit that meets warranty requirements.You can use the universal test kit, available for $15 from your Deere dealer, for engine oil, hydraulic fluid, or powertrain lubricant testing.
Here are the specific test results gained from the kit:
Spectrochemical analysis — levels of wear metals, contamination, and additive levels Viscosity Crackle Test for water in engine oil samplesWater by Karl Fischer Test for hydraulic/hydrostatic samplesFuel dilution Fuel soot Presence of raw coolant Total Base Number (TBN) — Extended drain indicator Total Acid Number (TAN) — Extended drain indicator Particle count — Reported in 4/6/14 and actual count formats
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Get in the know with Interim Tier 4 engine and biodiesel fuel informationEmissions and alternative fuels are hot topics that will only get hotter as new regulations loom large for 2011.
Find out what you need to know about John Deere Interim Tier 4 engines and the field-tested and proven technology behind them in the new brochure from Deere Power Systems. This off-highway diesel engine brochure covers the critical 174-horsepower-and-above units that are targeted by the next round of EPA regulations.
Got questions about biodiesel and your Deere iron?
“Using Biodiesel Fuel in John Deere Engines,” also from Deere Power Systems, covers applicable blends, expected performance, storage and handling, warranty considerations, and more.
You can get both of these brochures through your John Deere dealer or John Deere Power Systems distributor.
