trouble shooting manual of ballast regcilating … · 2019. 11. 19. · !t.!spect - look !gr ij3mae...
TRANSCRIPT
TROUBLE SHOOTING M A N U A L OF
BALLAST REGCILATING RIACHINE
!t.!SPECT - Look !gr i j 3mae 2nd defects i n c l u d i ~ b red sge. dist~rticn
ura-t.5, corros~on and ;yea:, checC fcr lea\ s, ~%xritb, I - ' a - an,'
!ha! a!! !!ems are cnmp!?!ad.
REPLP.CE Rerncve cld parts and subs!itu!e )with a new cr cverhsulec! cr
rerenrlitic.n;d part Fit new or o~lerhn~led or rer-cnditiened
par! in place of missins part.
C!LIER!-!P.UL - Dismantle. examine, reconditim or renew p3rts ss
necessary ?gainst given specificatinns, reassemble, inspect
3nd !PSI.
G€i;aial
Transmission
&zrj!-!rJ - !mljc.rln! [!ems lor FRY
Gsnera! Safety ?I22es
-~ - 7- - ' T i 3. Fad$, ; Probable Causes Eerlledirri A C ~ ~ O S I S 1
I I I
Ir\le.l____ - I_ -- -. 1- -~ - 7 . Engine dces 7 . Em~rgenzy stop 1. E~ergency stnp switch shou!d k;
I nct start.. swi!ch. !n release pcsit~cn.
2. t.10 fuel in ihe tank 2. Fill fuel in ihe tanh
.And %leer! air fmm fuel syste!3 as exp!ained be lo^^^:
i) Lo.ssen the Bleed Plug on the fupl filtzr and operate the priming pump until the fuel is fro? from air bubbles. Tighten the bleed plug.
ii) Then loosen Banjo Plug on injection pump and opera& priming pump until fuol is freo frcm air bubbles. Tighten the Sanjr, Plug.
3. Shiitdawn 3. Chech shut dowl mechaiiism merha!?ism stuck.. i) Release engine shutdo\+.m lever
from stop position. ii) Check electrica! shutdown cirsu!t for proper functioninn,.
3. in fuel syst;m. 4. Bleed air frnrn fuel system as ex:!lained ir! s. no. 1, ilnm 2 abcve.
5. Governor is ? t x L . 5, Replace mrnp!ete fuel i!?jector pcmp.
6. F.4irlismnnection of 6 Chech startin.; swi!ch and if any starting s\.vitch. misconnection is ncticed, rectify it.
7. Faclty valve 7 I . P.djust valve clearances follovi
c,!earanc~.. these stens v i) Llnsrrow bolts and rernnvs cy!ind;r
ccver ii) CranL the engin; un!il the inle!
va!ve is clcsed. ! h ~ n turn approxima!;!y half turn furthsr
i . _ . . i ~ - _ /!/)TL!e f35!3~ $3?ig.3 5f 5 6 9 - p ~ .3
fi 332-!i7 jhrz~!,2 ~ Z S S Se!w*ef. ::...:I 31 ]?:~3i 2n.ci !I;s ,--~ss h22.2 [.>r .,-A l,,E sei?ausi aii8* iniahs L . ~ ( L . ? With ! $1 ! > I , h j, I.?!!!
-I-'-'
A;;:-,; -- . ..- k.;; !.9.7553i?~ !he !?,:\ n!!! afi.5 J
r++j4!s! %;-a!?% 2f ;c.i~!i!?tq d
s.;r?;.is. Ref.% ~;as!.e!: ses!!n,; [!I?,;- ,nf ,?:,!i~:.d.3~ b z ? c.:!!?:
- ) g !och ~g , ! ! 2nd :e.;he:;b,
i i ~ ! \ / e 5!.13ra!~e5 !~ ' / th t!-;r nrszriihorl fsc- lar g z ~ g s fi?ontiggsd r , -" . - . . . . - - , - - .~-,
~ ! ~ ( ! i i ) 2.. got d.+~!y!~her. % .-. nn-.-It - - -,-%+, ,t.-h , i ~ h ~ r r ..,,", - %3e,~/L!e. r 9. \.IVrcng S.4.E rrrarje - 9, Lrse tt?; !nbe ni! nf i~%~mer?d;d
of engine .:r gra.2;. riper qi!~ijt;, ~f r.il. r
? Q. \;q.!nlp& bzt&ries. 19. Cl?scL e!~s?ia!!~to !eve! in the b31!3:%5. T ~ T z ! ~ ? ~ ! s sh%!c? be ,clean and the charqinq . . system shnu[d be :mrLinn J - Q>:er-ar;erj bt?gyj.=c ~ ! ? 3 ~ ! . 1 bs r$p!a%d,
1 1. !f i ject~?? n?! '! . Romc;::e fa~! ! ty i!?je!;tnrs and net J - it pmno-Is, c-erha~!ed ,! ca!iSrat& or r - ' , ~ functicning. a!!e~"~!j!,!e!~ rsr-,lars I -r.-'-l \,r,~;fh nei+j
'2ne. ? 2. Va!ves nct 12.i) Ct?.?cL ?he V=I!I/P springs and
seating prcperly. re?!ace the Srck-.n spring if anii J -
ii) Lep !he va!ves. iii! Lap the !/.!%.re ssat, requird.
1 z.. Tgp ir! 1 3 ) C ! ~ $ P . f g ~ ! refsrn nirie ,-'a- ". CO
sngine cr ii) !f return pipe is s!reaA>~ -J c!ean> 0.l .--I
i !~gded en$". ~s!jhyafjn!? nf fgz! psmp m q be f- def%r.t!\jr !hj! shf2c!!,2 he n;,? 0 *' zal!brat$@.
1 . ! S!afllr !-!!feciiys I'!, chf?.zh, re,z?i[f J; rep!^^, jf s!artei r;;.!?y rpc?~!:ed, I
.?eiecti:.e or pisinn rj.25~ I!.:,:
?:?gage.
-7 - - ~.
S. I icpuiis i' I zoh>bie cdUSeb ' T - Re~~~e i i r~ t i A ~ i r s r s Ida i, i ! ~ -
1 L, ! . m ~ t ~ y a : ~ ! 5,; .j&!' ?! ),.i I E!+-?!!L :! ~ , # r , r + ic r l ~ t :e2 , t!~!,;; tP -. -r I 1 - ~tar!e) s.~i!~!, <t,&?r cq:rci s;-[ecfrr.--! ., < , , - ~ ! r .,.
T.+ .j.-:) er!.?!!it - I: t r tb? d ~ ~ f ~ ~ :,:3!e;.-:: ,. ,1. .,
fls[ , z r ~ ~ : ! ;PC .-> ! a t 7 I c . ,S r32,;3!! ,:J t ,J ,i = '3 - -.-..%, ,.,-, 4..rp ,
:;!?13 ~?lenpjf! ,p"? :2n"sti,,?n I- - ' - * " , - <.
9'>!5! !~ !* j ;j! i-, ,:,""p ,. - , "',-: L , ~ --,. " 1
R ~ ; ~ ! ; - ? L P !he 313fl5:
3 's!lnfi!;l is ;~per&n,n Y k . ~ ! pi!:!.;':, 1:
CC.! !h!p~ir:n f.-;n~>jr,i (:! '~!2!1fit * - ' ..-.' - 3- Startsr coil may be burn! Replsc? th? start?!
4. Pinis!? is th??.aring !c?.zrsrit and *pottinn -J-- ."Y er!gq%d wi!h th? slarter in; but the ?nglne !s nc! c r ~ n l inn w ~ L E
tc. a S!art=.r c!u!ch assembly defective
Rep!zce th? stader. b. Battery is wea!i and is not able to
s~!pp!:' the !eq~!irecl cnrren!. Get zharged the battery or mplsqce it.
c. Engine may be sere& This can t e checkd by removing the st3rter ssemkdy and c r ~ n l ing the engin;. manua!ly. If engln3 is m! crant.ing then seek,. ?.%pert adv/r_;.
16 !gri!!!,x !,sy is CIN' 1 art;! -. ,- ennln? .., ,= / S
;.! 3?1. in3 but no! s"t!ina start \.d-!en s!a1-!2r l-ey is -. 7
sp;.rat+;..! 2
1.
Starts: is n.3t a!v!ng !he rqu!rscl RPM tc s!art !he snzi!?t d u i !n wsz! stzrter !ba!!ery or both. R;p!ace as per requirement. Efner;nni.y s!cp sj.G!ch !s pressed Re!sase the s~!.~i!ch. &o si! in fuel t a l h . Fi!i up the cue! p g ~ ? p c~ypljn,? is dhr531~ed.
