Drive Wear Inspection Quiz
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Questions and Answers

What is an indicated cause of scratches and grooves on a motor?

  • Use of incompatible fluids
  • Improper electrical connections
  • Abrasive contamination in hydraulic fluid (correct)
  • Excessive heat due to friction

What is the primary issue indicated by erosion (pitting) on a valve plate?

  • Excessive lubrication leading to deposits
  • Cavitation caused by overrunning load (correct)
  • Inadequate filtration of hydraulic fluid
  • Overheating from high pressure

What operational condition can lead to scoring marks on a valve plate?

  • Frequent and abrupt shifting of the motor (correct)
  • Consistent and careful adjustment
  • Failure to monitor fluid levels
  • Extended idle time of the motor

What can result from cavitation in a motor?

<p>Formation of vapor bubbles that cause erosion (B)</p> Signup and view all the answers

What may cause galling in a motor?

<p>Fast shifting back and forth or worn components (D)</p> Signup and view all the answers

What condition might excessive outward thrust loading of the output shaft cause?

<p>Scoring on the shaft (C)</p> Signup and view all the answers

What is the primary cause of wear in the seal area and bearing area of a shaft?

<p>Abrasive contamination suspended in hydraulic fluid (D)</p> Signup and view all the answers

What could cause uneven wear between the top and bottom of a shaft?

<p>Side loading (B)</p> Signup and view all the answers

What does severe wear on the output part of the shaft but not on the bottom indicate?

<p>Possible side loading (B)</p> Signup and view all the answers

How does contamination typically manifest in needle bearing wear?

<p>Visible scratches and grooves (B)</p> Signup and view all the answers

What could severe wear in the seal area of a shaft also indicate?

<p>High case pressure (D)</p> Signup and view all the answers

What causes galled wear in the seal area and face of the shaft?

<p>Abrasive contamination (A)</p> Signup and view all the answers

What does the indication of thrust load on the needle bearing side of the shaft suggest?

<p>Potential damage from excessive pulling force (D)</p> Signup and view all the answers

What indicates that a drive with normal wear can be reused?

<p>Smooth surfaces without scratches (A)</p> Signup and view all the answers

Which condition requires the drive to be discarded due to damage?

<p>Severe gear teeth wear with burnishing (C)</p> Signup and view all the answers

What is a likely cause of chipped gear teeth in a drive?

<p>Insufficient lubrication (A)</p> Signup and view all the answers

What does the term 'burnishing' refer to in the context of drive wear?

<p>Marks caused by the drive moving forward excessively (C)</p> Signup and view all the answers

What does corner loading indicate in a drive's gear teeth?

<p>Excessive wear or lubrication issues (B)</p> Signup and view all the answers

Which observation suggests that a drive can be used again?

<p>Smooth critical surfaces (D)</p> Signup and view all the answers

What is the consequence of running a drive primarily in one direction?

<p>Uneven wear on gear teeth (B)</p> Signup and view all the answers

What does light wear on gear teeth suggest concerning the condition of the drive?

<p>Minimal impact on functionality; may be reused (A)</p> Signup and view all the answers

What does chipping on the corners of gear teeth typically indicate?

<p>Corner loading caused by heavy motor load (A)</p> Signup and view all the answers

What condition must a disc valve meet to be considered ok to use again?

<p>Surface free of nicks, burrs, and scratches (C)</p> Signup and view all the answers

What is a probable cause of crown wear on a drive?

<p>Lack of lubrication (C)</p> Signup and view all the answers

What should be done prior to applying full load to a new motor?

<p>Operate the motor for one hour at 30% of rated pressure (A)</p> Signup and view all the answers

What does scoring on the disc valve surface typically indicate?

<p>Abrasive contamination in hydraulic fluid (A)</p> Signup and view all the answers

What might excessive chipping in the valve drive area suggest?

<p>The valve was not lubricated properly (D)</p> Signup and view all the answers

What kind of wear is typically caused by lack of lubrication or poor fluid viscosity?

<p>Normal gear tooth wear (D)</p> Signup and view all the answers

Why is it important for the valve drive teeth area to be in good condition?

<p>It affects the timing of hydraulic fluid passage (A)</p> Signup and view all the answers

What is indicated by severe gear tooth wear?

<p>Lack of lubrication or improper viscosity (D)</p> Signup and view all the answers

What might cause a disc valve to have a wear pattern around its surface?

