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Maintenance Measures With Unit Running Daily:

Check the oil level in coupling.

Temperatures of bearings, lube oil & working oil

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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. (centrifuge if required)

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Maintenance Measures With Unit Running


Every 3 months:

Measure, record and compare smooth running (vibrations) under the same operating conditions.
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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.
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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

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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. 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.
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Start-up
Trouble

TROUBLE SHOOTING
Cause(s)
1. Scoop tube in 0% position

Action(s)
Move scoop tube in 100% direction.

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

TROUBLE SHOOTING Start-up


Trouble Cause(s) Action(s)

1. Driven machine is jammed.

Remove obstacles. (Check fusible plugs)

Coupling heats up excessively during start-up


2. Oil flow too low
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Check oil flow

Start-up
Trouble

TROUBLE SHOOTING
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
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Check design data (Check fusible plugs)

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

Action(s)
Check the system and stabilize.

Fluctuations of output speed during manual control of coupling


(Control lever at standstill)
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2. Oil temperature is too low. (poor deaeration of oil)

Increase the temperature. (45C to 50C)

3.Gear pump is aspirating air.

Check oil level of sump.

TROUBLE SHOOTING
Output Speed
Trouble Cause(s)
1. Improper input signal to the actuator.

Action(s)
Check the controller and calibrate.

Fluctuations of output speed during auto control of coupling


(To & fro movement of control lever)
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2 .Air entering into the oil circuit.

Check and eliminate.

TROUBLE SHOOTING
Output Speed
Trouble Cause(s)
1. Scoop tube is jammed.

Action(s)
Remove obstacles.

Output speed cannot be controlled

2. Actuator defective

Check the actuator.

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3. Input signal problem

Check the controller.

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

Action(s)
Check the scoop tube position.

Max.Output speed cannot be reached

2. Fusible plugs responded

Find and eliminate the cause.


Insert new fusible plugs.

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3. Too high power requirement of driven machine

Compare the power data with the


project data.Check driven machine for smooth running.

TROUBLE SHOOTING
Pressures
Trouble Cause(s) Action(s)

1. Lube oil filter clogged

Change over lube oil filter and clean


the filter element.

Lube oil pressure is low


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2. Leak in the oil circuits

Check the pipe lines,coolers etc.

3. Improper orifice sizing.

Correct the orifices.

TROUBLE SHOOTING
Pressures
Trouble Cause(s) 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.

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TROUBLE SHOOTING
Temperatures
Trouble
Lube oil temperature too high downstream of lube oil cooler

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

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Lube oil temperature too high upstream of lube oil cooler

1.Fusible plugs responded

Find and eliminate the cause.Insert


new fusible plugs.

TROUBLE SHOOTING
Temperatures
Trouble
1.

Cause(s)
Bearing damage

Action(s)
Check the bearings and replace.

Bearing temperature too high

2.

Lube oil temperature too high

Check the lube oil cooler.

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3. Lube oil pressure too low

Check the lube oil system and


differential pressure.

TROUBLE SHOOTING Smooth Running


Trouble Cause(s)
1.Faulty alignment

Action(s)
Check and correct alignment. Check the foundation and retighten
the foundation bolts.

Uneven running, vibration and noise

2.Foundation bolts are loose, the foundation is defective

3. Wear or insufficient lubrication of connecting couplings

Check the connecting couplings.

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4. Unbalance of rotating parts

Measure the vibration and check the


runner parts.

5. Bearing damage

Check and replace bearings.

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