Franna Crane Project | Part 4 | Changing Hydraulic Oil & Filters

how you going guys Kurtis from Cutting Edge engineering so today's job we are going to be sorting out the hydraulic system on our crane our Boom Lift cylinders have already been made but before I can refit them I do need to drain the hydraulic tank and inspect everything inside so something I forgot to mention but a few viewers did notice is what happened to the O-ring between the piston and the cylinder rod when I was machining the new ones I did change the design of the end of the cylinder rod just a little bit so I could remove that O-ring out of the equation and what we ended up with is relying on a taper Lock metal to metal surface seal and the new design on the rods will seal 100 percent of the time there are multiple different surfaces in there for it to seal on and I won't be relying on a baby o-ring that can come apart and break down and cause problems with the cylinders so we did get our oil samples back there doesn't seem to be any metal in the tank or in the steering circuit but there is metal in the lift cylinder circuit this does have a hydraulic return filter and it also has a magnet lock inside so any oil on the return cycle back into the tank goes through a filter and pass those magnets and picks up the majority of the debris there was a very high concentration of water in the system and the reason for that is the Boom Lift cylinders their wiper seals were completely worn out and it allowed moisture past the rods into the circuit and then it got circled back into the tank so the first thing I'm going to do I'm going to remove the return filter and then we're going to open the top of the tank up so we can suck out all that old oil so as you can see when I drain the oil out of the filter there was a lot of debris in there you can also see the top of the filter has a magnet strip in it that catches any of the heavy metals and there is a lot of metal particles attached to it so what we're going to do now is we're going to open up the filter so we can see inside and see how much metal has actually been caught lot of metal this might take a bit of doing so what a general hydraulic filter is made up from it is made up from a steel outer shell it then has a corrugated mesh cage that actually holds all of the filter material and then they are generally resin bonded onto each end or they could be roll form so there's a tight seal around the filter and it doesn't leak it is designed to catch any debris so these hydraulic filters are a 10 micron filter which means anything bigger than 10 micron isn't going to make its way through it most filters can be cut apart so you can actually have a look at them inside but they are very sharp and you just need to be real careful with them so as you can see there is a lot of debris in the return filter so it has done its job see all that debris there so the next thing I need to do is pump all the oil out of the hydraulic tank into a waste oil drum the pump we're going to be using to suck the contaminated oil out of the tank it is an air Venturi pump so you use air pressure to put into the actual pump and then it creates a vacuum inside the drum and you have a vacuum tube that you then use to put into the tank in order to suck the oil out of so I do have a pump that I use for pumping clean oil but I'm not going to use that for contaminated oil because that just means I'm going to have to clean it before I can use it again that's not deep enough right so I've actually reached the bottom of where the return filter lives so I can't get all the way to the bottom of the tank so I do have to remove the fill point and then I'll shove the hose down there righto so we've got all the oil sucked out of the hydraulic tank that took about seven minutes and there was about 180 liters of oil in there so it is quite a quick process using the air pump system now that the tank's drained I'm going to open up the inspection port that's inside the wheel arch so we just hit an undo one bolt we can take off the plate and have a look inside the tank so we can see inside the tank there are two more filters and they are for the hydraulic pickup that runs up to the pump there is a little bit of sludge in the bottom of the tank and that's pretty much to be expected on a machine this age it's probably never been cleaned in its life there doesn't seem to be any metal in there but we're going to remove the two filters and have a look at those so those two filters have picked up a lot of debris there is quite a bit of dirt material in there and the water and oil have mixed together and actually created a bit of a jelly the inside of the filters is clean which means the filters have done their job and I needed to take them off because the part number that's in the Franna book doesn't actually correspond with any of the filter manufacturer's part numbers so I'm going to take them over to Mr filter match up a set of filters for it so we can put new ones in when we go to reassemble the crane what I'm going