<p>Subjected to fine abrasive contamination (D)</p> Signup and view all the answers

In what condition is it acceptable to reuse the spool valve?

<p>If the critical surface area is smooth and free from defects (A)</p> Signup and view all the answers

What is a likely consequence of the drive area wear affecting valve performance?

<p>Poor performance due to cross porting of hydraulic fluid (D)</p> Signup and view all the answers

What can be concluded about the machining marks on the top of the drive?

<p>They are likely due to bad tooling (A)</p> Signup and view all the answers

What is the main reason for implementing a proper run-in procedure for a new motor?

<p>To avoid severe wear and extend motor life (B)</p> Signup and view all the answers

What should be concluded if a disc valve shows no signs of wear on its critical surface area?

<p>The valve is suitable for reuse (C)</p> Signup and view all the answers

What could lead to scoring on the face of a valve?

<p>Using lower quality hydraulic fluid (D)</p> Signup and view all the answers

What condition must be present for a component to be considered OK to use again?

<p>No signs of wear or damage in critical areas (B)</p> Signup and view all the answers

What is the leading cause of hydraulic component failure?

<p>Contamination (B)</p> Signup and view all the answers

What damage on the output shaft keyway indicates it should not be used again?

<p>Severe wear and chipping due to improper fit (A)</p> Signup and view all the answers

What condition indicates spalling in bearings?

<p>Removal of small particles from running surfaces (C)</p> Signup and view all the answers

Which of the following is a cause of smearing noted on the Gerotor or Geroler?

<p>Improper lubrication or lack of hydraulic fluid (C)</p> Signup and view all the answers

What type of damage occurs due to cavitation in a hydraulic motor?

<p>Erosion or pitting (D)</p> Signup and view all the answers

What is the effect of an overrunning load condition in hydraulic systems?

<p>Causes the motor to cavitate (A)</p> Signup and view all the answers

Which statement about the shaft bearing mating surfaces is true if they show no signs of wear?

<p>They are free of nicks, burrs, or scratches. (C)</p> Signup and view all the answers

Flashcards

Drive Wear - Normal

Normal wear on gear teeth and ends of the drive, without any nicks, burrs, or scratches.

Drive Wear - Chipped

Damage to gear teeth caused by lack of lubrication, resulting in chipped or worn teeth.

Drive Wear - One-Directional Use

Excessive wear on one side of the gear teeth, indicating it was run in only one direction. This wear is often accompanied by burnishing marks.

Drive Wear - Severe

Severe wear on gear teeth, with chipping and burnishing caused by lack of lubrication or poor fluid viscosity.

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Drive Wear - Crown Wear

Wear on the corner of the gear teeth crown, indicating corner loading due to excessive wear or lack of lubrication.

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Drive Spline Wear - Light

Light wear on the drive's critical surfaces, indicating it can still be used.

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Drive Spline Wear - Water Contamination

Wear on gear teeth and chipping on the corners of the drive, with rust staining on the shaft indicating water contamination.

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Burnishing

The process of hardening the surface of a material by applying pressure, often seen on gear teeth.

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Corner Loading

When the corners of a gear tooth show chipping, it suggests excessive force was applied to the motor. This occurs when heavy loads are placed on the motor.

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Crown Wear

A sign of wear on the top surface of a gear drive, often caused by insufficient lubrication.

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Gear Tooth Wear

The regular wear and tear on the surface of a gear tooth, typically caused by insufficient lubrication or fluid viscosity.

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Severe Gear Tooth Wear

Severe wear on the gear tooth, indicating significant wear from lack of lubrication or incorrect fluid viscosity.

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Motor Run-In

A process where a new motor is run at low pressure, flow, and torque for a period of time, to evenly distribute wear and prevent premature damage.

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Improper Run In

A type of wear caused by improper start-up or run-in of a motor, leading to uneven distribution of wear and damage.

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Critical Surface Area

The smooth, flat, and scratch-free surface of the output shaft, indicating proper functionality and wear.

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Thrust Loading

A condition where loads are not evenly distributed on the shaft, often caused by misalignment or other mechanical issues.

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Thrust Load Wear

Excessive outward force applied to the output shaft, pushing it into the thrust bearing. Can result from improper alignment, overload, or excessive pressure within the hydraulic system.

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Side Loading Wear

Uneven wear on the shaft's top and bottom due to excessive sideways force. Suggests misalignment or improper loading.

