The Most Advanced Construction and Mining Equipment Training System Unveiled In Australia - Part 2 Bucket Control And Steering

The Model MF500 is offered with an optional front end, which is identical in every form to an articulated front-end loader.

The MF500 is so well designed that when the loader module is attached to the front of the hydrostatic transmission trainer, it puts the entire weight of the Model 500 onto the front tires. This was necessary because many of the problems that develop on loaders are only evident when the machine is operating under load. The bottom line is that when it comes to troubleshooting hydraulic systems if there is no load (pressure), there is no test!

Hydraulic Bucket Control System Training System

The Model MF500's bucket control system consists of a two-section directional control valve, dual lift/lower cylinders, and dual rollback/dump cylinders. For practical purposes and safety, the load consists of a large water tank. When filled with water, the "load" weighs approximately 400 pounds (181 kilograms). The loader can operate with or without load.

It's conceivable that the MF500 is the first hydraulic system delivered to Australia's shores that meets the MDG46 standard in its entirety. This is because the MF500's hydraulic systems are equipped with Safe-T-Bleed valves. Safe-T-Bleed is the only product in the world that is explicitly designed to enable technicians to "detect and diffuse" stored hydraulic energy post-lockout/shutdown.

Additional safety features include; velocity fuses in the lift/lower cylinders; mechanical locks that lock the bucket in the raised position; mechanical locks that lock the articulation joint in the straight forward position; and the bucket does not have a base, which makes it less that "adventurous" students will lift each other into the air.

Additional safety features are: the bucket cannot touch the ground, which eliminates foot crush incidents; closed-loop cylinder air bleeding system; Safe-T-Bleed valves on all cylinder ports; all pressure monitoring is achieved with non-invasive "connect under pressure" (CUP) valves; and the entire bucket and steering mechanisms are free of pinch-points.

The MF500 also eliminates slip hazards. Students can spend an entire day learning how to set-up, adjust, and troubleshoot hydraulic systems, and at the end of the day, there may be a few drops of oil on the floor. The components and oil transmission lines are equipped with "zero-leak" flat face quick connect/disconnect valves.

When students are using the MF500 to learn bucket controls the large panel PC with 24" touchscreen swivels around and sits in front of the student. All the relevant schematics and activities are selectable.

Every component in the bucket control circuit can fault in real-time. One or both lift/lower cylinders can develop an internal leak across the piston seals, and the directional control valve can develop a leak across the spool/bore. The hydraulic pump can also "wear out" in real-time. The directional control valve is equipped with cylinder port relief valves and anti-cavitation valves.

When a loader is experiencing a "down-drift" problem, if the problem lies in the directional control valve most mechanics cannot isolate the problem - is the oil leaking across the spool/bore, or is it leaking across a cartridge valve? 

MicroLeak testing makes it possible for mechanics to isolate the problem in 5-minutes. Try to imagine how many directional control valve assemblies have been removed from machines because mechanics could not isolate a cross-port leakage problem. Regrettably, it's the cartridge valve that is usually the problem.

Here is a link to a YouTube video of MicroLeak testing: https://www.youtube.com/watch?v=3E7dehBBvLw

Students learn also how to set cylinder port relief valves and also cross-port relief valves.

We have a client that was replacing directional control valves on their large front-end loaders at the cost of $US67,000.00. When their mechanics mastered MicroLeak testing and were able to apply it, 99% of the time an operator complained that the lift/lower cylinders were drifting, they eliminated the problem by replacing a $US350.00 cartridge valve.

Ironically, with the money, they saved by replacing one valve they could have purchased two MF500 bucket control training systems.

The MF500 is so advanced from the point-of-view of troubleshooting that it far exceeds TAFE's learning outcomes. FPTI invented MicroLeak testing. In short, MicroLeak testing makes it possible for technicians to test 98% of the components in any mobile or industrial hydraulic system with the power source safely locked out. Each test takes approximately 15-minutes to complete.

The hydraulic system troubleshooting error rate (HTER) in the U.S. is north of 80%. That means 80% of components removed from hydraulic systems are in good working condition. MicroLeak testing is guaranteed to reduce the error rate to below 1%.

Note: I have personally traveled to Australia on two occasions to try to "sell" MicroLeak testing to TAFE. As with most countries that have standardized apprenticeship training programs, the administrators of the training programs are, with all due respect, "set in their ways." There is no doubt that if TAFE introduced MicroLeak testing into the apprenticeship training program the country would save billions of dollars in unnecessary component replacement, downtime, international freight, overtime, unnecessary component rebuild, and increased productivity.

Note: Any country that is sincerely interested in adopting MicroLeak testing please contact me. I am interested in traveling to your country to teach your hydraulic instructors MicroLeak testing.

The MF500 is specifically designed to teach students a revolutionary new way to performance test hydraulic components. However, it is also be used to teach students the "traditional" way of testing hydraulic components.

Hydraulic Steering Training System

When students advance to the steering module, the large Panel PC with 24" touchscreen rotates around and sits in front of the steering wheel. 

The hydraulic steering training module consists of the identical components found in most articulated vehicle's steering systems: hydraulic steering valve (orbital type); cross-port relief valves, dual steering cylinders, variable volume pressure compensated axial piston pump, and hydro-pneumatic accumulator.

As with all other hydraulic components, all steering components can "wear out" in real-time - including the hydraulic steering valve. Also, all components are equipped with FPTI's exclusive Safe-T-Bleed system. 

In addition to learning hydraulic safety, the steering system is equipped with mechanical safety locks identical to those found on all articulated vehicles. 

I have seen instructors desperately trying to show students wear in components by taking good valves and filing the seats. Then they have to go through the laborius and messy task of switching valves while the students look away. All FPTI's products with troubleshooting capability are designed to make components wear out without the student (s) ever knowing. All faults are electronically activated. 

The MF500's ability to teach troubleshooting is so advanced that the nitrogen can be discharged from the hydro-pneumatic accumulator without the student's knowledge. 

Why did FPTI design the Model MF500? Many instructors wanted a hydraulic training system that was as close the "real thing" as possible. The MF500's design is based on a skid-steer loader and an articulated vehicle. 

The most desirable feature of the MF500 is the ability to permit students to learn with a "real-life" machine that is operating in real-time. The MF500 eliminates a wide variety of hazards. While the "construction machine" is in motion and operating under full load the student can learn to make vital adjustments. Also, the computer can randomly select faults in a given circuit, or the instructor can select faults for focussed training.

The MF500 is also ideal for competency testing. It can be used to test students or to determine the competency of new hires.  

The MF500 is available with either an electric motor drive or diesel engine. The electric motor drive is the most desirable because it is quiet enough that the instructor and students can have dialogue while the systems are operating under full load. 

Other desirable features of the electric unit are zero-emissions; no consumables; no need to have special permits to store diesel; no heat source from the exhaust and cooling system. 

As with all FPTI products the quality of the visual aids and textbooks are consistent with the quality of the training simulators. The textbooks are superb and the student activities are exceptional. All component and circuit functions are animated. Also, FPTI doesn't charge outrageous licensing fees.

FPTI also provides unparalleled train-the-trainer workshops. 

This cost of this fantastic training system is below US$100K

For more information or a quote, please contact me - [email protected] or visit our website at www.fpti.org

For enquiries within Australia please contact our dealer - Bestech

Contact: [email protected]