to do next is I am going to jack up the back of the crane so I can remove the back tires of it so I can have a bit more access into the hydraulic tank just got to make sure they're loose we're good that's coal that's the spacer ring so I am going to refit the old filters because I am going to flush out the hydraulic tank and I don't want any debris getting into the pump pickup or anything else so what I'm going to do now is I'm going to flush out the lift cylinder circuit and what I mean by that is I'm going to flush from the hoses that go up to the lift cylinders back into the tank I'm not going to be flushing the entire system that would mean removing the steer cylinders and the boom extension cylinder that in itself is a massive job I would also need to remove all of the valving all of the hoses and the pump because there was only metal found in the lift cylinder circuit it is the only one contaminated with something that can do a lot of damage so we're going to flush it and try and get all of that material back into the tank we can clean all that out put new filters in there and fill it up with fresh hydraulic oil I'm not too concerned about the water that's going to be left in the rest of the hydraulic circuit I've already pumped out 180 liters of contaminated oil and I will be putting 200 liters of fresh hydraulic oil in there so it will dilute the water quite a bit I'm quite comfortable with putting new oil in there and just keeping up with Filter changes to try and pick up as much of it as I can so the way we're going to flush out the hydraulic system is I have repurposed a fire extinguisher in order to feed jet A1 which is kerosene and air pressure back through the system into the tank so all I did was I emptied the contents of the fire extinguisher I then machined up a threaded cap that screws into the top drilled and tapped that to put in a tap and then an air fitting on top and that's what the compressor goes on to I then drilled and welded in a bung in the bottom of the fire extinguisher and put a fitting in there so I can screw it onto a hydraulic hose so what this basically is is a pressurized bottle to force fluid through the fitting in the bottom and that will then flush out the system and take all of the debris with it ha ha that's sick that's so cool so that was pretty cool if you saw our last video you would have seen the military aircraft fly over the top and circle around us well we sort of knew he might be coming back today so he did do another flyover good to see you mate and he didn't land this time unfortunately but I don't think you'd probably get clearance for something like that but maybe he can ask the question and one day he'll actually do it what I've done now is I've put jet A1 inside the canister and I've just put the air lead from the compressor onto the tap so when I open the tap it is going to force the Jet A1 back through the circuit and back into the tank leave that on for a bit and it'll blow all the Jet A1 back into the tank what I'm doing is I'm simply going through each circuit I'm capping one side off and and then forcing jet A1 through the other one so we're just going to do that three more times righto so all four of our hydraulic lines have been purged back to the hydraulic tank so you may have noticed on two of the flushing cycles it was quite slow the two lines that were extremely slow they are what is used to lift the boom up in the air so there is a lot of pressure in behind those and there is a check valve there so in case something goes wrong it doesn't drop the boom on the ground the other two are the return circuit back to the tank from the lowering side of the cylinder they rush back very fast because they don't go through a check valve so with all of that done we can now get on to cleaning out the hydraulic tank there is a little bit righto so I've got the hydraulic tank completely cleaned out got all the mud out of all of the corners we did find a little bit of rust in there and I'm going to assume that's because water usually sinks to the bottom so it's time to start putting this back together first thing I'm going to install is the new filters much better so essentially these aren't actually filters these are strainers but they do filter out debris these filters are 125 micron which means anything bigger than that can't go through so all of the filters have been replaced there's one more thing that I need to do before I can put oil into the tank and that is change out the sight glass on the back side of the tank what's doing oh no got to take that off again so I've just discovered the way this sight glass has been put into this tank is they've held nuts on the inside so I do need to take out the inspection plate again in order to get my arm up in there to undo them so now that all that's done we can now fill our hydraulic tank with our new hydraulic oil what we're going to be using is hydraulic 68 and it is a high-tech oils product it is Australian made and Australian owned and to pump it in we're going to be using a