3
Replace the cgup!!nn 3'
Fm! ~ L I I R ~ z3y k'e r l s f ~ ~ t ! i ~ e Cl+p!3,:.; t/i& ngm,-2
r r
2. R!??d frnz f ~ l ! 5y5t.e~ 2s .3-$/n!ajn~'j j!? ? ! P : ~ C ?f :>?Ti! l j 2 ) ~
P - ,- -. .*I.,,. ,- i l L ' V V C .
?. ,&.$!.!st 
.- . . .. . - . - . . . - . . .- - - . - . . . .- . . . - . - . .. .. r. S. j ra~iits Probable Causes i Eei~i&iai kciiocas
6, Fuel in]est!cn i i m i r ! ~ IrnpropFr
Eu!;sssiv% - . '1. !?estr!s!?c! fus! lines black :sine!-* 2. Plugj.in2 cf igj3ctcr at idle. s p r q hn!zs.
3. C!?ct?d injectn! bca.:!;< 4. Lmn, id!% period.
5. GISLO! h!cw-by cr I22t.2"~ ., .
% 3~sl;en or ?.rnnz piston rings.
7. !njectcrs n?eds ;-alibrati5ns.
5 , Excessive 1. Pcsr q~al i tp cf fuel. white smoLe a! id!?
2. GrxLec! II?~EIC?~!F b ~ d y 3. Cccl!an! temp?rat~!re
!~\8!.
4 Lsng id!? pericds
3. Replaze the brnf er! clne. 3. D9 not mn the ensine a? id!?
~p?sc! fci inn9 p+ric..r! 5. Rep!ace the dsfsactive g s ! - E!
5. Vss ths pistgn rings c! standard :art no. from ensine mznufadurer
7. Get the engine ~3lit'rated through specified agency
? . LISP pr.2:~: g3d9 @f feel. II w!!! be better if f ~ e ! is tested chernicslly
2. Replxz the cracL.ed nnc 3. P~!ririn J taints! s2ason tcp ilp
the radiator with h i l e d \vater t~ keep the water templrature n"rrn31.
4. Dn nnt run ih5 snglne a? id!; i.ped fsr long perieds.
5. Gel the injectcr ca!ibrs!sc! and ca!!ed the ;i%ine siirvic? crnr;in;;r %r setting sf \ia!ve 3 rd injectinn tirr.in9
7 F < < ~ s ~ ! v ~ : . &s!!ici,?d e. . C k a n !he air fiitsr r ~ r r?$ac.+ if SITIC! 2 l~nd?; r ~ q ~ i r e d I1#3i( pi@ tg:bt. .-,ha;g;.r -. " Q?? it c!?~!?
compressor. .. 5 .;sa!ity c! fee!, -. 3. s'x,e 2s K l l \ - \ ' 1 .
?. Res!!i-,!sd &?I l i r l ~ ? ~ . 4. ChjcF. !t:e kie! lines ZIY! c!esn it 2s per rsquirsinen!.
- . . . --- - -- -~ . . - + . _ a , _ ,. . I TFOU~IUIS I ~ ~ u L v S 1 Rrrt1r4ioi &~i.iOie.=
!
i ! , - ~ . . . . .. . . ~ . ~ - ~ i - ., . :. FN. !~ ! ;sc;g;' ,. c-iibr j i i . , ; ! < . . <I;+: I?!? !I I:,,!?;;:: ::!!!l!::l.?;j l[!r. ,!!,:;I!
.,.. i!? r,~rrecr: :.,- =:.*Y~I: - -..,-, -d-,=r,,-,; ,
. . l:.,i:*v-!.r,: r;-c;?: , ,<. ~. .,. . . , . . l L i i,j.;+ l r , & > , . b : . , ,. . .I :?!
5 A,c!j~~sl tap~c! clearance 2s u, Incorrecl tappet iiidicated in sf.: .:jiiij. c!ti3~3xn.
7. Fa!~!ty 7. 1: ths mrn~rnei i i of damper!f!p.b?e! clamp~i/f!y~vtieel is eccentirc balance. replace the same.
a. FLIP! p ~ m p 8. Get the fuel pump calibrated.
c~iibiatio: incoiiect.
1 1 . nutput r.f the 1. Eirty fuel filter and =fininn -, t J , , - !st)!, f~e l !i!?e.
7. Air /I? fus! system.
1. Rep!ace fuel filter and c!ear! fu?! !!ne.
-. -..." P.!=-d air from systsm as e~ep!zinuil in pzra I(?).aS",ve.
3. Esmn?,~ f x l t y injxtnr and a?t it o~erhau!sd tsr alternativ2iy rsplzce it ~ i t h nev! cne.
4. ,A,rjjust t:a!ve a:!eara!?c.as zs .!.7(iii)
5. C!san!R?n!ac~~ r a/: fi!ter e!emn!. 6. Ensine needs repairs ir! wcrt.-
rh.nn -., ,.. I-' . 7 . C;c;y?m~r ns5.l~ !?plirs in
~)2r!. chnp 1. E5p!ztc. !~!bs ~ ; j ! fi!!?!
elemen:. 7 1 lcri nrOn3r grad? ~f enains -. --- r r-
3ii.
Oil c~~ntrr;! \rz!ve no! 3, Cs!! the servic? ensinser in[ - .
l.a>~r!.i!?, 3. re- j~ r;.f c?n?rc.! I:~!;.,E~
A ,zi! I G . ~ ~ ! t z y la?2' 4 Fi!! the ci[ u ~ t o rqci red !?\in! 5 ~ . C % S E ! \ I P i i~ , : ! i~ai j~,~? a;!just ins!in&inn.
cf 5ngine.
?4. Fy_!e! ssr;s"mr-.- 7 Lube q!! !e2+! t c , ~ r i~,:,!,! LC':. !-!i,$-[, high.
A - Incgrec! :et?ir.~ cf !:!j9ct,>r
! No. I - 2
-~ - - - - I Fauiis / Frobabie Causes - I i(err~ediai Aciiorls -1 I I I L - ~
I -. - --- A A , .
-2t.c;. ni! 1. lnccrrs-! !2be s!! 1, prcp;r 2nd n~tat!t; 3 .- ~cnnsc!mp!lon t95 brand. ! ~ b e ci! 3s r.?r~mm~". j2d 5~ ~-!ir$ 9EM.
2 . Ecessive - " Adjust inr!!na!!o~ incliii3iiCTl 2: nnilins - ' a""
3, ni! !?\!el to5 h!r;h. 3 Ksep !he Iuba ~ i ! leva! w!!h!n limits
1. E*!ernal and 3 . Prevent the leal as;. intern21 Oil !=Is.
5. p5r.r c~mpressicrn. 5.Rep!ase cnmpression rings cr vzlves. \Js!ve sezts hss t3 be I2pp"d.
E. Rrol.en or v.Tons pis!nn rings & Imrn 5 Engin? dna fcr !op cverhanlin~ o?lt piston!!iners.
76. Mixing nf diesel 7 . Ex!ern?l cr intsrnz! I . Prevent the !oCr;e. in nil. fue! !eaCs.
2. Dmaged injactnr 2 Rep!ace the dafactive nne. O-rings.
3. Long idle periods 3. Po not r m !he engine a! id!e cnaed -r--- f ~ r !2ng perinds.
4. Dribblinc; of injectors. 4. %!ibrats injectors.
.-r.---.- - . ~ ~ ~ , f . . , : J & , ~ l ; j : ; ~ R J L - ~ % 7-
Rcsi~peciiai Ai;iiurEs -1
! I I ! NO I i I I
~- ... . .- - i i i ... .
? . --.-, 1 ,n ,C.!F .[!!re; s,.,:si~*:~ . . . . . . . . . . . .. . . . . . . . i .2.--1 ,-,? :-,,-,,fir=: < F! F, ~n-,::- ,= i : ! ! a r :,:c+z,?~~ <.z:!:!,-& - ' t - - , ' - ' - .*, - , - .>
! ,,-,:-:! c , r3 : :< * : r ; - h dr!,; :':.j,:ti:,~7r! ::x!.:i ;.i :c.nIzr-s f:!15! !f !,-r4! r i :sr i . . . . . . . . . . . . . . ' '-.I-'-'-- - -
,r,r;c:, l-.,$-..L- . . ,,,z,; k an,+ rL.-,air . -y*. ,Zf rG:~,!>,~.> -, r ,. .-,,.. ' '- r ' .- -
, : j 3~{ ,~~!~ : , - i ><?.-! !,I,! . I : . . & , - . .. ;. , - 5 I I - - .... .<.d -. .~ ' Itl.,ii ;..( . . _ . . . _ , . JL " "
!e?! !!'Ci - 1 1 T?.; !;!@ !!:I,!,; 1 ....... j. ~ ! ~ ~ u ~ ! 122s t-,ir-*=e
-J 1- '1-
res&a;-,,;? !> ,;~c,!:e[s a.;!i si!s!?r?is, czrry o ~ ! [ z.!\>c .... ,.-- I:} ... , n s = - .... s.y+i?! rw, , .. mi:c A , , . , rs ;? , . - . - >i?z:! , . -.
