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MAINTENANCE MANUAL FOR CANE KNIFE TURBINE LUBRICATION POWER PACKS

TURNKEY BMG HYDRAULICS SOUTH AFRICA DURBAN


TEL +278 315792232 E-MAIL: office@bmghydraulics.net

CONTENTS:
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Basic information of hydraulic lubrication and filtration Lubrication design Hydraulic schematic Recommended daily maintenance and duplex filter change outs Recommended yearly maintenance Electrical control panel design Electrical circuit

Regular filter element change-out is CRITICAL to the life of your machine. Contamination causes 90% of all hydraulic and lubrication system failures!! The hydraulic lubrication tank is designed to lubricate the turbine bearings. Special attention to the cleanliness of the oil and power pack must be undertaken. Every week an oil sample must be taken to ensure that no water or particle contamination is present. Performing this test every week will bring an early warning before costly catastrophic failure arises. Water is one of the most common and destructive contaminants in a fluid system. When water contaminates a system, it can cause serious problems such as: Corrosion by etching metal Fluid breakdown, reduction of lubricating properties and oil oxidation Accelerated abrasive wear Bearing fatigue Increased acid level Viscosity variance

Whether you use a mineral-base or synthetic fluid, each will have a water saturation point. Above this point, the fluid cannot dissolve or hold any more water, this is called free water. Free water is usually seen as cloudy oil or puddles of water at the bottom of a reservoir. Water which is absorbed into the oil is called dissolved water. At higher temperatures, oil has the ability to hold more water in the dissolved stage due to the expansion of oil molecules. As the oil cools, this ability reverses and free water will appear where not visible before. Water is everywhere. In service, water can get into a system via worn cylinders and actuator seals, coolers or through reservoir openings. Water can come into contact with these entry points when water and or steam are used for cleaning. Condensation is also a prime water source. As fluid cools in a reservoir, the temperature drop condenses water vapour on interior surfaces, which in turn causes rust. Rust scale in the reservoir eventually becomes particulate contamination in the system. When free water becomes present, the system needs to be checked for point of entry of any water contamination. The oil must be replaced or use a vacuum dehydrator to remove the water. If water is present and all entry points for water to get in are resolved, a side unit must be installed with Par Gel water removal filters.

FILTER ELEMENTS ARE NOT WASHABLE AND MUST BE CAREFULLY AND LAWFULLY DISCARDED AFTER CHANGE-OUT.

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SET UP PROCEDURE BEFORE TURBINE STARTS Turn the flow control valve clockwise until closed On the electrical control panel, turn the switch to the on position The pressure gauge on the filter closest to the electrical control panel must read 600KPA If the pressure is low, adjust the Brass relief valve on the power pack to the required pressure Turn the flow control valve anti-clockwise slowly until the pressure gauge closest to the turbine reads 100KPA Manual set up is complete START UP PROCEDURE On the electrical control panel, switch to auto before the turbine starts up The electric pump will start up and build up pressure The pump will continuously switch on and off. This can be adjusted by the timer in the panel +/one minute. During shut down maintenance period, switch the lubrication tanks to the off position When the turbine starts up, the electric pump will run until the timer trips out and the electric pump will switch off The mechanical pump will take over at this stage Check the pressure gauge closest to the turbine when the electrical pump is off. Should the pressure gauge read below 100KPA then adjust the flow control valve accordingly Any loss of pressure in the system from the mechanical pump will switch the electric pump on TROUBLE SHOOTING The electric pump runs when the turbine is in Check relief valve pressure Check pressure gauge nearest to the turbine operation should read 100KPA Adjust flow restrictor Check pressure switches electrical Faulty mechanical pump - service required No water flow to cooler Oil temperature rising Cooler cores are blocked - service required Oil cooler cores damaged service required Oil is contaminated with water Check direction of electric motor Electric motor runs but there is no pressure Check drive coupling Check relief valve setting

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RECOMMENDED DAILY MAINTENANCE


1. Check oil level in tank. Top up only with Turbine grade oil CASTROL PERFECTO T68 or equivalent oil, if required. 2. Attend to any oil leaks. 3. Check electrical control panel for any warning indicators regularly 4. During operation, check the tank oil temperature (+/- 40 50 degrees) Never continue to operate the system if the tank temperature exceeds 65C. If there is a sudden rise in temperature, check the oil cooler by taking a temperature reading from the water inlet port and the water outlet port and oil inlet and oil outlet. If there is no difference in temperature from the inlet to the outlet, either there is no water supply or the thermostat is faulty. If the above mentioned are satisfactory, the cooler must be sent for a service.