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Shaft Contamination Wear

Scratches and wear marks on the shaft caused by foreign particles contaminating the hydraulic system. Indicates poor filtration or system contamination.

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Shaft Seal Contamination Wear

Wear in the shaft seal area, usually caused by contamination. Can be triggered by abrasive particles in the hydraulic fluid.

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Bearing Journal Contamination Wear

Wear in the bearing journal area, indicates abrasive particles in the fluid, and possibly inadequate lubrication.

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Needle Bearing Contamination Wear

Wear within the needle bearing area, caused by contaminants. Points to poor fluid filtering or improper maintenance.

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Severe Contamination Wear

Severe wear in the seal area and the shaft surface, caused by contamination. Indicative of severe system contamination.

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Even Contamination Wear

Excessive wear due to contamination, causing uniform wear across the surface.

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Disc Valve - Damaged

A disc valve with scratches, nicks, or burrs on its surface is considered unsafe and should not be reused. These imperfections can disrupt smooth operation and lead to potential failure.

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Scored Disc Valve

Scoring on a disc valve's surface indicates abrasive wear caused by contaminants in the hydraulic fluid. This contamination can damage other components in the system and should be addressed immediately.

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Valve Drive - Excessive Wear

Excessive wear on the drive teeth of a valve typically indicates one-directional use or lack of lubrication. This wear pattern can lead to timing issues and reduce overall performance.

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Valve Drive - Chipping

Chipping on the valve drive teeth is a serious issue caused by poor lubrication or fluid viscosity. This damage can affect valve timing and performance.

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Disc Valve - Good Drive

A disc valve with smooth, flat drive surfaces free of nicks, burrs, and scratches is good to use again.

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Cavitation

A condition where fluid cannot enter the motor quickly enough due to excessive speed and low inlet pressure, leading to violent bubble collapse that damages the motor.

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Overrunning Load

A condition where the motor is overloaded, resulting in excessive wear and tear on the valve plate.

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Erosion

Wear on the valve plate caused by the Geroler rolls coming into contact, often due to an overrunning load.

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Scoring

Deep scratches or grooves on the valve plate caused by abrasive contaminants in the hydraulic fluid, possibly due to lack of lubrication.

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Galling

Severe damage on the valve plate caused by excessive back-and-forth movement, possibly due to a worn Geroler star.

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Keyway Chipping

Chipping or damage on the keyway of an output shaft, usually indicating a loose mating coupling.

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Gerotor Smearing and Erosion

A condition where the gerotor star face and roller ends show signs of smearing and pitting, indicating insufficient lubrication or overloading of the hydraulic motor.

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Overrunning Condition

A condition where a hydraulic motor is turning so fast that it begins to consume fluid faster than the pump can deliver, resulting in cavitation and damage.

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Contamination

Damage to hydraulic components caused by a lack of lubrication, resulting in the removal of small particles of material from the surface.

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Study Notes

Drive Wear

  • OK to use again: Teeth and finished surface show no signs of wear, nicks, burrs, or scratches. Inspect gear teeth and ends of the drive.

Chipped

  • Do not use again: Chipped or damaged gear teeth are present. Lack of lubrication is usually the cause.

Wear

  • Do not use again: Excessive wear on one side of gear teeth suggests the drive ran in only one direction. Lack of lubrication or poor fluid viscosity could lead to chipping. Burnishing (a burn mark) may indicate drive tooth wear.

Burnishing

  • Do not use again: Severe wear and burnishing. Likely caused by lack of lubrication, poor fluid viscosity. Often associates with drive movement in one direction.

Gear Tooth Crown Wear

  • Do not use again: Worn corner of gear tooth crown. Indicates corner loading. Could be due to excessive wear or lack of lubrication.

Drive Spline Wear

  • OK to use again: Smooth, flat surface in spline area free from nicks, burrs, or scratches indicates light wear.

Wear - Gear Teeth/Chipping

  • Do not use again: Light wear and chipping on gear teeth and drive corners. Rust on the shaft (not on teeth) suggests water in the fluid. Corner chipping suggests corner loading. This occurs when the motor is under heavy load.

Crown Wear

  • Do not use again: Wear on the crown of the drive. Suggests insufficient lubrication.

Wear - Gear Tooth

  • Do not use again: Normal wear is ok otherwise improper lubrication or viscosity is issue.

