Troubleshooting (lubricating system)

About IHI failure handling

IHI will replace a defective part in the event of a trouble attributable to IHI which occurs within one year from the delivery of new product.

For any failure of product caused by other reasons, IHI will respond to it by repairing or updating.

If you wish us to examine a failure cause, an additional fee may be required.

* Please note that a failure cause may not be identified depending on the product condition.

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Single line lubricating system

Description of main equipment

Single line lubricating system EP-11B

EP-11B

(1)
Level rod
(2)
Electric motor
(3)
Wiring φ12
(4)
Pump cylinder
(5)
Mounting holes 4-φ15
(6)
Relief valve
(7)
Relief valve
Grease vent screw
(8)
Low level switch
(9)
Reservoir
(10)
Pressure gauge
(11)
Pressure switch(ps)
(12)
Grease filling port R1/2
(13)
Discharge port Rc1/8
Single line lubricating system SK-521-2-LLS

SK-521-2-LLS

(1)
Motor
(2)
Round shape terminal (with M4 screw)
(3)
Terminal box φ22 Hole
(4)
Gear oil supply port Rc1/4
(5)
Gear oil drain port Rc1/4
(6)
Rotating direction of pump shaft
(7)
Short-cut hole 1 discharge port
(8)
N/C Red
(9)
N/O White
(10)
COM Black
(11)
Lead wire:AVS 0.5
(12)
Empty switch(LLS)
(13)
Follower plate
(14)
Grease Filling Port R1/2
(15)
Discharge Port 2-Rc1/8
(16)
Mounting bolt 4-M8x40L
(17)
Grease Reservoir
(18)
Return port Rc1/4

Single line lubricating system Troubleshooting guide

Single line lubricating system Troubleshooting guide

Troubleshooting chart

  • It is advisable to start investigation into the cause from the easy ones and to execute the troublesome operation later.
Symptom Cause Countermeasure
〈CASE 1〉

The “FAULT” signal lamp is ON or the “RESERVOIR EMPTY(Low Level)” signal lamp goes ON and the grease pump is stopped.

Low level switch activated. Fill the reservoir with grease, using the grease pack.
〈CASE 2〉

The “FAULT” signal lamp is ON or the “MOTOR OVERLOAD” signal lamp goes ON and the grease pump is stopped.

Thermal relay activated.

  • (1) Motor circuit wiring broken (or the single-phase operation is ON.)
  • (2) The plunger of grease pump is stuck or broken.
  • (1) Check and repair the motor circuit wiring.
  • (2) Replace the cylinder and plunger as a set.
〈CASE 3〉

The “FAULT” signal lamp is ON or “OVER TIME” signal lamp goes ON and the grease pump is stopped.

Time-up of the alarm timer.

  • (1) Grease leakage in the main pipe from the grease pump outlet to the master distributor.
  • (2) Air trapped in large quantity in the main pipe from the grease pump outlet to the master distributor.
  • (3) Air trapped in the pump.
  • (4) Faulty setting of the alarm timer.
  • (5) The cycle switch of the master distributor has failed.
  • (1) Check and repair the piping.
  • (2) Disconnect the fitting halfway of piping and operate the grease pump to vent air together with grease.
  • (3) Loosen the piping near the grease pump outlet and operate the grease pump to vent air together with grease.
  • (4) Set the alarm timer to the value determined by adding 5 minutes to one lubrication time.
  • (5) Replace the cycle switch with a new one.
〈CASE 4〉

The “FAULT” signal lamp is ON or “HIGH PRESSURE” signal lamp goes ON and the grease pump is stopped.
(Indicator rod comes out)

The pressure switch is actuated

  • (1) Foreign matter is caught in the master distributor and malfunction is caused.
  • (2) Leakage of grease caused by the lower setting of pressure for the relief valve in the pressure switch (discharge port block), or foreign matter is caught in the valve sheet.

How to reset the pressure switch:
(Refer to Fig.3 on page 4)
Loosen the grease vent screw using a standard screwdriver.
(Just loosen it slightly and do not removed.) When the grease vent screw is loosened slightly, the grease is discharged and the indicator that presses the limit switch will retract.

