Professional Documents
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Hybrid System
K8HS series
Instruction Manual
6. Trouble shooting・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・・P-38-40
CHANGE MAIN FILTER
OVER
SFF COCK
ACTUATOR
DPS No.1
DPS No.2
PRESSURE
GAUGE
MAIN FILTER: CONSISTED OF SOME NOTCH WIRE ELEMENTS
ACTUATOR: ROTATE BACKWASHING ARM WHICH IS INSIDE
OF MAIN FILTER
BY‐PASS FILTER(SFF): CONSISTED OF SOME CARTRIDGE
ELEMENTS
CHANGE OVER COCK: CHANGING TO MAIN or SFF
( Depends on situation)
DPS No.1 and No.2: SETTING POINT IS 0.06MPa
PRESSURE GAUGE: MESSURING MAIN FILTER INLET, OUTLET
and SFF INLET
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-2-
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L.O. Hybrid System
K8HS series
-8-
INITIAL RUNNING for 350 hr : DIAGRAM
CHANGE OVER COCK
HANDLE “R”
OUT
-9-
IN
MAIN
SFF
FILTER
INLET OIL
OUTLET OIL
SHUT
INITIAL RUNNING for 350 hr : STEP 1
CLOSE
HANDLE “R”
OUT
-10-
IN
CLOSE
CHANGE OVER COCK
After pump running, please vent air of SFF .
After venting air, close a valve.
OPEN
(PARTS No. A‐104, 830)
HANDLE “R”
OUT
-11-
IN
MAIN
SFF
FILTER
INLET OIL
K8HS series
-12-
NORMAL RUNNING : DIAGRAM
CHANGE OVER COCK
HANDLE “L”
OUT
-13-
IN
MAIN INLET OIL
SFF
FILTER
OUTLET OIL
BACKWASHING OIL
ACTUATOR OIL
STEP 1 : FILLING UP WITH MAIN FILTER
BEFORE CHANGING 6WAY COCK
After 350hr,
CHANGE OVER COCK Prepare to use MAIN FILTER. OPEN
(PARTS No. C‐46, 1005)
Vent air of MAIN FILTER and Fill up
by a valve and Please make sure
MAIN FILTER and SFF pressure are
same after venting air.
HANDLE “R”
OUT
-14-
IN
SHUT
INLET OIL
SFF MAIN
FILTER OUTLET OIL
OPEN
(PARTS No. D‐8, 1028)
※ If venting air didn’t complete and change to MAIN FILTER,
Air went to the engine and engine inlet pressure fell.
STEP 2 : CHANGING 6WAY COCK
( COCK HANDLE will be RIGHT to LEFT )
CHANGE OVER COCK OPEN
(PARTS No. C‐49, 1008)
(PARTS No. C‐56, 1015)
(PARTS No. D‐8 , 1028)
(PARTS No. D‐108 , 1047)
HANDLE “L”
-15-
INLET OIL
MAIN
SFF OUTLET OIL
FILTER
BACKWASHING OIL
After changing the cock to Left side, please
open 4 valves. This flow is normal operation. SHUT ACTUATOR OIL
Maintenance timing and How to do
At Normal running ( Diagram A )
• When alarm No.1 goes off・・・ See page 20‐28
It means Main Filter should be cleaned
• When alarm No.2 goes off・・・ See page 30‐32
It means SFF cartridge element should be changed
-16-
At Emergency ( Diagram B )
[If main filter is used, change to SFF as soon as possible and contact us]
Ex: Actuator does not move or something wrong See page 34‐36
• After changing, when alarm No.2 goes off
It means SFF filter life is only 5days
NORMAL RUNNING : DIAGRAM A
CHANGE OVER COCK OPEN
(PARTS No. C‐49, 1008)
(PARTS No. C‐56, 1015)
(PARTS No. D‐8 , 1028)
(PARTS No. D‐108 , 1047)
HANDLE “L”
OUT
-17-
IN
MAIN INLET OIL
SFF
FILTER
OUTLET OIL
BACKWASHING OIL
ACTUATOR OIL
AT EMERGENCY : DIAGRAM B
If main filter was broken
CHANGE OVER COCK
Ex:
Actuator does not move …
or something wrong.