.4
ancJcr !esL 235 3). -. , , Ih.. ;..I^.' I,... i ........ I , ,, I , ' I ,,I I, I.'l, l-;.
I , .- !r!j?<t!!(? !."rI;it 1.2 L!?ec!. $.+tti.~; !fa!ues 2r.d a!-!cJ,/pr rL!5! s;yg!?~! f~;"Cc:r!, T..~~TIC! / f r c n l ~ i r ~ r ? ' - 7-." --,' ,:!,z[e( f!,,!>5,
?. ,! .2 ~a!?p!?.?sion tco .:; c:c!;ck :y3!,/55, ~y!j;ld;i.f: !Ul;it, Pistons r 7 . r p[.s{on ril?as,
&pi[.-; cj- i;p!zce npf2m:ti,e!~ p;rc!~: /f rpq~!jrpd,
. -- - -. - - -. . - -- - T--- S. ' - 7 Fcruit:, rroh"" c;"" 1 iier~raciiai A ~ i i o ~ ~ s
110. I i ~ ~. . . -~ - - - - I . . . - . . . - - ,, -- - --
Tarhly !-;-: 3': P I ~ 'i tT!ec?!~ gi! &.?!p :, t&*, rep,?;! !?
d! .!n-p!p. ,- ! ,>rnaj 1 1p:es~cry 9,- ,,[l,j ! ,-J ,,jf>j<>,
c< Qil Iesba.;? 31 1, "il..ft.+3 inir-s r . v I ,;!b~:j ?!!iwbc4.:bpmi, 6qf:2.:~ c:..!
t ! r ? ~ ,?arc;+! -, wcdlnf ,... : ,.,ll d r ? ! ~ pi; , - !%I. d p 2nd 13.7'1f,
{-;;rss 2nd ,+l r ; .a 1
T ~ e a ! 31 - 2- - G ~ r ; , ~ i r . ~ - i- .?r c~p!_3:? turt.p.hjj i l~. 3-.
i@l?npc!!c!3 t.~tw20! !
Il?! CASE QF EF;NG!?!E FAILURE DURING TRP.FFYC BLOCK WORK!?!G.
(Mzbe a r r s n ~ a ~ ~ r l ? o- ..-. fctr c!ssring the sectien by asling for assisting [ jnw~! or by !ctriin.- Y with sther mac!?lne, if WO~I ins ir! the s m e SYP~ICI. )
1 Machins s!oppsd 1. Sudden rise ir! Engine 1 . Sr~k .ase of V-be!! tc.! w te r dnrina wr!. in2 in temperaturi.. pump. Rsplace the hr?L.en P",
" blac!. section. -. Level of water in iadia:~; is loo !cw .Top up ths radlatn!
3. Teriipsrat~r? of air surroun2iq; ~!?glne msy te !w high In this .:as? shut down !h$ engir!? for 2 !it!!e duration
2. Suddep, drop in si! I . PP?~ gr3de C7f !cbs ~ i ! . Use pressnre rsccmm~n&rj ,i;arl; *.--- of s!!
2. Sudd~n heaily !fa!.a- ;j-~ Prsvenr !he !esbs~e an@ rsfi!! !hn rrar~!- .:zs.; L!:;-!Q ?af; I!fi?!t
3 Chnl.iq c,f oil coc.!?r c w ! ~ ! !c 3 ,-l;;ial;~:j
4 Mising of C(i2se! m y t3 l . j 'jlartf iii ,:iaiii, c a e Chsc: :hs 9 3 i l i c ~
sf %!.,ii>g SIX! ieE!! tk15 C I ? ! ~ !
--lss zftsr drallning the pr+c!nns ., Fli(i!re ~ \ f 5il - ? Li_!b? 2i\ pt!m: jc !r, t.2 ;?p?!!i.,"
n, in," t' ..,, ,. n! r ~ p ! ~ i ? d
. . ; . OF r r n n I:. , J - I rwlr
> Ti:, 6 .-,..-, '- - ,. , - . I - - - , ,-.. --r' - "11 t s v s t ~uc: !CIVL. iii A , -8 ~ z ' ~ r [S'V?~ iR i ~ ~ ~ i b u ; , ~ I I A 1:
- . (if ,a! sh.:*t~!,j tbs L IC" :~ mii:im~!m !gar! ! js : !.3lb, !f !?c+;essary: rsr_n!jr. !hs ,?i!,
r , 1.c 2.. ! ?!."
\>!3.?5 z;?..; ij7J!l-)Z-# \,!,&! C-
!!,y rJ3!j,,,.:-.- .:*!i;, : l i 7 t 3 1 ~ fi!th:!;:,!;:? -, - ., ,.-, - . . : .>! :q,!2.:e f ! !?~! f:~: r,r!>py?
c!-+ I!*,?? pf
4 , Air . , I 4, Ppcl! hyc!!aulic oi! .?- jntr;il~,e ininks ' "'-'.- JC"
i ! 3 ? ~ ! . , ~ irrinic I - " ' -.
3117il , .. 91-1 r:kipry/n82 . ahy!nfinzl 2,-,1 ~r>,-i, !ir>hIan kk>s i~->lsbc jcr!?~!! 2s UC ' I . .'. ilz-J. .. ... . ... ._ ,, r-.q2i!sd,
5,. E~c:L f!? pc!!nF. i!-:af! nj 5 F/;.m?!!e !he t3ic;l +n s-p!! rl, mtcr. rs>!ca!, .A!sr? -i!i*cy the prime mc?-i.e!
^!-.I, 21 I<i:il r &
~ - - - -- -~ - - ~, 'T;diis i i Probable Causes Earr~edial A c t ~ o t ~
1do.j -- - I -
,' s ! ~ , sE.w!i,2r? ti!;,?! ! Rsp!:!:r t!?? fi!!ei c, F2u!!y sr!riicn i.311," 2 Repair 2hznni a - !h2 r a l : ~ :.I +,!! ir: .;y~!em, % A 21S.Ih2r35 2i! tr.3~; tt:?
sys!em ) L p y m ~ ,-jr! .!L i : :~pr&i .~= l,>.:!Rep!x$ the b::J ;,tir-:i I
shaft i!) Rqi~!~.;. thc shetlr?t; . ;::!IIF iii) ch:gr$ def;~t!i.s CC.E;.!!~>~: .J
I I .C!n!ch, en! C! jdjn~!- ! 1 Adj!!~! c!L!!c~. mer~!.
I 2 Pump is d~ rnagx l 1 1 R5plare with new one
Pumps ir!aLe 1 . P.ersticn. n~isc.
? P.es!rictd or par?!y clogged sucticn !ins, suction filter.
3. Pump running tee fast
4. Cnupling misa!ign?c! (I?:=. to this, tearing n v b i -I g ~ t dam-.ged, there will bs 3
play a! shaf?, abnorma! sc,und will t?r ct?serv=<)
5 Reser\.loir not *ven!ed nrp-.nrlv r r - " J '
5. Su,::tion Fi!trr too small :n S!,S.
7 41! !eats at pJm; kt>! e p!pe jnints 2nd zir r l f ~ : : ? . ~
tI?!~~!gh in!st line
I . i I ! !he reservnir with th; cri! up-!o required !s?ve! to prevent aera!io~ ii] Chscl. a!l connectlens n? inlet sidr c,f nllmp 2nd peu! r-.
hydrau!ic fuel ever ~nspec te j leaC.sge. L~ak.age has bee!^ found, if n9i.e stons r Fill hydrau!ic tan1 tc, !he fu!! nsr1 iii) Chec!. condition of purnp shaf! seal Change. if reqn!!i)sd PI--n nr ycp!a.:;. the fi!tsr or -. u ..-am w
!ins,
3. Reduce sp$xi ~!r'tn r-- pressrited limit.
3. R~al ign the pump sh3f? 2nd p r i m mover shaf?.
5. P.ir tbreather ~ljleenIng I!;.!YI~.:!~ sh~.u!d s!e2ned
b Fieplace by p r q x r sirs cf Fi!!;r,
-. . Tzl e artlnr as t ~ p l i n s d !n
sn.i 1 ! ! - n r w 4
gc)o?'E. I,vZ%
5 Racdia! c?r axial !,zeding !no h!g!?.
5 Ini!isl spss'! r i s ~ s .
7. Inadequate conling 8 Css!!fia sys!em is
dirty^ 9. Differentia! pr?ssu!e
too !I&?.
ICI. Pre~s"r3 to" high.
1 1. Wmng type sf pressurs l:a!ve~
I?. F ~ ! l ! y operation ;n system.