  • (1) Overhaul and clean the distributor or replace with a new one in spare.
  • (2) Adjustment of the relief valve:
    Loosen the screw once, then retighten it till the discharge pressure becomes 22.6 MPa {230 kgf/cm2}.
  • Caution:
  • In this case, measure the position (depth) of adjusting screw beforehand.

If the problem cannot be solved with this adjustment, disassemble, clean, and reassemble the relieve valve.

  • Caution:
  • In this case, take care not to lose any internal parts.
〈CASE 5〉

Grease pump is operating, but the pressure gauge indicates the low pressure or the “FAULT” signal lamp goes ON and the grease pump is stopped.

  • (1) Pump cylinder or plunger is worn or damaged, resulting in decrease in the discharge capacity, or foreign matter is caught in the check valve.
  • (2) Malfunction of the pressure gauge .
  • (3) Grease in reservoir is harder than specified.
  • (1) Replace the cylinder and plunger as a set, and overhaul and clean the check valve.
  • (2) Replace with the new pressure gauge.
  • (3) Change the grease in the pump, reservoir and piping to the specified one.
〈CASE 6〉

The needle of pressure gauge is deflected substantially.

  • (1) Air trapped in large amount in the pump or reservoir.
  • (2) Grease in reservoir is harder than specified.
  • (1) Loosen the piping near the pump discharge port and carry out air venting while operating the pump.
  • (2) Change the grease in the pump, reservoir and piping to the specified one.

Troubleshooting chart ( B-type Distributor )

Symptom Cause Countermeasure

The indicator pin of the block signal or reset signal of the distributor has popped out.

(The “HIGH PRESSURE” signal lamp goes ON)

  • (1) The distributor is defective.
  • Caution :
  • To pinpoint which component is defective, check the master distributor first, and then the secondary distributor and tertiary distributor sequentially.
  • (1-1) First, observe the block signal pins of the master distributor to find out which secondary distributor line is defective.
  • (1-2) When a questionable secondary distributor is identified, observe the block signal pins of the distributor to find out which tertiary distributor line is defective.
    (If no pin has popped out, this distributor in question is defective.)
  • (1-3) When a questionable tertiary distributor is identified, find out which lubricating point is defective by either of the following ways.
    • ○If the tertiary distributor is equipped with the block signal, observe the pins to find out which lubricating point is defective. (If no pin has popped out, this distributor in question is defective.)
    • ○Remove one discharge port plug of the distributor after another while operating the grease pump and find out which lubricating point is clogged. (Additionally, loosen the fittings of the lubricating point side as required.) If no grease is discharged even after all the plugs are removed, this distributor is defective.
  • (1-4) Overhaul and clean the defective distributor. If any failure is found out on the lubricating point side (for example, no drain port for grease is provided), eliminate the cause of the failure.
  • Caution:
  • Record the position and orientation of each part during this procedure so that each is installed correctly later.
    • (a) Remove the plug from the side.
    • (b) Pull out the piston carefully so that no scratch is caused on it.
    • (c) Clean the distributor inside and the piston with kerocene.
    • (d) Assemble the distributor, paying attention to the position and orientation of each part.
If the cause of the defect cannot be eliminated even after the above, replace the distributor with a new one.
  • (2) The lubricating point is full of grease as if clogged.
  • (2) Check the lubricating point and eliminate the cause.
  • (3) Piping is broken somewhere between the master distributor and the lubricating point.
  • (3) Check the piping route and repair breakage.

