DataSplit User Manual

9 TROUBLESHOOTING
9.1 Troubleshooting principles
Use the following principles as guidelines for locating and solving system problems:
1. Be aware of the normal operating situation.
2. Recognize a system problem (see, hear, feel, smell) - for example:
• Smoking and overheated brake band: see/smell/feel
• Drum not turning fast or slow enough: see drum, depth and speed display
• Engine vibration: feel and hear unit shake
3. Identify the system status before the problem.
4. Analyse the actions that immediately preceded the system problem.
5. Identify possible causes:
• Refer to the manual to verify that all setup steps were done correctly (transport,
connecting, rigging up, etc.)
• Is problem mechanical, electrical, hydraulic, or combined (use schematics and look at
most likely area first)
• Systematically eliminate a possible cause before continuing with next possible cause
• Solve the cause and the problem:
Use maintenance procedure from manual where available
Permanent solution where possible
Temporary solution (always with long term fix proposal)
6. Test the solution to ensure it is effective.
7. Register actions in Logbook to track recurring problems.
8. Report error and solution appropriately.
9.2 Troubleshooting table
The following troubleshooting table for the K-Winch DataSplit C provides possible causes and
suggested solutions for common problems.

PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY

LEVELWIND SYSTEM
Noisy levelwind chain Too much slack in chain Tighten chain tensioner

Levelwind carriage judders during Dry slider bearing Grease the bearing
horizontal motion

ENGINE
Engine stops Fuel tank is empty Fill fuel tank with diesel and restart engine

Engine exhaust is blocked Remove obstruction from exhaust and

restart engine

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PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY

Emergency stop button is pushed Release emergency stop button and
restart engine

Air inlet valve is closed Open air inlet valve

Sentinel valve is activated Reset sentinel valve

Diesel engine creates excessive noise Worn shock mount diesel engine Replace faulty shock mount
and vibration shock mount

Engine temperature too high Coolant too low Replenish coolant as necessary

Fan malfunction Replace fan or V-belts

Thermostat malfunction Replace thermostat

Engine oil pressure too low Engine oil too low Replenish engine oil as necessary

Oil pump malfunction Replace oil pump

Engine does not cutout at the pre- Wrong setting of the over speed Change setting of the over speed
adjusted over speed setting controller controller adjustment screw

Other engine problems Check the supplier documentation

HYDRAULIC SYSTEM
Noisy hydraulic pump(s) Air bubbles in oil Check hydraulic oil level. Replenish oil as
necessary.

Contaminated oil filters. Clean and/or replace oil filter(s) as

necessary

Zero hydraulic control pressure Hydraulic system oil level low Replenish hydraulic oil as necessary

Broken coupling between motor and Inspect through hole in coupling body.
pump group Repair/replace coupling.

Major leak in pressure lines (hose/ Repair as required

coupling)

Restricted or broken suction line Remove line and clear obstruction or

replace line

Worn/broken pump drive shaft Replace pump drive shaft, coupling or

coupling or drive plate. drive plate

Drum does not turn when DRUM Hydraulic pressure lines to winch Check lines, connect or replace hose(s)
CONTROL lever is operated motor restricted or open

Pump not generating pressure to Check setting relief valve (back of

hydraulic motor hydraulic motor)

Hydraulic control pressure is zero See problem description above

Main relief valves (hydraulic motor) Screw in or remove/replace cartridge

not screwed in or cartridge leaking

Worn out packing ring or HD seal. Replace seals

MEASURING HEAD
Measure wheel does not rotate smoothly Friction level in the bearing is too Replace the bearing
high

Accumulated dirt Remove wheel, clean parts and reinstall

WINCH TRANSMISSION
Oil leaks Worn seals Replace seals

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Version 1.00 ASEP K-Winch DataSplit C, Project no. 9884/5/6/7, 6 October 2009
 DataSplit User Manual

PROBLEM POSSIBLE CAUSE SUGGESTED REMEDY

Leakage at plugs Replace / re-tighten plugs

Excessive noise from reduction gearbox Low lubrication oil level Fill reduction gear with oil

Drum does not turn when DRUM Brake applied Disengage drum brake
CONTROL lever is operated

Hydraulic problem See HYDRAULIC SYSTEM on page 220

Pneumatic pressure loss (indicated Check air compressor and air receivers.
by pressure gauge on the SmartView Repair if defective.
control panel) Check all pneumatic lines in body and
control panel.

Drum continues turning with DRUM Excessive temperature caused by Change oil using recommended viscosity
CONTROL joystick in neutral contaminated oil and flush system.

Valve spool sticking due to scored Remove valve and repair or replace as
spool. necessary.

Valve spool sticking due to weak/ Remove valve and repair or replace as
broken return spring necessary.

Valve spool sticking due to excess Check pressure across relief valve and
pressure caused by defective relief repair or replace as necessary.
valve.

Valve spool sticking due to binding Repair or replace control rod or lever as
control rod or lever necessary

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