13. Wrong ssals. 14. Filter dirty or too
smal!. 15. Pump running
speed high. 16. Ca'titation 17. Oil fnms. 72. \/entifig dirty. 19 Sys!em
i~iitarninaieit. -70 Sharp LtenGs in
S' .'*'"" U ~ ~ C I ~ I line, --, -1. B.z?st p m p fziled.
L~mi! !c! acrep!&l!? ?m;Jun!. - .
,:heck ~li.;!lrnent Chs,:!. ma. przssu!e if n$+d?-Jil In'xease p n p s i r a?d insta!l pip% cif !srger n~)rnir?a! tere
7 increase cogling capc i !~ . 8 . E=tablish causP and repzir ths
rfsfect. 9. lncrsase pressn!? set!ing of
re!i?f va!vs. 1 O.Redur)e pressure s~ittin47 a'
11 Replace t?y approprizte type cf va!vs
1-7 Check circu~! IZ mnrf~f;) !hs system.
12 I?ep!ace by su~tahle ssalc 14 C!%n f ~ l t ~ r or replac5 by !3rger
type 15.Reduce s p e ~ d
1GE1~ed !he sys!Sm. 1 ?.Vet?? S:IS~?~.
13. C ! m i @n!s I 9.FIush systsm a c t : if n??d?d rlic! I=. r -
aid flush out. 2C E!!min?ts bends er a! !?as!
rediice lhem. Fctat-a!ish 173~25 n r j - -- -- defect.
7 Mp+ify !he prassur? ~&!irr,-a 3
,1- --. - - ..-..;- . - ! -~
I P i~ba t i e . Cdusrs:, ---- 2 e,ble cell ! rdu'4d I.J0.!
I -- - ~
! i . . . . . .- - .~ ~ ~
! I S.il 2.7;- ,I. ; ..l..!j: ..--..,-.. , , p>; ,!3,: .? rj.+,;ii,~$ p3rp
J , pL!n-!n c:,nfi d ,-.,... +.i .. ,-.I L: -. ,; F,e;.!!2,;e sh??;. c -. .. > ' I : 2 , ,.-,,, - ~ . . , . % , i ; - i ., .. z ! . r , F!! !L:-! :,,C!::.I-:? : - ..,:, .~:,mt-:!.=i.zI:t . - , , .,.. . - . . - . ,
. - i. - . :fi;r~r,r;,-, . .",A- ,*, j-- ->ck ,31 -.. r . -,,.. ..7,'-! . . -;.I-,i , - - - -1..3 .,--,-. -311.- -, -n,4 , - I-:scI =,..-. =I: - , ..
- - < 3-d!.
K. ,. - .. -
- . - ! I .! I ! : , ! ! - 1 , !b:.-:z 255 p p ~ ~ ~ ! . : , - ,. - .. . , -. -. . . , < . - . ? . - . . - - , - < . - : 4s ,, , -, ,:;tli!!bI, ,-,c,z> I. ,:, I ..,. ., -, ;'k. .., ..,.' ..,.. -. . , , , . . , + . . .. ... . . / / ,_, . . . ,,., L.i...r , , r,ri:sII;C
1- ' -' ~ ' - '
!7ig!.;. ' . . rJ,r-r! r,lal,i :I:[,.?.:. fl.;,! 2 ~ i k v ; ? ~ m ~ + ~ fi-!.:ix>r siir,; r?pb!r.
" ' - ' - ~'
K&,? #:\3i-iia~i.
1, a!! iarnt-,.~.~ 211 !r.z Ii~-,.> 1 : h ~ L . : j ? ~ ~ ! j ! . hinh , .,*. '. -
c" . t - , , I , r , I ? , T~qr.:r ?-.. 8 - !.:,:, !:;+;, ! !I!*;! ?as.^;. ~ ~ r ~ ~ ~ g r ~ se!!ir!r: 3'
W2:k " ni! SF;!! a[ m.?!,?; -. " 1:!7.5c!. h:! ya!$p>, C he& if l-~of! r [p!a!,c; is i!? ~ c ; ; ! ! ~ s ~ ,
: - . 'Q' Rjfig ~ i ; r.,-..I :n!s!t t., Ret,!ace '.t)' Ring izhrr!. / f I--", i- r
defectivs. s t rs! .~ is &f+.;:i~je. 4. [!?a+qua!c~ ~:!~!j!:t: I- 4 . E.-p'ir pump or ~:h!?se f ~ r
.Aslioery. !z?;ar Y - +!i~,,=~i I '
5 - . Too much : !zy 117 th? 5 Eq>/ lce b~z:l~-;c 3'
?haft. - / . !+:.;rru!ic f!u!d 1. System pr?ssi!r$ is ? , . . L.-lit ... L ict .*.. thc ., ,.- pressure ,n=u ,~a te
J 8' 3-
9\!??!722\w. tc.5 h/.?h. . ihs r.3~1, 'I-..,-. :iio+ nryssye, 2. Qi!?:; f!!!i.l -. 131n.n cr cha!??e J fj!!3rr 2nd
s!raine!-c. . Fluid !l\!.5! is !f>.\!. -,
3. Fi!! 1113 !he f l~ i id !O I!.!!! E T I ~ ~ 1.. 4. t-!ydra~!lic f!~!ic! -2f 4 c!-,nrt, f!gid f ~ i r,~,-~rter r -P- . L"~sc-s!!Y,
incorrect :iisc~si!s~ J - If, chanse of fluid is r+qgi:&, f!ush !he nr?!irs syst.-m r!c! !:!iafigf fi!tei . ffesl? 111 ai;l ,.-.,...
5 Fau!ty rcc.!!i?l: ~;,.-!s!;,. 5. C h e ~ ! , ~ i ! ="!rir f;y trash Q!? oul 03 sj;ls cc,:;!i!!.z st~$z.-sc, C!a3r! Cu nl wit!? i r pres.ure 3 steam + i3ressure. 0
H i I !!g!.< b,,; I:,. fi,~e!ha~!! . . ., -.-k,,,- 2: rep!^^? f~u l t y p ~ ~ . ~ ~ ! - ! ~ ici~r!.~~!l,,,. .:fL!? cc,~p.2!?.>r?o. !>> t>ji%y:I ;:!!!?:. ::,>!.,,+, !itcii.g( zr!,:! rtr!!y:.:l+r
3; ?<;!,,<! ! ., >.I, ,< -,r ,;:p!?, r' c?n?.-~::rari!; i:: ! ,. $! Z ! !, ,
: - #t<pl!:?;: r;!+.a!!,?p
wn!s ; . r l +,+q[,! ?f,<<
lubiiiiaiisr. 4 F', !V:;:S [EL! :!rig [,-.? .
fast !L E . ce-ci,~e ty %hi - 1
,."-A,. luau> (k .?*S$!VC lo~rds il?!k
t5 cpera11r:g press^!!? may damage the bearing).
-- . .r..-..----.. ~. - - T-~-- --n -7-- .-. rciviis I rwo,di.i'.; z ,u3el u~elh8?,2i~iii & , L & O C & ~ I 3. 1 I ! No,, 1 I ! I - . ~- . ~~. . ! ... ., -~ - . -. ~~ ~ . .. - - ! Erra;[,y, ~ r e c s - ; ; . , FD~:L~,;~-. i t t i ! , i rb! z!;.; t [ - ! ~ p!!, ,>!,?a;? ! b l $ ti:!!. .?!;.
$I;< ;.i! :=fill . , > . , t.,,,f!-. ,,.,. ,-!z>r# ., .. ;,I! .,,
2 , bqjr,z,n,; pt-.;,,,= ;"!;:- -. - 2 : . ~ - ? , - - - I , I - , : . r-r,.. . I - ., . d : .. . - . ,. - , :;- .;! 1:. ! I , ,, ,.2, . . . . P I - . -4:. L . ,;,-7, :!!=.A
' - - , ' .'
$!3"' *-- , 'I./! r , . . I.::,.. , . ~
I - , ! , 2 h Z :;. 3 -
, r . .+!:. .- i I'-5-r -
seat ;.i-li? p! ,?::I; ,A!!!! :!!<.,;> !.
?is!!.!-; .ti,$ !r'!c ii-; 5. - . i r ! ~ ~ ; ? ;..i~tnl-! af!er di-.,!?-lan!!inn J '
m3in .L3~..:!;, J checl ~!c:/+m;n! zffer re-
zs ,se~~:b ! i~g 3 - . Lo!.! :~!essure ? \ja!\!.j p . ,A,dji!s! vr.!i,+ ! arlj~s!ir!g ~ r ~ & ,
nc. pre5~11.r~. ac!jusi+i tc. p:c;:!e: r , r ~ r n c ~ ~ ! r ~ .... settin;, Q -. /r. 2. P!L!Q \/e!.!t r~t!?f ie~! jq3.