Autogreastar

Description of main equipment

Autogreastar SK-505BM-1-LLS

SK-505BM-1-LLS

(1)
Round shape terminal (LA-103 φ3.3)
(2)
L=250 Lead wire AV 0.5 Blue and red(+)
(3)
Lead wire AV 0.5 Black(-)
(4)
Motor
(5)
Empty switch(LLS)
(6)
Lead wire AV 0.5
(7)
N/C Red
(8)
N/O White
(9)
COM Black
(10)
Reservoir
(11)
Follower plate
(12)
Grease filling port G1/8
(13)
Air vent screw
(14)
Discharge port G1/4
(15)
Mounting screw 3-M8x28L

Troubleshooting chart

Trouble situation Cause Countermeasures
When the power supply is turned on, the pump does not work. Malfunction of electric control equipments. Check them and Repair the malfunction portion.
Disconnection of motor lead wire. Check and repair
Trouble with the internal part of motor. Replace the motor.
A galling is made in the plunger because it catches a foreign substance. Replace the lubricating pump.
The operation of the pump is abnormally slow. Voltage drop Supply a prescribed voltage(24V DC).
(In case a battery is used, charge it, or replace it with a new one.)
The relief valve is working. Malfunction of distributor. Disassembling and cleaning of distributor. When the piston does not move because it is set too tight, replace the distributor.
The discharge port which should not be filled with a plug is plugged. (This often occurs when the number of bearings to be lubricated changes. Note that a plug already inserted at the time of delivery from the maker must not be removed.) The plug should be removed, as a result, if there is a surplus discharge port, it should be short-circuited to any other discharge port at the external so that the grease flows to a bearing. (See the following figure, for example.)
P6:fig.Reference
The inside of pipe is clogged with a foreign substance and the grease line is closed. Inspection and cleaning, or replacement or repair.
The pipe is broken and the grease line is closed. (In the case of a resin pipe, the pipe may be broken due to over-clamping of a joint.) Replacement of the pipe.
The pump works normally, but the distributor does not work. Air trapped in large amount in the pump or reservoir. (for grease) Loosen the piping near the pump discharge port and carry out air venting while operating the pump.(Please push follower plate by stick)
A large amount of air is in the pipe. (This may be often caused at the time of a trial operation or replacement of pipe.) Operate the pump for a while until the distributor works.
A foreign substance is attached to the check Valve of the pump. Disassembling and cleaning of the check valve.
Damage to a part of the check valve of the pump. Disassemble and inspect it, and replace the damaged part.
The sliding surface of the plunger and the cylinder is injured or worn. Replacement of the lubricating pump.
There is an grease leak caused by loosening or disconnection of a pipe joint. Tighten the joint firmly.
There is an grease leak due to breakage of pipe. Replacement of the damaged portion.
Malfunction of distributor
(There is an grease leak inside the piston because of injury or wear of the piston hole.)
Replacement of distributor.

Dual line lubricating system

Description of main equipment

Dual line lubricating system EPA-25E

EPA-25E

(1)
Level rod
(2)
Reservoir air vent plug
(3)
Reservoir
(4)
Pump main body
(5)
Lubricant inlet port
(6)
Wiring port φ22
(7)
Terminal box
(8)
Hanging hole 4-φ25
(9)
Pressure gauge
(10)
Relief valve
(11)
Grease filling port R1/2
(12)
Lubricant drain port
(13)
Grease level gauge
一元式グリース給油装置(デュアルライン)EPA-25L

EPA-25L

(1)
Level rod
(2)
Reservoir air vent plug
(3)
Reservoir
(4)
Pump main body
(5)
Lubricant inlet port
(6)
Wiring port φ22
(7)
Terminal box
(8)
Hanging hole 4-φ25
(9)
Pressure gauge
(10)
Lubricant drain port
(11)
Grease filling port R1/2
(12)
Switching pressure adjustment screw
(13)
Relief valve
(14)
Discharge port
(15)
Return port

Dual line lubricating system troubleshooting guide

Dual line lubricating system troubleshooting guide

Troubleshooting chart

  • It would be convenient if checking begins with the simplest cause and the troublesome operation is made later.
Symptom Cause Countermeasure
〈Case 1〉

「FAULT」 signal lamp is ON, or reservoir「EMPTY(LOW LEVEL)」 signal lamp goes ON and the grease pump is stopped.

The low level switch of reservoir was activated. Fill grease with the barrel pump or grease pack.
〈Case 2〉

「FAULT」 signal lamp is ON, or 「MOTOR OVERLOAD」 signal lamp goes ON and the grease pump is stopped.