Milwaukee transfer pump yes they are designed for water it does say it on the box but providing you do clean them out after every use or you don't try and run petrol through them they generally last really well righto guys so we finished pumping our 200 liters of oil into our hydraulic tank it only took 25 minutes and two 5 amp hour batteries that were about three quarters full pretty happy with that considering the pump was only 400 Australian dollars and about twenty dollars worth of hose and fitting so pretty good where is he here [excited Staffy noises] ooohh hold on gentle good boy [chomp] [crunch crunch] [nom nom nom] righto now that we've got all that completed we can get on to fitting our new cylinders onto the crane first thing I'm going to do is I'm going to remove all of the old hoses off the valve blocks in the front of the machine righto guys so we've got both of our new cylinders fitted onto the crane the pins went in pretty easily a lot easier to put them in than it was to get them out now all I have to do is refit the hydraulic lines down to the valve block and fit the hydraulic pipes so I won't be refitting the lights or the angle bracket and the reason for that is I really want to paint the angle bracket and the lights didn't work anyway so there's no point putting them back on so I'm not going to be reconnecting the pressure sensors that go onto the bottom of the cylinders and talk to the crane safe system we're not using the crane safe at the moment and the wiring is extremely damaged so rather than re-hook them up for no reason we're just not going to bother until we completely rewire the crane and then we can put all new wiring through for those righto guys so we've got everything fitted we've got all of our oil changed we have all of the pin positions on the cylinders greased and all of our lines hooked up let's get this crane fired up and cycle these cylinders so that worked out really well the cylinders cycled exactly how they were supposed to we haven't got any leaks coming out of any of the fittings and none of the cylinders are leaking so that's been a successful rebuild of our Boom Lift cylinders everything went pretty well to plan now that I've cycled the cylinders and got all the air out of the system I just need to top up the hydraulic oil righto guys so that is the first stage of our project completed this took about a day to put all this back together and that was with Karen sort of getting in the way every now and again all up the cost of everything that we have done today we've got about 850 dollars in oil about 350 dollars in filters the pipes and hoses a friend of mine has the facility to make his own stuff so I got them heavily discounted at about two hundred dollars and there was about sixty dollars for the new filler neck and the sight glass so all up round figures about fifteen hundred dollars for what we did today so the next part of this project I'd like to tackle will be the steering cylinders but I do need this area for an upcoming job so I won't be doing them straight away just gonna have to wait until we get the next little bit of free time so I hope you enjoyed this first part of the project thanks for watching [ __ ] we'll recycle the steel oh yup [Karen] send it to big stack to melt oh you son of a [ __ ] [Karen] ewww oh god [Karen] oh that's so nasty [Laughter] [Karen] sorry if you guys were eating [Karen] anything good in there oh hang on what's this [Karen] [Laughter] typical Kurtis [ __ ] elbow deep in a [ __ ] mud hole [caw caw caw] go away Russell righto are you ready okay [ __ ] off Russell [caw] he's got a friend [CAW] ohhh SHUT UP [crows get louder] [Karen freaking out] ah he wha wha what are you doing [Karen] I just wanna I don't know about this nah just come over here BANG [Karen] AHhh [Laughter] that's not funny [sigh] now you got to fight the filter oh yeah heh ahh it's gonna stick to the sides [Laughter] that was funny [giggle] dang it oh no [Laughter] lucky you didn't fill up the tank first yeah see that's the thing when you do this port here if any of them leak while you're filling it you don't get it yeah you don't get any other choice there's no second chance there [Karen] whatis it meant to see through that yeah [Karen] oh that's your finger [Laughter] I thought I thought it was like a cloudy cover [Laughter] no it's my finger it's oh no he's a mess it's his jackets coming off you're a mess

Channel: Cutting Edge Engineering Australia

Views: 289,658

Keywords: cutting edge engineering australia, machinist in australia, machininst, abom79, cee australia, franna crane project, MAC 14 Franna, 14 tonne crane, Franna crane, franna mac, franna, yard crane, workshop machinery, boom lift cylinder rebuild, boom lift cylinder, crane repair, franna crane repair, hydraulic cylinder repair, hydraulic cylinder rebuild, cylinder, making new boom lift cylinder, hydraulic filter, changing hydraulic oil, changing hydraulic filter, replacing oil filter

Id: My622esNR04

Length: 46min 8sec (2768 seconds)

Published: Fri Jun 16 2023