.. q?eri t / ! ~ $ t2f
a . - A ,
1 ~f.!-e'jl, .-\r,&r\, -'I- -
thpn c,!! .):!!! I I . ~ . 11:. [!-p 3 -
1 . ;!.: 's!"S~!!T~
,fl!i
2 D/q!~!ted ,:pptr:! - -, ffel.!!3c? spr!n.g f., ,!;, ,
.. - .. f l l c m r r l p!?i,,r>.ji , ,; ,' 'i ,:, $?+ 'p !~~e p~pp?!, ?! ;+3:
In 33v-r 4~ \l?r~t tt $.> ii8flcj F?p!lci: ! ~ c t r j ~ t i ~ ~ ? ~ L n 1 ::;lorj;a
VZ~L." nr i f j~e 21~3 ,,e,li n+ t :; the relief val.;e.
5 , ?/a!ce pr?ssl?re 5. Set re!ief vzlve nressgie r a!!s-.s! t c ~ tc !5O PS! higher !hap sib?!
!hat nf a i ~ t h e r ra!ve va!ves ir! circuit in ciicu~t.
4. \!a!ve clc no! 1. Spec;! s!icL s. ? . Clean stucc spoo!. i i l i i i t i ~ n 2. Watei conden- 2. Shech condensed . ~ t e i .
catinn in s\/stem 3 Oil tempssatni? tcn 3. ChscL !he functinn cf ci! ccnler
hiah. a!?d c!ean thc radiat~r fins. 4 . Oil speed !nc hish. 4. ChecL. speed cf th? pamp,
5. Internal !eaL.age. 5. Prevent Ie3L~ge. 5. Tan!. !!ne under hi& C. Ch%! pressure in tari!.. !Lie.
pressure. - - . Cgntr~l !ink dirty. :. Clean !ins. prop~rly.
5 Vz!v+ cS3Jer- ? System pressu!;: !PC ? . ,+k!j!!s! spring pressure tieatit-,n 3 high.
', -. Dirt in !h=. system. - C!ean ?he svstem. 3. Spa! stict-.F. -J. - . Ctiecl and clean cpi?;\!. 4. S p ~ c ! de f~ r t i r2 1 ChsrL 2nd rep!?r? spx ! . ~f
defec!ive.
I -~ .
Fauils e 7 ' '- Remediai Actions -!
I I i rroijaijie Causes 1 I I
i . -.1 . - i ~ - - ~- .. . - b+>fr.r g,sCrg 1, 2 % tc ca\:!tat!sn 1 Check flol>: I!ne for 3bstruc!!or !z~.! (pi3$~gri=?if ! ! is 1n.1 rsrnc..!;. it. Meis.;. not approar:t?!n '3
n !rj r.-r-, 9
obs!rnrtinr!). * -. Vane sprincj brnl en. 2. Ch~nge !he spr~nn . . J
3. Shaft ssa! leaks 3. !?ep!acs !!?e seal 1 Casing !eaLs. 4. First !ish!er! - hrjlts then check
fnr cracks and se.!ing. 5. Oil temperl-?we !on 5 Check. cclcling circntts.
high. 6 Mctor p r t s 5 . Ranl3cs -r rlef?ctive p1Tt~. T i~h ten
defe,:?.!i.e. bcllts unifcrrn!y. .-, -. Mntnr cv~rhests. 1. Mctcr is of ur~der- 1. !fists!! rnntnr cf proper ~ p i ? c i t \ I.
capacity. 0 -. P.stc?r \mm DL!!. 2 !?eplsce !he r~ tn r . 3 lnad0r;u3!e meling. 3. Check the c ~ ~ ! i n g circ~i!. I Pressure !oc hiah. 4. !?edr?re pressure setting a! relief
val:.e. 5. Wmnr; sea!. 5. Rep!ace hi' p r~pe r siz? seal.
3 Spe'i' less or! 1. Inlet pressurs tco mots:. low.
2. Mctor parts defective.
3. Oil temper&n!s !<ca high
4. Out I?! pr2ssure !CC
high 5. Pert plat? dcss no!
mace cnntacts.
1. !ncre3se pressnre by resntting relief valve.
2. Chnge defective parts.
3. Check ccl?!ing circni! Hydraulic c!! rco!er may be defsctivo
4. Check the system pressire.
5 Qismantle the m d ~ r and rspair as per req~irern~3nt.
T-,- -- --- ~ .
is . 1 Fihihs --r --&[tBeddak &ci,o.Et5 I I rroudi'it. Cduses I
! N n I ! ! ! :-I-. .~ - . I. .. ~ ~ . . -1 - . - . - - - . . i
1, E-.~.z"! 1,751 js '!,21 ' ! - . : I, - ! ? ! 1 - - 35 i!? c7,r,-:.-,=r 2~+,~-,:, . - , ." -. . . . . . ,:21;,= m,-, :q:.,~;-,~,r<~, r,s,---->r.,
. - , * - , , - . , - > , . -. - - . -, . , --- .. +fe,r!!:.$ - .- " t2i!er 1 , rm;. , , - . ,>+?I$) -. , a ..,--, ls>n , ! rst-,!~::+, 2 5 !~,~~!!i~,j, ' -r
,-lrS3-t~7~,-l ?,r ,$9i&z;i,!.~5. - ' - . Y J 1 - -
> ,, Brpc:~? ~>i!i!.)ij?i ? .. FL--- -..-... . 1. sn4j r~; !?! ; ! r y ! ? ~ , ? , !? l ' i Q T c ~ 4 ~ . ) \ . - , - y ! n ! rs,qz&:!, [y?.:!,,:!,-~2,~ ;:,:,:per!>;,
4. Ses! 2: hp>p!:-! !!r.,:.!. J ?.5;!3<4 5ief53!/\'~ S C ~ ! .
cy!in.js! !. !?+in?, - 5. !~ter%! !~&.>;;e i!? 5 , i ?he :iz!gn r:,!in+y
~\Tcc~? !CC\ cy!inilsr. s!eev* rep!ac;, if !cq~!jr+fl, E P.ir is r:ol in !he G. Ci-!;c$ !!?e j!?!5f !/!?* of t;l!?L, and
;SSEiVGii. .2iain CDC~.. .
7. E!rea!h?r (ns. 837135) '7. ;'!ea!i !he brsathers. ars dzs?!y layerz!.
3 -. Plnw !ecL. is n,~! 1 -217. w ~ y !/a!\.~e inn. 7 . R ~ ; ? ! ~ c P , /! req~irer!. worhitv Y . 1 ZgQ38) is rfereg!i~s,
Lubricaticn is nc2t -, -. ~ ? h c r L - , a . u < , , f;lr . # , nrnrsrr p,-,a.-, 1, .--. zhyj~atjon pmpsr.
3, ,b.ir resorycir is 3. Chec!. the j ~ ! e t !ine of !an/; and smpty. drain cccl ..
- 1 Cylir?ders not '3. Repair ! r3:,1!2~2, 3s r~quired. funcliot?ini: p r c ~ s r ! : ~ ~
5. Sreathsrc, are dust,!;. 5 C ! s r ? hrsa!herc,. 3. H ~ i n s 3r9 "r.! ! . 3!2 wai: ..-, ,.-. hnrn !J~ !L I~ 1 . Repair ! re~!l .-e, 3s r c ,~~ j red .
,"-l
!3lol.\i!?g. (!in. 12-$C.?~1) i: ~ d ~ f ~ c i i ' " ~ ~
-. .4i! !ea!,ap in pipe ? !!7!?ecC. a d s!~.. P !?&age. Co line b ~ ? ~ - ~ e e n fi
c\r reservcir 2nd her:?. k
-. ., HCTS 3TE l̂ '2,2!y ?.Dismnt!e. !:!52r! s!ld f$. 0
rii.i!!.j!r?
lr. cl~ts!y atmosp".!~ +!:ii-;.:; - ?v/clrling.
4. Pr;,i!?.; hrzl? 7 Sgfficie!?? &r prassi!:? ! ci??;!. i r !inr.- a!?rj ~>~t-;n~zticns, jfi!!!! r?.>: r d ? ~ ? ? is nn? &ljy;r& :.?, Ti.;h!sn the ! C Q ~ S rc!>:~~finnc. >,<tit!, i r press~re, 5 ~ r ! q hrs!.,~.