Thermal relay was activated.

  • (1) Wire breakage in the wiring of the motor circuit (or the motor operated with a single phase).
  • (2) Grease pump plunger stick or broken.
  • (1) Check and repair the wiring of motor circuit.
  • (2) Replace the cylinder and plunger as a set.
〈Case 3〉

「FAULT」 signal lamp is ON, or 「OVER TIME」 signal lamp goes ON and the grease pump is stopped.

Time-up of the alarm timer

  • (1) Grease leaking from the piping section from the grease pump outlet to distributor.
  • (2) Air trapped in large amount in the piping section from the grease pump outlet to the distributors.
  • (3) Air trapped in the pump or reservoir.
  • (4) Faulty setting of the alarm timer.
  • (5) Faulty limit switch of the pressure control valve, resulting in failure of changeover of grease supply line.
  • (6) Broken parts in the pressure control valve, resulting in failure of changeover.
  • (7) Foreign materials caught in the piston of pressure control valve, resulting in failure of changeover.
  • (8) Either the pressure setting of relieve valve in the solenoid-operated reversing valve is extremely low or foreign materials are caught in the valve seat.
  • Caution:
  • Take care not to lose internal parts when carrying out the operation shown in the right.
  • (1) Check and repair the piping.
  • (2) Remove the fittings halfway of the piping and vent grease and air while operating the grease pump.
  • (3) Loosen the piping near the grease pump outlet and vent grease and air while operating the grease pump.
  • (4) Reset to the running time for one lubrication plus 5 minutes.
  • (5) Check the limit switch installation condition. Check whether the limit switch roller is in the center of switch cam or if the bolt of mounting plate is loose. Replace the switch if faulty.
  • (6) Replace the pressure control valve with new one.
  • (7) Disassemble, clean, or replace with the new pressure control valve.
  • (8) Adjustment of the relief valve:
    Loosen the screw once and tighten it till the discharge pressure becomes 22.5 MPa {230 kgf/cm2}
  • Caution:
  • In this case, measure the position (depth) of adjusting screw beforehand.
If the failure cannot be corrected, disassemble, clean and reassemble the relief valve.
〈Case 4〉

The pressure gauge shows a low pressure though the grease pump is operating, or the 「FAULT」 signal lamp goes ON and the grease pump is stopped.

The pressure switch is actuated.

  • (1) O-ring of the pump section broken.
  • (2) Cylinder plunger of the pump worn out or damaged, resulting in decrease in the discharge capacity.
  • (3) Pressure gauge accuracy deteriorated.
  • (1) Replace O-ring with new one after disassembly.
  • (2) Replace the cylinder and plunger as a set.
  • (3) Replace with the new pressure gauge.
〈Case 5〉

The needle of pressure gauge deflected considerably.

  • (1) Air trapped in large amount in the pump or reservoir.
  • (2) Air trapped in large amount in the piping section from the pump discharge port to distributors.
  • (3) Grease in reservoir is harder and other than designated.
  • (1) Loosen the piping near the pump discharge port and vent air while operating the pump.
  • (2) Disconnect the piping at several points to vent air while operating the pump.
  • (3) Replace the grease in the pump, reservoir, or piping with the designated grease.
〈Case 6〉

Certain distributors not operating.

  • (1) Piping from the distributor discharge port to the bearing is crushed.
  • (2) Bearing is full of grease and in the blocked condition.
  • (3) Distributor sticking with foreign materials.
  • (4) Reversing pressure of pressure control valve is too low.
  • (1) Check and repair the piping.
  • (2) Check the bearing and correct if necessary.
  • (3) Disassemble, clean, or replace with the new distributor.
  • (4) Adjust the pressure so that all the distributors operate. (See Page 7.)
〈Case 7〉

Grease pump doesn’t run in spite of pushing a button switch.

  • Miss wiring for “a limit switch of pressure control valve” or to the control panel.
  • To connect the terminal No.5 of the control panel to COM(common) of the limit switch.
〈Case 8〉

Although the grease pump is operating and pressure rises, the pressure control valve cannot be changed over.