Wear & Chipping

  • Do not use again: Severe wear. Improper start up or run-in procedures are a common problem.

Wear

  • Do not use again: Severe wear caused by lack of lubrication or poor fluid viscosity.

Wear and Chipping

  • Do not use again: Severe wear is noted. This is typically due to lack of lubrication.

Spool Valve

  • OK to use again: Smooth, flat surfaces free from scratches on spool valve. Seal and bearing areas show no wear.

Scored

  • Do not use again: Excessive Outward Thrust loading. Excessive case pressure and backpressure can cause this type of wear.

Scored

  • Do not use again: Uneven wear between the top and bottom of shaft. This is due to side loading and/or contamination.

Scored

  • Do not use again: Wear in seal and bearing area, likely caused by abrasive contamination in hydraulic fluid.

Scored

  • Do not use again: Severe wear in needle bearing area. Contamination of the hydraulic system is likely the underlying cause.

Smeared

  • Do not use again: Smearing or wear on the output shaft (not the bottom part) indicates side loading, likely from a pulley or chain being too tight.

Galled

  • Do not use again: Severe wear in the seal area and the face of the shaft, caused by contamination. More wear on the output end than on the shaft top usually points to possible side-loading.

Galling

  • Do not use again: Damage on the needle bearing side of the shaft. This indicates thrust loads, pulling forces, high case pressure, and/or high back-pressure.

Scored

  • Do not use again: Severe wear, even wear throughout the surface. Likely the contamination issue.

Scoring, Smeared

  • Do not use again: Damage to the keyway resulting from improper cup-link fit. Likely contamination suspended in fluid.

Galled

  • Do not use again: Severe wear (material removal or grooves) around shaft. Indicating lack of lubrication, and abrasives in the fluid.

Galled

  • Do not use again: Galling is noted. Presence of material removed from one surface due to friction, and attached on the mating-component surface. Suggests lack of proper lubrication, high backpressure, or thrust loading.

Scored

  • Do not use again: Scoring marks on disc valve surface suggests contamination, possible in high-pressure hydraulic fluid.

Disc Valve

  • OK to use again: No wear on the surface. Free from scratches, burrs, and nicks.

Wear

  • Do not use again: Wear pattern suggests contamination, probably fine abrasives suspended in the hydraulic fluid, on the disc valve surface.

Wear

  • Do not use again: Chipping in the valve drive area. Wear is likely due to one-directional operation, insufficient lubrication, or viscosity. Poor lubrication and fluid viscosity can cause timing issues; and cause hydraulic fluid to cross port from high pressure side to low pressure sides, resulting in poor performance.

Valve Drive

  • OK to use again: Smooth and flat surface of the disc motor valve drive surface which is free of any damage or wear.

OK to use again

  • The teeth and finished surface show no signs of wear, nicks, burrs or scratches. Inspect gear teeth and ends.

Bearing

  • OK to use again: The shaft bearing mating surfaces are smooth and free from nicks, burrs, or scratches.

Spalling

  • Do not use again: The bearing shows damage due to spalling, where material is removed from the running surface. This is a progressive process that spreads and is often indicative of contamination.

Output Shaft Keyway Chipping

  • Do not use again: Significant wear or chipping at the coupling end of the output shaft. Suggests the coupling is improperly fitted to the shaft.

Gerotor or Geroler - Smeared and Erosion

  • Do not use again: Smearing across the gerotor star face and roller ends suggests a lack and/or improper lubrication. An overrunning condition is also a possibility.

Scoring

  • Do not use again: Wear in the Gerotor roller areas is likely due to contamination.

Erosion/Pitting

  • Do not use again: Erosion on the valve plate indicates the motor likely cavitated, usually due to overrunning conditions, where the motor turns too quickly, not enough fluid can be pumped in, which leads to vapor bubbles collapsing with high impact causing component damage and/or heat issues.

Scoring and Erosion

  • Do not use again: Erosion and scoring on the valve plate, likely caused by overrunning conditions.

Galling, Overrunning Load

  • Do not use again: Galling, chipping, and scoring suggest a possible overrunning load condition where the motor may have been shifting back and forth too quickly.

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Description

Test your knowledge on the inspection of drive wear components and identify the various conditions that determine whether a gear can be reused. This quiz will cover aspects such as chipped gears, excessive wear, and burnishing effects on gears. Understand diagnostic indicators crucial for maintaining gear integrity.

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