' nsfartiti;. t i t - r rL G - - . . . d , . . . d ~ . ~ - - , -,.- - . R~r-,lrrr.=. . . - y .-.. -. P.,rsLs & , ,*, spr in~. ~r'rjnn
I- ' "3'
. ,
- - - - - -- - I5.7-T Tau i ts f P~obabie Causes 1
Tk:is m i , 2 I! !he .3;.8i;r2p5!3Lee h i I r - c t c I c /rj j ~)iS!r-~m ,..-., . . - -...-..-! P ' - - - - . ' - ' .'"r-'---
irr:pi!!se ,:.:!?;?ii,i,>n. S.QE a!T!.."nt t,: .:?,s: a ~ ! i ! ! l n ! ? !!!
iinp'-l!sE !GCt : ? q ~ ! i r ~ - 2 r2!s:js/2!i2 S ! ? G ~ [!!I,$ 3
men!^ fy 5 .?,>k+!? ip!ke sp/r3! r5jnfsr~s-r h c ~ e hrairf rei!?!::r<-~:nr.q! I r e z?mu!d !he L.;!ler t:-:hr~i.-, 2:On,nnc cvc!?s ;.I ,!?::.I. ~f rp.snz!-,?li?ifs" ifirk ~ressi!:s. Th; S.2.E irnp .... - , - - I!CC ! g ~ ! s r a n ! I - .. lira- . . -
[r,! 3 f.2;~ cr,/ra! -r p : ~ i g f o ~ ' ; e ! ~ ~ ~ ~ (? @OR-9) 2-2 Z,@r?,Clr?C' c\!,:lps ZJ! 7 33:,.:: r r : ~ . ' . i m ~ ~ qje ia: in~ sfid a; +213g1'~ (g.~",,
2 . The hctss has !-ursl. This \ntoulcl indicate I!iai Either a stronger hose is but r e IS RQ the pressure !ias !?eec!ed c !!?e hyc!rau!ic incllcz!is!? nf mu!!ip!e pxc?sdeC! ! mi!?!m?!m r ! r ~ ~ ! i ! h?c 3 ma!-f~!"c!/~n. b r c k a \!ires in. t!?e burs! strengih cf t!?? ~.a.hich is czusing nn~!sua!!y ?n!ir? !enn,th f thp h ~ ~ 2 . !?i?h press~j:; ';enrJiticns. hcse. T!?e h 'se m y
.*. uisc b ~ i i ~ t in inor5 thin cne place.
3. !-!csc= ! h s bL!rst. P.1 The pri!nary f!j!?ctic!? !:!
c.?aminati.:!fl i,qdica?+s tl.2 ~cs/ey je !c nrnteg-i tha r'-L-"' . ' I -
1 L - 11 IC v i i e IjisiiJ is ri isied i i EIeiiieiiis and !hs Cn?,sr h s th?! may deslrsy cr bee!? ::[!?, 3b325.j ~r lexclle !he ! ? . ~ S E :;.Jv~~c ~jet$ri~ra!;,$ L,&!t4. are:
1. A!?r~sinn. ? rltt i jn -. .. .. . 2, Eztteiy ,+.*:id. 4. chsmic2! r!,,,jni,
'3
~sluli.~;i:,. 5. He.! '7 c .,--..-- - u. L<.I C ~ I I C i-.G;d.
! - -- Faulls j ~ r o D a b r e ~ a " & r I iierileciiai ciciions I
I I NO. / . ... ~ , . I -- .. L -- . . . . . . . . -~ 1 .- ~- I -~ . . - .
4 t,:, Tcrqcina ~ ; f 2 h i i r f r~u l !~ QJS? ~\!!/t:e! fi!tinnc a- or /ilin!_~ tp h j & f!a!!ened cu! ~ n n ! r ~ ! h c ~ e will 5~r; tbs! !h;re !s n~ !\!jis!ing f;lr.;;.
!n +zn? 2 t k p !Q,>~E. the :̂ei:fn!c?m?g! r.p 3 hydra?!!^ hcse ; 1 T 0 3 E -, d-- anrl l qe rs 2nd ~!!CII??I the appsz!s !;. h,zs; tg buyst !h:pL4n>
Y
Linked. It %c !he enlarcyz! gaps btiist ii i this 2iea %?VYyY~ei; S~3lded and a!sct plai!s o! *:ire stran~js. spp53rs t" t3r !?v!sterl.
5 Fi!tir!g blew cff I! may be thz! ths ChczL. mznulartiicer's ins!r~!~rtions. at th? end of the iwong fi!tins has been The h5s5 should be !nsta!lo:d v!~!h hr.se put on the hos?. In th? ono~!gh s!xC tc ccmpensa!e fcr th?
case of a crimped fittlng pcssih!e 3% shor!enins !h2t may th? wring mshine occur \ h e n the hnss is ~et t ing may hflve been pressnrizec! RechecL. the c!sed resul!ing in ov?r manufar,!urer's specification and or under-crimping. par! ncs.
5. Hcse is !eaC.iw at !he fitting taecause nf a crach i!1 the metal tube adjacent t.3 the tlraze C? 2 split flang.; head.
7 The hose fitting has been $!led i iui the ht2se. Ths hcsr has besn consider- 3b!y str?trhelj out in length
Th5 f!t!!ng may have be?n 1 ~ ~ ! i 9 d irprcper- !y ta the hose. Because the crack. is -- adjar-?t -*-, to !he braze and nn! in the braze .I-.- II lib is a siress iaililis tsrour;ht on by a hcse !ha! is .trying to shsrter! ~lnrl?r press~re and has inscfficien! slflcl in it to dn so. 1 This may not be high
pressure application l-105s.
2. Insuffcip-nt sapport nf !he !lose. !t is esf.an&ja! !c, cgnnnrt rr-al yery !onn !$nnt+s sf a W"
h ~ ~ 3 , ~~pecia!!;, if they are vertics!.
The fit!ins should be fi..ec! prcpsr!y.
The hcse assen?t?!y or change the roct!ng tg r?!!eve the f o r c5~ cn the fit!ing
1 USE. the h ~ r e as per the pr?sscre d!!uid line.
2. .A!! !he hoses shnnlc! he supprl.rte"y clampinn, the same a! pr~_~pe: distance nivlnn J "J
sufficient slai.t.c be!ween hFm c!amps tn meC-5 ~ ! p f5i the p3ssible 4 % shnrting that ccu!d !3! E. p !3X v.ben !he is presc,ur!sed
1 - - ~ ~ ~ .. re , * 7 +-hzr,x2 the k3ztieri;,
4. t?c,r!?s are nnt S!!yni!-13.
I. Circnit brc.2l.er CET' is 1rinpe;r ' r
3. Emer.;er!cy pL!mp j. li i- . , - r - -a: . .-
a ~JClX'al lVT.
4. C 1 t? re!ay K 3 s d~fscli;.e.
Switch no. S-25 fcr !?f! hsrn a!?d S-25 fi3r r i ~ h ! hnrn 3r9 defe'ltiv5 ,283 is defacti-5
? . Relay ki! is defec- !ive.
2. CY-0 I: ir: '"FF' prjsitifi!?.
i !-na ...-- is defel̂ tii15,
I, Ch;!,t \!t!irS ni;. 72, f it, if rsq~iree ,2lhepr!i~e PCI! in ?2'~r!-.lnn r~:?rliti,?n
3 --' '-"'-". , , I 2 , ? 3 2n.j rectify it, if
rrq~!/red. 3. Cl-tec!.. an,? rsp!ac%, if r;q~!ired.
1 .,I i . . a x < f ! - S\)j!c? !?o, S - ~ C L /i?~!/+,, i T O I - I ! ~ ~ ~ tho ~c, j !~h, > , -v,%.
c,\j! ir?k,!sm, Dsfsctiv*. Ri,;!?{ rsar in - S?n/itr!? !-I,Q : , - L ! ~ I f?.;r_tify ! r$p!!am:- !he $%itch. nu! picti!?rn. ~3 f~ , - t i , :~ ,
.- :., - - -T
I ~. -. r - - FdUii r--- %ldbit: causes
I 1 1 Rer~~eciidi Aciior~s. I No I I . . . . I . . . ' . !.Ai!~g
. ;< . .i f p ! < + - . r , # ! ! , ,
-iI !Aicn.? tomniato ? \.A!!qg i n - p ~ t I ! Peplarn riarn:anad s?.! -- . ' , . 3 r~-"- '- '-- --, .-3-
!n-nn! hsa-ily !eat inn at 555! a ' Y
: , : F . - > ~ , I ~ ! Y !
- Pressure s.ittjfin J sf R+!ief \ ; S ! ) J ~ 5 be sii! 2! ~ ! j e f v.!v3 ,2r! 3 ~ 3 : ~ -1 75 bsr : v a ; " ~ bail} is dist~rbec!
3 D. C, valv? fnr v.?nS in- 3. !?sp!sce with new o ~ e . c!u! is defec!!~?.
4 Lock va!ve 1.2. 4. Replace it, if necesssr b. 733663 is defectiv?.
5. Double pump 4 5 5 Repair ! rep!.re 2s reqnired Z! GPM) nn. 739313 1s i ldici ive.
6. Suctinn strain% is 6, Clean I rep!acr, 2s rorll I- lire1 c!oggerf.
b) i n p n 1. Pressurs setting sf relief 1. - Fsr dolm, relief va!ve shccld problsm. va!ve is disturbed be set at 1 QCI -1 19 bar.
