Maintenance & Trouble shooting

General Maintenance Measures of

VOITH
Hydraulic Couplings

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

Maintenance Measures With Unit Running

Every 1000 hours of operation:

Check operating oil for contamination or for its reusability. (centrifuge if required)

Maintenance Measures With Unit Running

Every 3 months:
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 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.

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.

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

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.

Trouble Shooting

TROUBLE SHOOTING

Start-up
Trouble Cause(s) Action(s)

1. Scoop tube in 0% position

Move scoop tube in 100% direction.

Driven machine cannot start after the driving machine has reached its rated speed

2. Oil pump not delivering any oil

Check the oil level in the sump. Check the direction Check oil pump itself.

3. Starting torque too high. Driven machine blocked.

Check the driven machine itself.

Start-up
Trouble Cause(s)

TROUBLE SHOOTING
Action(s)

1. Driven machine is jammed.

Remove obstacles. (Check fusible plugs)

Coupling heats up excessively during start-up

2. Oil flow too low
Check oil flow

TROUBLE SHOOTING

Start-up
Trouble Cause(s) Action(s)

1. Lack of cooling water. Water is too warm Cooler contaminated

Check cooling system. Clean cooler.

Coupling heats up excessively during operation

2. Over loading of the coupling
Check design data (Check fusible plugs)

Output Speed
Trouble Cause(s)
1. Momentary fluctuations in the driven machine.

TROUBLE SHOOTING
Action(s)
Check the system and stabilize.

Fluctuations of output speed during manual control of coupling

(Control lever at standstill)

2. Oil temperature is too low. (poor deaeration of oil)

Increase the temperature. (45C to 50C)

3. Oil pump pressure varies

Check thePr. relief valve

4.Gear pump is aspirating air.

Check oil level of sump.

Output Speed
Trouble Cause(s)

TROUBLE SHOOTING Action(s)

1. Improper input signal to the actuator.

Check the controller and calibrate.

Fluctuations of output speed during auto control of coupling

(To & fro movement of control lever)

2 .Actuator speed is too high.

Check and control.

3 .Air entering into the oil circuit.

Check and eliminate.

Output Speed
Trouble Cause(s)

TROUBLE SHOOTING
Action(s)

1. Scoop tube is jammed.

Remove obstacles.

Output speed cannot be controlled

2. Actuator defective

Check the actuator.

3. Input signal problem

Check the controller.

Output Speed
Trouble Cause(s)
1. Scoop tube not in 100% Position.

TROUBLE SHOOTING Action(s)

Check the scoop tube position.

2. Fusible plugs responded

Find and eliminate the cause.

Insert new fusible plugs.

Max.Output speed cannot be reached

3. Too high power requirement of driven machine

Compare the power data with the

project data.Check driven machine for smooth running.

4. Working oil flow rate too low

Readjust flow rate.

Pressures
Trouble Cause(s)
1. Lube oil filter clogged

TROUBLE SHOOTING Action(s)

Change over lube oil filter and clean
the filter element.

Lube oil pressure is low

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.

Pressures
Trouble Cause(s)

TROUBLE SHOOTING Action(s)

Differential pressure across double oil filter too high

1. Lube oil filter clogged

Change over lube oil filter and clean

the filter elements.

Pressures
Trouble Cause(s)
1. Lube oil filter clogged

TROUBLE SHOOTING Action(s)

Change over lube oil filter and clean
the filter element.

2. NRV of AOP jammed

Check Non return valve

Lube oil pressure too low during normal operation

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.

Pressures
Trouble Cause(s)
1. Oil level too low

TROUBLE SHOOTING Action(s)

Check oil level & top up.

2. Mechanical wear to pump

Check pump parts.

Working oil pump pressure too low

3. Leakages in the oil circuit. Check the internal piping.

4. Pr.relief valve jammed or setting distrubed.

Check the valve&Correct the setting.

Temp.
Trouble
Lube oil temperature too high downstream of lube oil cooler

TROUBLE SHOOTING Cause(s)

Lube oil Cooler Problem 1. Cooling water flow rate too low 2. Cooling water too warm 3. Cooler is contaminated

Action(s)
Increase the cooling water flow rate Check and clean the cooling system

Lube oil temperature too high upstream of lube oil cooler

1.Fusible plugs responded

Find and eliminate the cause.Insert

new fusible plugs.

Pressures
Trouble Cause(s)
1. W.Oil pump not delivering oil.
-oil level too low -working oil pump pr<1.5bar -working oil flow rate too low

TROUBLE SHOOTING Action(s)

Check oil level & top up.

Working oil temperature exceeds 110 deg C during operation.

2. Fusible plugs responded

Check&Eliminate cause.

3. Working oil cooler.

-cooling water flow rate too low -cooling water too warm -cooler contaminated

Check&Eliminate cause.

4.Operation outside the planned characterisitc curves.

Observe the design data.

Temp.
Trouble Cause(s)

TROUBLE SHOOTING Action(s)

1.

Bearing damage

Check the bearings and replace.

Bearing temperature too high

2.

Lube oil temperature too high

Check the lube oil cooler.

3. Lube oil pressure too low

Check the lube oil system and

differential pressure.

Smooth Running
Trouble Cause(s)
1.Faulty alignment

TROUBLE SHOOTING Action(s)

Check and correct alignment. Check the foundation and retighten
the foundation bolts.

2.Foundation bolts are loose, the foundation is defective

Uneven running, vibration and noise

3. Wear or insufficient lubrication of connecting couplings

Check the connecting couplings.

4. Unbalance of rotating parts

Measure the vibration and check the

runner parts.

5. Bearing damage

Check and replace bearings.