HANDLE “R”
OUT
-18-
IN
MAIN
SFF
FILTER
INLET OIL
OUTLET OIL
SHUT
-19-
Alarm No.1 goes off…
-20-
How to clean Main filter elements
FILLING UP WITH SFF
BEFORE CHANGING CHANGEOVER COCK
CHANGING CHANGEOVER COCK
Open (PARTS No. D‐8 , 1028)
CHANGE OVER COCK
and
VENT AIR of SFF and FILLING UP
by the valve.
Vent air valve
HANDLE “L”
-21-
MAIN SHUT INLET OIL
SFF
FILTER OUTLET OIL
※ If venting air didn’t complete and change to MAIN FILTER, BACKWASHING OIL
Air went to the engine and engine inlet pressure was fallen.
ACTUATOR OIL
PREPARING FOR CLEANING ELEMENTS
After venting air of SFF, Close these valves
CHANGE OVER COCK as same as picture. CLOSE
And then, change the cock LEFT to RIGHT
HANDLE “R”
CLOSE
OUT
-22-
IN
CLOSE
OUTLET OIL
SHUT
PREPARING FOR CLEANING ELEMENTS
OPEN
CHANGE OVER COCK
After changing the cock, (Parts No. C‐46, 1005)
drain main filter’s L.O.
HANDLE “R”
OUT
-23-
IN
MAIN OPEN
SFF
FILTER
INLET OIL
OUTLET OIL
SHUT DRAIN OIL
MAIN FILTER Assembly and Disassembly figure
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※
※U‐NUT TIGHTEN TORQUE
BOLT SIZE TIGHTEN TORQUE
M8 8.8 ~ 9.8 Nm
M10 15.7 ~ 19.6 Nm
M12 24.5 ~ 34.3 Nm
※ Protector must not be removed
Elements are often cleaned only when they are clogged up, we recommend that they
should be overhauled for inspection and cleaning once every six months at least.
1 Immerse the elements in petroleum detergent
and wash down adhesive matter and sludge.
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NOTE:
When using a metallic vessel for cleaning elements, place a suitable device on the
upper edge of the cleaning vessel in order to protect the elements from direct
contact to the edge of the vessel.
2 This cleaning tool which we recommend can
remove sludge in notch wire meshes by air blow.
Cupper pipe
CLEANING ELEMENTS ‐2‐
3 Confirmation of cleaned condition of elements
When finishing cleaning, examine the element before light. If the light is caught
though the notch wire, the cleaned condition is accepted to be good.
! CAUTION
When a filter is opened, cleaned and assembled, make sure that the following points are observed.
A) Handle the elements in such a way that its surface is not damaged. In addition, make sure that
none of the nuts, packing or something are dropped and should be installed properly.
B) Do not disassemble the elements and a cage with any reason. The elements will be serious
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damaged.
C) Do not leave the elements upright condition during the work. The elements will be serious
damaged as well.
! WARNING
A) When the elements and parts are cleaned, make sure that ventilation is adequate and at the same
time, follow the precautions related to the use of the cleaning agent. In particular, take care not to
allow any cleaning agent to come in contact the skin, eyes etc. directly. Use protective gloves and
other suitable protective gear. Further, in the case of cleaning operation which last for many hours,
wear appropriate personal protective equipment.
B) Do not use cleaning agents that may corrode the elements or cleaning agents which have a bad
influence on the human body. In addition, observe the cautions and warnings given be the
manufacturer of the cleaning agent used.
C) If a heavy part is lifted verify the balance and safety first. Then move the item to a safe place and
carry out any maintenance or inspection work.
AFTER CLEANING ELEMENTS : STEP1
FILLING UP WITH MAIN FILTER BEFORE CHANGING 6WAY COCK
After cleaning,
CHANGE OVER COCK Prepare to use MAIN FILTER. OPEN
(PARTS No. C‐46, 1005)
Vent air of MAIN FILTER and Fill up
by a valve and Please make sure
MAIN FILTER and SFF pressure are
same after venting air.