- Fc?r up. re!ief V?I!VP sh~~u!C! tme set a: 270 - 280 bai.
2. Re!ie! va!ve is 2. Repairlreplace with new nne. defective.
2. D.C. va!ve fcr wing np- 3. R-nl2a-e . .-,. ..-- it, if necessary dovm is defective.
4 Double pump no 729343 4 Repair I replace. 2s required is defective.
5. Suc!inn s!rain?r is 5. Clear! I rep!ace. as required. c!agged.
6. Mclticn ccntrol va!ve nn 6Dismantl?, repair1 rsp !ac~ if 7466Q7 get defective required.
-, -. P!c% upldc~!.~m 1 Sea! !eaL.122 in ! . Chec!. !eaCag~ 2nd replace it. !f
prob!em. cylinder required. rl -. 9 c . \I?~\I;. !car 8 -r 1.8 / 2. Rnpzir ! rep!zce as re#quired
down is &fE.ctivi.~ - 7 - . Syction strzine! is r Fi.;.p!3ce it3 if nerss~ary
clog.;ed. 1 @suh!e p~!r!p IS 4 !?3~3!1 i r ? p ! 3 ~ ~ . if n5c?SS3rx {~
beieciive
-~-~ T-----,:, .- ~ . .- . . ~ ---. -~ - i ! S,. 1 ~ d b i 1 6 Pt~babile -_C&LIS~CIS Reirieibi,a; L,$hiicrins.
I 1 I ?.! .!h I I I - . I . . . ., ~ - ~
- . 5 , " * , - . .-., , , ; , : , : , .. ..-. ,. ! - -. 5 ! ! :I
?44f*:!!.,.;2, .-7t,.. ; r+-;;$.-; -.-
2. .- P ! d : t 1 sez! !??I. a,;?? ! : ? h ~ ~ - l . -.., !?=!.A,;? 3r!d ;ar,l.,.= ' - r '-". - !' !I i!?-,2~!{ tr?:;!:h?!:-; !;,.-;nii f;?,
1- -. - . . - - - ;. - ,-l:->4~, ! rar,l3?5 ?: p<n[!ii+,:! - , .?!l* !!:. ; .. .!lr.':c. - *.", , , . ' -r I L
i*1.ay rr:z!fll:?._:i.>jjjn; . . -
7 , SQr..!/~,!! > t ! + / ! ! j ! ! j 5 Rat?Ia.-= !! ! ! !13C3$53!V. '.-r'--'-
.-!og.;;-d I Q s h ! ? p~)!?!p 4, Rep?!! ! r,=p!ace, if !!~,;;;.?~~!y
defec!;;.~;. 5, f 3 ! 5, I! s!-!.:.L!!.:! ts3 s l ! ?! 17n -175
I. _ _ d i s i i j i k ~ . V ~ I
4 . 5 r c . c ~ 2) 1 ; / j.z'E."! 1, Spa! ! f l . / ! ?~ b e y i ! y i!? !. 8:!&-!.. the !%!age ! ? d r@;tify
pr.zt.i=.!n ~y!ifirjer(7Q79? 7 ) . !!.
2 , ?rerrgre set!ifi~ !-5!i-3f 2 , R s;a!t",s chou!d be z! b valve PT! ! ? ! ~ ! r ? c ? ! ? ! ~ ! ? 70 - ? 7 5 krar. ,.- .,fve ba;i
7 n c ,,aji,e is A = f a , - l i ~ ? , . . -.-. .... .- - u s - - . , 3, Qi~rr!!i?t!e, ~!??r!, r e ~ z i r .cr re?!=.= if :eq,,ir&
I
4 . F!n\..c j j , 2. njr;ria!7!!;., ~ . ! 3 3 ! ! renlace, Lo,-.-- 2 5
733630 is eef+:t[$!+, rant n -,,..33 rirori --. , - . C)cnb!~ p\!fi?rb is 5. Rep!ss~ it by ,239.
I"
defective. ! r is ? I . !r! rc>min.; ;jressL!!=. !.!c! 1. P.djgs! !! 3! 135 - 145 hs!
~ ~ ~ f ~ ! ~ ~ ! ~ , ., >pproac!?ir:g at Brczz IL?c!cr prcp?r!y.
., p,ep!2!ze it i~!"i/t!? !?e?ry cn5.
. Eroom m;.tor n.o! in -.
c'pera1ic.n. 1:. Less oil in hy,i!ai?!ir; 's!~!.. , 3 T.2;' 2~ the fu!l zar):, OI 4, Pc!np nc! rje!ji,?
. . .-. -. .- .~ .. . . ~- . S. F;suii Fs-obabfie Cadses I Reiijeciiai Actions. No '
I Transmiss!'3.' r,rnhl~m Fs - . . . n - , , . !n !",.r.qng dye !'I ~?.!+?ic,h !r?.nsmission ~ n a r t , ~ . . .a, i a t l ~ pump and motor may ge! dar?ar;s
? - . $5
transmissinn hyijr%!/z pressure
3 Boost pressur5 is '!right but no transmission pressure.
Transrn~ssion purnp boost p!?3SQ!L3 !!?suffici;nl Boos! pressure sheuld he ~ O ~ P S I
2 . The pull cab!$ link.sge tc the transmission pump may be disccnnected.
. ~ -- . . . - Pn!tin.; !he tnnb (cnt irt !rznsmiss!c'n rlisccr!n~c! i.nr!!r.71 ! ! operztinq %bin1 I and rn!&e it 9? ant: clot:, wise tc 1oc.1. pecition !n disccnl;c,t !hs iransiniss;on yeai bur. Dtsconnect tho drlve shafi on !he Z X ! ~ before !c?.nnS !he machine.
C!ear! !he dirt$! .; suc!~on str'iner 7 7664. 13eech flow cf fi!ter. if mq~ i red cham35 it. Adjust bcos! pressure d the relief valve. Da,~aned '-3 /\?ear boos! pump s h o ~ l d be repaire4lreplas;d. Replsc~ the shaf! if shaft of ktcnst pump fcund broken Restore the c.sr?nection
TI -. Faulty adjustment of 2. .*.djust the relief va!~~; relief valve.
3. Pump shaft broken. 3. Replac? the pump. 4 . Excessi\ve in!ernal 4. Rep!ace the pump.
wear of a x i l pistnn pump
5. Transmissisn meter 5. l?ep!ace motcr. 3h2fi biohefi. MGoi rntzting free!!,.
6. Mctor coup!er ~ ~ 4 t h 6 Replace coup!er. transmissicr! gear- b ~ n h i~L . i n .
X!. BEP.!?!NG
Impronar r-. rr'm r and cperg!in~ !.-?mpera!~!;..
Contamina!!cn by fnreign ma!ters during ins!a!!a!inn.
. . %he!? hearing fai!ure is fnund, even if it is insignificant, it !s !mportant to investigate the phenomencn tc detprmins thp causes. Ai this time. not nnly hearing hut a!so the shaft housing, and lubrican! used \.ri!h the bearings should be comprehznsi~vely investigated, tng~.the-r with the hearings. TC judge th? causes of fai!ure, sufficient kno:v!edge and e<perienco in bearings and !uhris?nt 2nd a gond understanding of the characteristic nf !he equipment 2% nscessary In addition, consideration of the instal!a!ion and operation process of the hesrings /S reqzired,
? 7 Tima s f Frac?urc ccclryefic2 .tn.s .zrz5s~ - ! ! ! n ? ! : l ~ i s , it i s !!T;:r.~vtn: i.2 zs,~:~:a!?!t, dafcrmit-,c. !h; + i 7 , = a , --.-. .,... , - ., , - .,. . . - frz:{~!r.? a - 7 h-.- llcj th; ,,,><~ih!~ ri, -.L.--.! d , --A? . , ,- ,-*2,.d,.. CF rzi!~!r* .:?!-I !i!-:;!.ze !!-: >,-,- ,?,r, ..<,, ii:,,? . t;? lhs 3 .,,.- ~/;TE. .;f fv . j# - l r ric ~ C T I t r r~t ,y.- F2r ~ - f a ~ - - -0 , I U . - L - I - iYYUll -I ,-- , - , - "I!:--, ti%e c.f fra~tu;c ~!,:cNI:~!?c~ p?,: re!?!?.! c;rnsos ;lr? *:a!egcri:;..? 3!?d !/5!e8j r;lh!e.?.j
?ah!% 9-? Time nf i?ril&age ~ C C C ~ ~ P C C P 2nd CL)sPC_ '----$ ~ .
