4.maintenance & trouble shooting 1

7/29/2019 4.Maintenance & Trouble Shooting 1

1/26

Maintenance

&Trouble shooting


2/26

General Maintenance Measuresof

VOITHHydraulic Couplings


3/26

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
http://localhost/var/www/apps/conversion/tmp/scratch_3/Pictures/Front%20panel.JPG


4/26


Every 1000 hours of operation:

Check operating oil for contamination or for its reusability.

(centrifuge if required)


5/26

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.


Every 3 months:


6/26

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.
http://localhost/var/www/apps/conversion/tmp/scratch_3/Pictures/Top%20view.JPG


7/26


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.


8/26


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


9/26


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.


10/26

Trouble Shooting


11/26

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
http://localhost/var/www/apps/conversion/tmp/scratch_3/Pictures/svtl.exe


12/26

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


13/26


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


14/26

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
http://localhost/var/www/apps/conversion/tmp/scratch_3/Pictures/Output%20side.JPG


15/26


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)



16/26

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



17/26

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



18/26

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


19/26


1. Lube oil filter clogged Change over lube oil filter and clean

the filter elements.

Differentialpressure across

double oil filter

too high

http://localhost/var/www/apps/conversion/tmp/scratch_3/Pictures/Rear%20panel-filters.JPG


20/26

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



21/26

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



22/26

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


23/26

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


24/26

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.


25/26

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


26/26

4.maintenance & trouble shooting 1

Documents