After commissioning the Motor Orbital OMR 200, standardized operation and scientific maintenance are crucial for ensuring long-term stable performance and extending its service life. This document outlines operational protocols, daily monitoring, maintenance schedules, and troubleshooting procedures.
1. Standardized Operation and Operational Monitoring
Startup and Shutdown Procedures: Motor startup must occur under no-load conditions. Gradually accelerate to operating speed, run-in under no-load conditions for no less than 20 minutes, then gradually increase pressure to working pressure. Similarly, shutdown should be performed smoothly to avoid sudden hydraulic shocks.
Load and Speed Limitations: Never operate the motor simultaneously at maximum working pressure and maximum speed. This constitutes extreme conditions that significantly accelerate motor wear and may cause overheating damage. Adhere to the specified values in the performance parameters table. For intermittent duty cycles (intermittent operation), the duration at maximum pressure or maximum speed should generally not exceed 10% of the total operating time per minute.
Operational Monitoring: During operation, regularly inspect the motor and system's working condition. Closely monitor for abnormal temperature rise, leakage, vibration, noise, or unusual pressure pulsations. Immediately shut down the motor upon detecting any abnormalities, investigate the cause, and perform maintenance before resuming operation.
2. Continuous Hydraulic Oil Maintenance
Hydraulic oil is the “lifeblood” of the motor, making its maintenance critical.
Viscosity and Temperature Management: Continuously monitor oil viscosity to ensure it remains within the normal range. Maximum oil temperature must not exceed 80°C. Darkening oil color may indicate overheating, while a milky appearance suggests water contamination.
Cleanliness Assurance: Maintaining oil cleanliness to ISO 18/13 standards is essential. Regularly inspect filter condition and replace elements promptly based on differential pressure indicators or maintenance schedules.
Regular Replacement and Prohibitions: Hydraulic oil specifications must be regularly tested. If values exceed limits, replace with fresh oil. Mixing different types or brands of hydraulic oil is strictly prohibited to prevent chemical reactions causing oil degradation. Oil change intervals should be determined by actual operating conditions and may be customized by users based on specific circumstances.
3. Regular Maintenance and Troubleshooting
Regular Maintenance Schedule:
Perform the first oil change and filter cleaning approximately 50 to 200 hours after initial operation.
Thereafter, replace hydraulic oil and filter elements regularly according to maintenance guidelines, with intervals determined by operating environment and load conditions.
Periodically inspect the tightness of connecting bolts, especially rear cover bolts which must be tightened diagonally in sequence to the specified torque.
Avoid Disassembly Unless Necessary: Do not disassemble the motor unless a malfunction is confirmed. Improper disassembly and reassembly can easily introduce contamination or cause damage.
Failure Symptoms and Handling:
Air in the System: Foam in the reservoir, system noise, or sluggish motor operation indicates trapped air. Bleed the system.
Braking and Slippage: Internal leakage is inherent in motors. Relying solely on inlet/outlet closure for braking may result in slow slippage. For reliable long-term braking, install a separate mechanical brake.
Difficulty Starting Under Full Load: Note that the starting torque of a hydraulic motor is typically lower than its rated torque. In applications requiring full-load startup, verify that the motor's starting torque meets the requirements; otherwise, the working mechanism may fail to start.
4. Precautions for Special Applications
Driving High-Inertia Loads: When driving components with significant inertia that require rapid braking or directional reversals, a safety valve (relief valve) must be installed in the return line to cushion the impact. This prevents damage from severe hydraulic shock.
Lifting and Traveling Equipment: When the motor serves as the power source for lifting tools or traveling mechanisms, a speed-limiting valve must be installed to prevent accidents caused by excessive descent speed of heavy loads or excessive speed during vehicle descent.
Low-Temperature Start-up: In cold environments, increased oil viscosity can cause suction difficulties for the pump and potentially lead to cavitation (though cavitation generally does not affect the motor itself). Monitor fluid level indicators; use low-temperature hydraulic oil or implement preheating measures.
Adhering to these operational guidelines and maintenance points significantly enhances the reliability and service life of the Motor Orbital OMR 200. Operators and maintenance personnel must fully understand these requirements and cultivate consistent adherence to standard operating procedures and regular maintenance practices.
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