T-- _ C._ - _I - . - - - I ;- -- . I illit ~ ~ d r - t u ~ t I ro i i i iy Ti inpropei:7 ,A,- . .~ -,- - . -
i - ~, UClCLl> I ;"?is- - / . . _ . I . I cZ~CC- ' / i s j 1 vauses i appro- i design or j kmncant, 1 In i mouni- i sealrng 1 Occurrence ! priate / shaft i
I i lubrication 1 bearings 1 ing of device ! i
1 1 Use of I housing or j method or 1 1 / bear- sontaniina- !
I bear- 1 other I sealing i ' tior? of wirter, I
i I I ..'a- '"0' 1 i f i ~ t a ! ! ~ - I da,~;,.~ I ------ I I .'us! or cth-r 1
i ( t ioii i i I f---: UI rigii I
I aspects or I I .. I matters, I i 1 i improper I I
I I I i i i lubricant
I .- - . I-- - !p-*. 1 ina i --
1. Cizx!u:e
ishonage O f i ~,-- -. I
i
i I I --I
! I I I ocziiiriiig I
j ! I I i irr~rnediateiv
I i I I I I
after bearinqs - i d 1 I i I
I were mounted or I
i 11 i ( I I ,, I I within a shori j ,I I I v , ? l
time after I I I I
I I
I rnnuntin? I i I I -- I
I - I 2. F:;-c!uie + - -f i
I I I I I I----- -I I Cciriiing
~mmeaiateiy I 1 I I 1 1 1 I I
i ! \I I ~ \ i ! I j after overhag! i 1- - ~
I I 3. Fracture I
- - - -2.- 1 I -, I
I I I I
I I 1 occurring after I
i i I 1
I !~!br/ca!~!\niaz. ,
I i I
I I i
i supp!i?d I I
- - ~ '
14. Fiactiiie 1 - - ~- -- ! I
- ~ f . i-- - . i I I
i i i
i i occurrirlg I
I 1 I I i I I
1 immeaiateiv i I i I I after repair or I I I 1 I i' I i I
i 1 $1 1 I 1 reinoval of shaft I i I I
I ho~tsing or othe!- : I I
I I !
i 1 '5. Frscture ?-- - -
- - + - i + - - I I I occuiriiig d l i i j i i ~ i I I I I I
i norrnai operaiior~ 1 i I V' i !
I I i i
I L : I 'J 1
~ - ! - . - - ' - - -. . ..L I I ! . - - - - . .L -- A . ~- -- ~- ,, -
7 - sexing Faitur? D;.far,ts ir !h? zppearanre d t6sl!.ing 3!% l?ferr+c! !E as k a r i ~ l ; fli!u!e. T&-!+-3 .Jr=scribes brzring failure: firs! assigning geni.r>l !err? !c each typ? cf !ai!~lr? !rprl s;rj!ng mfirs detai!;.;! .:!zss!fj.-a!lc~
Tsr?!~. 2 - . ., . . .
Fa.inr.res Fdisure -- - - ~ delalis -- -~ .- + rriaa~i - Cd~ss{t&ererlce) - . . - -
~ o l c n i ~ a t l ~ u < ' Flabs P~tting 1 Wear Fracture Wear. fretting I---.-- Clnavo~dable F!zw [;-us! f'fa~! f,r_hjnc y d . I I
I I S*izuie Biifiiiin$nicL.s siiaiilses i------ l inp~upe~ haniii~ng
I jcuttlng I Rust Gorrosion Seizure. D~scnlnraiion. Smearing- I ~ ~ p r ~ p e ! lubrica!ior! -. .- - - -- - .- -. .. . - . - - . - . -
- - - - '7 -- - - - Tab!e-3 -. -~ - -. - - - r > - Fauits . . Probable Causes -. 1 Rernediai . -~ - Actions - ~,
Increase in 11 ~ x c & s i v e l ~ tight 1. ~ e ~ l a c e with a n%w hearing ; I temperature bearing internal / (Correct hearing internal
I clexance. c!earance an+ in?erfe:ence 1. 2 . Replaie w~th a new ijcaring 2 Creep of bearing
i nn.;. I (Correct interterence). <
I I
3. Excessively heavy 3. Remountinn, (Corrsr-1 !r?ad hy I load. I
I adj:jiist~ng housing). I , 4. impisper csntering 1 4. Remounting (Correci centering or 1 in mount~ng. , widen mounting clearance). ! 5. Defect in bearing. ' 5 Replace with a new bearing
I I 1 (Take proper countermeasures
' after ir~speciing ihe causesj. I _ b. improper volume of 1 6 , Correct lubr~cant volume.
1 lubricant. i I
7 Improper lubricant ! 7, Change to proper l u b r i ~ n t if
I reqtiirsd. 1 8. lr~lljroper lubricaliirrr a Correct lubricant method by ,
method. ) remountina or replacement with ! new parts. 9, E,<c?ssive inter- 3. C ~ i i a ~ t ~n:srfeience by inskalling j ' f;.r?nce at oil seal. new seai or changing seal ! j 10 Shortage of 10 Supply lubricant in suff~cient
lubricant. ; quantity ( ? 1 .!mproper nil seal. I 1 ? Cor:ect oil seal type or sealing :
: rnsihoii. ' 12 id~lII0rmal confact 12 Remounting or modify parts. !
with labyrinth seal or I i
- - -- o!herpsr?s - - , ,: . - - ~
.... . - - ......... ~ .~ ~- , . 1~ - ........ I gearing ring, Zoiiiny eieinelii 1 tsedi~tng [ii-~g I age
:.. : . . - ; 1 . . . . . . . ... . . - . . . . . . . . . . - - . . - - - - . . . - , r;,,,,,;., ,3111irn I ; C C ! ! ~ ? ijn!(?n s:<i,;c :
F ! ! , Prcb'3! F;I!! , ; Y--".12 il.,...- I -,..<.;-- Jut ,a-c ;iiez,ce / si;?ace 1 ei ; ! cage puide ~ ~ r t a c e '
, "L""'7y 1 i I;cricie i i Eoiier e i ~ d i x e I I
1 1 i I <I ( ~ ~ S C P I s ~ - ! I ? ~ c P
I .~ ~
. . . . . I 8 . . 1 . . 1 ! / Flaking pitting / - I L ' / ~ I
. . . . .. .. ...... k.. - I. .I .- ~ .... . 1 I + .-I.. .,
I i I \I ! .... .... ..I ......... j..~
i I----
I I ', !
i 1 Nicks I 1 .... .
/ Scratches .- . -+ . . . .
Isiuving i ......,... + ...<. I . . . . - - . - . -
iiusi v 1 . ---+ -
I ~ a i i a s i * ~ , i ~ v I \ i ! .......... --- 1 . - . . . . . . -. . - - ' - 1 .... -- .
',mpzrtznt !tern For BRF.?
;;lfn!;mher tc m$,? !h3! 3!! prcfec!/~n i t --,-.v., -, , < 31d safety .!syires are place 917 m~chinp 2nd !&b2rti!3s .>rder ssper,ia!!y t.h.fi.rti;n it is being drivar! frnm site t!? si!5.
. @ . ! \ ~ y s . k.eep the marhir?? s!;en. E..,cessiv.rti; ! cr clrease - ni? the !~:arhi!?e ca!? rallse \ ~ I I , .- - t17 5!/p an$j fa!! ! ? d is a!sc 2 pn!~.n!il! fire L. . - - . - . 4 I (0-ill U.
C!?h/a:,s IPII the machine .5efcre I !cave. b!!?~Le czre t h ! !he rfi~zhige IS p ~ ! ~ ~ f e C j i!? a~,-zrd2!?~e : , r ~ ~ ~ ! ~ ! / ( ? ! ? ~ ,
\A!heneiler yo^! h w e the nppnrl~nity b?.hi!e ~!3/!!!?2 - !n "at Y - SL!! nfi e I - - inh,
C!Q snme ~f the sms!!er .m~in!enrl!?cs j ~ l k S " C ~ 1s !ight~n/f?g !scse iiuts and 3nlts and c!eaning !he !machine.
Shr~ 4jit Pznd!!. Sr. Prefesscrl Tiact- M3':hinesI !RICENI Pun2
1 St Shri R.E. %i. Ey CEI TF.?C!CR!Jhlnsi,
3 . Suni! G~p ta . Principal! IRTMTC! P!!ahabad
SIShri Prilr? Kumx Shrivastavs, ?!;erendia Pmad , C)?. Kapoor, P.rtrinc! Kumzr, li?ohi?. blaesrn Siddiqui, P..?1 Srivastalva, Vailash Chandra, San? Lzl,
Eirectgr! Trac! FJachines P.RERM. SEIDesign SEIDesigr?. ST.GM SI?.hTM SRPJTM. PP. !@??A.