  • (1) Foreign matter present in the pressure control valve, which causes malfunction.
  • (2) Piping to the pressure control valve is wrong.
  • (1) Disassemble, clean, or replace the pressure control valve.
  • (2) Connect No.1 line of the main pipe to the end connection on the right side (When viewed from the side of adjusting screw) of the pressure control valve.
〈Case 9〉

Although the pressure control valve is changed over, the solenoid-operated reversing valve cannot be changed over.

  • (1) The spool of the solenoid- operated reversing valve is stuck due to foreign matter.
  • (2) Wiring to the limit switch of the pressure control valve or the control panel is wrong.
  • (3) The solenoid is burned out.
  • (1) Disassemble, clean, or replace the reversing valve.
  • (2) Connect the N/O and N/C of the limit switch to Nos. 6 and 7 terminals, respectively.
  • (3) After examination, replace the solenoid.

Manual pump

Description of main equipment

Manual pump MP-113, MP-123 Dual line

MP-113, MP-123 Dual line

(1)
Level rod
(2)
Valve handle
(3)
Discharge Port (2-Rc3/8)
(4)
Mounting bolt (4-M10x40L)
(5)
Pump handle
(6)
Pressure gauge
(7)
Air vent
(8)
Filling Port (R1/2)
Manual pump MP-323 Single line

MP-323 Single line

(1)
Level rod
(2)
Mounting hole 4-Φ11
(3)
Mounting bolt (4-M10x40L)
(4)
Cycle indicator
(5)
Return port Rc3/8
(6)
Discharge port Rc3/8
(7)
Pump handle
(8)
Pressure gauge
(9)
Air vent valve
(10)
Grease supply port (R1/2)

Troubleshooting guide

Manual pump Troubleshooting guide

Troubleshooting chart

  • It is advisable to start investigation into the cause from the easy ones and to execute the troublesome operation later.
Symptom Cause Countermeasure
〈Case 1〉

When operating handle,it is abnormally light.

  • (1) Air is mixed into grease in the reservoir.
  • (2) As grease is hard, the pump does not suck in grease.
  • (1) Loosen the air vent valve under the pump and carry out air venting while operating the pump.
  • (2) Change the grease in the pump, reservoir and piping to the specified one.
〈Case 2〉

The number of operations of the pump operating has increased more than during trial operation.

  • (1) A large quantity of air is in the pipe.
  • (2) Lubricant leaks because the joint of main pipe is loosened or the pipe is disconnected.
  • (1) Disconnect the joint of the pipe and operate the pump, then purge air completely.
  • (2) Re-tighten the joint or re-connect the pipe.
〈Case 3〉

Grease pump is operating, but the pressure gauge indicates the low.

  • (1) Foreign matter is caught in the check valve
  • (2) Pump cylinder or plunger is worn or damaged, resulting in decrease in the discharge capacity.
  • (3) Malfunction of the pressure gauge.
  • (4) The quantity of lubricant in the reservoir is small and air is sucked.
  • (1) Overhaul and clean or replace the check valve.
  • (2) Replace the cylinder and plunger as a set.
  • (3) Replace with the new pressure gauge.
  • (4) Fill the reservoir with grease, using the grease pack.
〈Case 4〉

The needle of pressure gauge is deflected substantially.

  • (1) Air trapped in large amount in the pump or reservoir.
  • (2) Air trapped in large quantity in the pipe from the grease pump outlet to the distributor.
  • (3) Grease in reservoir is harder than specified.
  • (1) Loosen the piping near the pump discharge port and carry out air venting while operating the pump.
  • (2) Loosen the piping and operate the grease pump to vent air together with grease.
  • (3) Change the grease in the pump, reservoir and piping to the specified one.

Contact

  • IHI Rotating Machinery Engineering Co.,Ltd.

  •  
  • 135-0062
  • 7-12,1Chome Shinonome Kotou-Ku Tokyo Japan KDX Toyosu GRAN SQUARE
  • TEL:+81-3-6703-0440 FAX:+81-3-6703-0443

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