CHANGE OUT OF DUPLEX FILTER PROCEDURE


DUPLEX FILTERS ALLOWS THE CHANGE OF THE ELEMENTS WITHOUT INTERRUPTION OF THE SYSTEM THERE IS NO NEED TO SWITCH OFF THE TURBINES FOR ELEMENT CHANGE OUT 1. When the filter blockage lamp is on, the filter element needs to be changed 2. To replace the filter element, the lever will point to the element that must be changed 3. To remove the filter bowl, use a 32mm ring spanner and turn anti-clockwise 4. Take care when removing the filter bowl to not damage the threads on the outside 5. Remove the element by pulling in a downwards direction, have a container ready to put the element in 6. Discard the element in a lawful manner 7. Install a new element with the correct part number V8361BC20 8. Push the element onto the filter head stem 9. Lubricate the O-ring with rubber grease or Vaseline on the filter bowl 10. Screw the filter bowl and turn clockwise by hand until the O-ring is reached 11. Use a 32mm ring spanner and tighten until the bowl stops 12. There is no need to over tighten the filter bowl. The bowl does not seal better when it is over tightened. If the filter bowl leaks by the threads, remove and replace the O-ring inside the filter head. 13. Once the filter bowl is installed correctly, the element needs to be bleed 14. Find the bleed screw located above the element changed on the filter head 15. Use a 5mm Allen key and turn anti-clockwise 2 to 3 turns out 16. Pull the lever towards you until the air is out and oil drains out the bleed screw 17. Release the lever and tighten the bleed screw. Do not over tighten 18. Only change over the lever when the opposite element becomes blocked and repeat the above procedure OIL SPILL KITS MUST BE CLOSELY ASSESSABLE FOR ANY ACCIDENTAL OIL SPILLAGE. DURING CHANGE-OUT PLEASE WORK CAREFULLY AND CLEANLY. ANY OIL SPILLAGE MUST BE CLEANED UP IMMEDIATELY.

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RECOMMENDED YEARLY MAINTENANCE PROCEDURE


1. Oil must be drained and analysed for further use 2. Inspection cover must be removed and inside of the tank must be cleaned out with an oil degreaser 3. Inspection of the inner tank top lid must be checked for rust 4. Replace the mechanical pump suction strainer (Part no. SKB-3 + 3 to 2 RI) 5. Replace the electric pump suction strainer (Part no. SF86D200G) 6. Replace the air filter breather (Part no. BR110) 7. Replace the filler filter spin on can (Part no. CS06BN) 8. The pressure switches and relief valve should be serviced and set by Turnkey BMG Hydraulics 9. After cleaning, coat the inner tank top with clean oil 10. Replace the inspection cover and install a new O-ring 11. Fill the tank with the correct Turbine oil grade 12. Check the level gauge when filling the tank, approximately 600 litres of oil 13. Check around the inspection cover for leaks

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ELECTRICAL CONTROL PANEL


WARNING: VOLTAGE INSIDE THE CONTROL PANEL IS 220 VOLTS DO NOT WORK INSIDE THE PANEL WITH OUT THE CORRECT LOCK OUT PROCEDURE FAILURE TO COMPLY MAY RESULT IN DEATH
CONTENTS:

1 x overload switch for 4Kw electric motor 525 volt 1 x 3 way switch ON / OFF / AUTO 1 x emergency stop push button 1 x water proof electrical box 5 x lamp indicators Motor overload pump running low oil pressure low oil level Filter blockage (RED) (GREEN) (RED) (RED) (RED)

THE CONTROL CIRCUIT DESIGN


Note: Pressure switches are normally open contacts, (P 1) is for low pressure (P 2) high pressure 1. When switched to AUTO position, the electric motor will start. 2. Hydraulic pressure will raise (P 1) will close; electric motor will stay on until (P 2) closes. This will turn the Low oil pressure lamp (RED) off. The adjustable timer will time out and switch off electric motor. 3. IF (P 2) opens, low oil pressure lamp (RED) will switch on and the electric motor will stay off 4. IF (P 1) opens, electric motor will start and cycle through the above Filter blockage indicator (normally open contact) When the filter elements clog, the lamp will switch on. The duplex filter must be changed over and the element must be replaced. Low oil level indicator (normally open contact) When the oil is low, the lamp will switch on. The operator must immediately check for leaks on the pipe work and tank area. The oil must be topped up with the correct HYDRAULIC TURBINE GRADE OF OIL ONLY. When switched to ON position, the electric motor will run continuously

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