4.maintenance & trouble shooting 1
TRANSCRIPT
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Maintenance
&Trouble shooting
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General Maintenance Measuresof
VOITHHydraulic Couplings
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Maintenance Measures With Unit Running
Daily:
Check the oil level in coupling.
Temperatures of bearings, lube oil & working oil
Lube oil and working oil pressures
Differential pressure on the lube oil filter
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Maintenance Measures With Unit Running
Every 1000 hours of operation:
Check operating oil for contamination or for its reusability.
(centrifuge if required)
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Check the vent filter for impurities.
Measure, record and compare smooth running (vibrations)
under the same operating conditions.
In case of any problem, please check first the alignment.
Maintenance Measures With Unit Running
Every 3 months:
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Maintenance Measures When the Unit is at
Standstill
Every 2 Months:
Clean vent filter.
Check smooth running of actuator.
Visually inspect gear stage.
Check operating oil for contamination.
Check oil level. In case of too high oil level, check for water
content in the oil.
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Maintenance Measures When the Unit is at
Standstill
Every 8000 hours of operation or at least annually:
Analyze operating oil for aging and other specifications.
Inspect and maintain connecting couplings.
Check the actuator functioning.
Check alignment and foundation fixing of hydraulic coupling.
Visual inspection (corrosion, general condition etc) of hydraulic
coupling internals by removing inspection cover on top housing.
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Maintenance Measures When the Unit is at
Standstill
Every 8000 hours of operation or at least annually:
Visual inspection of tooth contact pattern.
Inspection of fusible plugs.
Check and maintain A.O.P. motor
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Maintenance Measures When the Unit is at
Standstill
General Overhaul:
In the event of a change in operating behaviour or after maximum
5 years operating time, variable speed & geared variable speed
turbo coupling should be overhauled.
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Trouble Shooting
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Trouble Cause(s) Action(s)1. Scoop tube in 0% position Move scoop tube in 100% direction.
2. Oil pump not delivering Check the oil level in the sump.any oil Check the direction
Check oil pump itself.
3. Starting torque too high. Check the driven machine itself.Driven machine blocked.
Driven machine
cannot start after
the driving
machine has
reached
its rated speed
Start-upTROUBLE SHOOTING
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Trouble Cause(s) Action(s)
1. Driven machine is jammed. Remove obstacles.
(Check fusible plugs)
2. Oil flow too low Check oil flow
Coupling heats up
excessively during
start-up
Start-up TROUBLE SHOOTING
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Trouble Cause(s) Action(s)
1. Lack of cooling water. Check cooling system.
Water is too warm Clean cooler.Cooler contaminated
2. Over loading of the coupling Check design data(Check fusible plugs)
Coupling heats up
excessively during
operation
Start-up TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Momentary fluctuations in the Check the system and stabilize.
driven machine.
2.Oil temperature is too low. Increase the temperature.(poor deaeration of oil) (45C to 50C)
3. Oil pump pressure varies
Check thePr. relief valve
4.Gear pump is aspirating air. Check oil level of sump.
Fluctuations of output
speed during manualcontrol of coupling(Control lever at standstill)
Output Speed TROUBLE SHOOTING
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Trouble Cause(s) Action(s)
1. Improper input signal to the
Check the controller andactuator. calibrate.
2 .Actuator speed is too high. Check and control.
3 .Air entering into the oil circuit. Check and eliminate.
Fluctuations of output
speed during autocontrol of coupling(To & fro movement of
control lever)
Output Speed TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Scoop tube is jammed. Remove obstacles.
2. Actuator defective Check the actuator.
3. Input signal problem Check the controller.
Output speed
cannot be
controlled
Output Speed TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Scoop tube not in 100% Check the scoop tube position.
Position.
2. Fusible plugs responded Find and eliminate the cause.Insert new fusible plugs.
3. Too high power requirement Compare the power data with the
of driven machine project data.Check driven machinefor smooth running.
4. Working oil flow rate too low Readjust flow rate.
Max.Output
speed cannot
be reached
Output Speed TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Lube oil filter clogged Change over lube oil filter and clean
the filter element.
2. Leak in the oil circuits Check the pipe lines,coolers etc.
3. Ext.lube oil supply too high. Adapt the orifices.
4. Pr.relief valve set too low. Correct the setting.
Lube oil
pressure is low
Pressures TROUBLE SHOOTING
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Trouble Cause(s) Action(s)
1. Lube oil filter clogged Change over lube oil filter and clean
the filter elements.
Differentialpressure across
double oil filter
too high
Pressures TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Lube oil filter clogged Change over lube oil filter and clean
the filter element.
2. NRV of AOP jammed Check Non return valve
3. Ext.lube oil supply too high. Check the sizing of orifices.
4. Pr.relief valve jammed or
setting distrubed. Check the valve & Correct setting.
Lube oil
pressure too low
during normal
operation
Pressures TROUBLE SHOOTING
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Trouble Cause(s) Action(s)1. Oil level too low Check oil level & top up.
2. Mechanical wear to pump Check pump parts.
3. Leakages in the oil circuit. Check the internal piping.
4. Pr.relief valve jammed or
setting distrubed. Check the valve&Correct the setting.
Working oil pump
pressure too low
Pressures TROUBLE SHOOTING
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Trouble Cause(s) Action(s)Lube oil Cooler Problem
1. Cooling water flow rate too low Increase the cooling water flow rate2.Cooling water too warm
3.Cooler is contaminated
Check and clean the cooling system
1.Fusible plugs responded Find and eliminate the cause.Insert
new fusible plugs.
Lube oil temperature
too high downstream
of lube oil cooler
Temp. TROUBLE SHOOTING
Lube oil temperaturetoo high upstream of
lube oil cooler
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Trouble Cause(s) Action(s)1. W.Oil pump not delivering oil. Check oil level & top up.
-oil level too low
-working oil pump pr
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Trouble Cause(s) Action(s)Temp. TROUBLE SHOOTING
Bearing temperature
too high
1. Bearing damage Check the bearings and replace.
2. Lube oil temperature too high Check the lube oil cooler.
3.Lube oil pressure too low Check the lube oil system anddifferential pressure.
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Trouble Cause(s) Action(s)1.Faulty alignment Check and correct alignment.
2.Foundation bolts are loose, Check the foundation and retightenthe foundation is defective the foundation bolts.
3. Wear or insufficient lubrication Check the connecting couplings.of connecting couplings
4. Unbalance of rotating parts
Measure the vibration and check therunner parts.
5.Bearing damage Check and replace bearings.
Smooth Running TROUBLE SHOOTING
Uneven running,
vibration and
noise
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