HANDLE “R”
OUT
-27-
IN
CHANGE OVER COCK OPEN
(PARTS No. C‐49, 1008)
(PARTS No. C‐56, 1015)
(PARTS No. D‐8 , 1028)
(PARTS No. D‐108 , 1047)
HANDLE “L”
-28-
MAIN INLET OIL
SFF
FILTER
OUTLET OIL
BACKWASHING OIL
After changing the cock to Left side, please
open 4 valves. This flow is normal operation. SHUT ACTUATOR OIL
-29-
Alarm No.2 goes off…
-30-
How to exchange
new SFF cartridge elements
PREPARING FOR EXCHANGING NEW SFF ELEMENT
Close (PARTS No. D‐8 , 1028)
CHANGE OVER COCK and
Drain SFF’s L.O.
OPEN
HANDLE “L”
-31-
INLET OIL
OPEN
MAIN
SFF OUTLET OIL
FILTER
DRAIN OIL
SHUT
SFF Assembly and Disassembly figure
This is fine filter, so please be careful of
contaminants from outside at a maintenance.
ELEMENT UNIT
Please make sure of ※
-32-
assembly of SFF
ELEMENT UNIT every
year, even if alarm No.2
did NOT go off.
Note:
We recommend at
least 1set of SFF ※ DO NOT FORGET TO ATTACH IT
elements should be
arranged for next
exchanging. ASSEMBLE OUTSIDE
-33-
At emergency…
Ex: Actuator does not move or something wrong
-34-
How to change to SFF,
If Main filter is used
FILLING UP WITH SFF
BEFORE CHANGING CHANGEOVER COCK
CHANGING CHANGEOVER COCK
Open (PARTS No. D‐8 , 1028) If ACTUATOR has
CHANGE OVER COCK some problem…
and
VENT AIR of SFF and FILLING UP
by the valve.
Vent air valve
HANDLE “L”
-35-
SHUT INLET OIL
MAIN
SFF
FILTER OUTLET OIL
※ If venting air didn’t complete and change to MAIN FILTER, BACKWASHING OIL
Air went to the engine and engine inlet pressure was fallen.
ACTUATOR OIL
CHANGE to SFF by CHANGE OVER COCK
After venting air of SFF, Close these valves
CHANGE OVER COCK as same as picture. CLOSE
And then, change the cock LEFT to RIGHT
HANDLE “R” CLOSE
OUT
-36-
IN
CLOSE
OUTLET OIL
SHUT
-37-
Trouble shooting
-38-
Trouble shooting
-39-
show correct pressure not open order to avoid the pulsation
The robber cap which is Cut it
top of the gauge is not cut
DPS alarm does not goes Wrong wiring Correct the wiring
off
Some gauge valve does Open it and adjust the valve in
not open order to avoid the pulsation
DPS alarm abnormally Wrong wiring Correct the wiring
goes off
The elements are not Refer to page
cleaned Cleaning elements
Trouble shooting
Checking item
MFG No. (6‐digit)
Model name
-40-
Main filter inlet pressure MPa
Main filter outlet pressure MPa
Oil temperature ℃
-41-
HYDRAULIC ACTUATOR
TYPE : X-3050
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2. Trouble shooting
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L.O. Hybrid System
K8HS series
-46-
K8HS series is advisable to use a sampling valve of the "MINIMESS" type.
Sampling valves, which are MAIN filter and By-Pass filter outlets, are installed on
the each top covers.
To obtain representative samples, it is essential that only sample bottles cleaned and
qualified in accordance with ISO 3722 are used.
<PROCEDURE>
The procedures below must be followed precisely in order to avoid external
contamination that would invalidate the test result:
1. Operate the system for at least half an hour prior to taking the sample in order to
distribute the contamination as evenly as possible within the fluid.
2. Clean the outside of the sampling valve. Attach a capillary tube to the valve outlet.
Open the sampling valve and flush at least one liter of fluid through the valve. Do
not close the valve after flushing.
3. When opening the sampling bottle, avoid tearing the cling film. Hold the cling film
against the bottle. Before completely removing the cap, lift the film ever the cap so
that cap and film are removed together. The cap and film must not be placed on any
surface; they must be held in the hand facing downwards.
4. Collect about 200 ml of fluid in the sampling bottle (min. 100 ml).
5. Cap the sampling bottle immediately and carefully wipe the battle. Then close the
sampling valve.
6. Label the sampling bottle with details of the system (number, date, etc.).
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K8HS3-D
-49-