1.0 - Maintenance

SHANGHAI HEAVY MINING MACHINERY LTD.
FOR KSPL CTG BANGLADESH
INDEX
1.0 - MAINTENANCE.................................................................................2
1.1 - LUBRICATION....................................................................................3
1.2 - PREVENTIVE MAINTENANCE.........................................................3
1.2.1 - PREVENTIVE MAINTENANCE SCHEDULE.................................4
1.2.1.1 - PREVENTIVE MAINTENANCE TABLE.......................................8
1.3 - EXTRAORDINARY MAINTENANCE.................................................9
1.3.1 - APRONS VERTICAL ALIGNMENT.................................................9
1.3.2 - REMOVAL/ASSEMBLING OF THE TRANSPORT ROLLERS.......9
1.3.3 - APRONS REMOVAL/ASSEMBLING.............................................11
1.3.4 - REGENERATION OF PARTIALLY WORN APRONS...................12
1.4 - MAINTENANCE TOOLS..................................................................12
1.5 - WEAR-OUT PART DRAWING LIST.................................................12
CopyrightSHMM
705 5 200083, Web: www.shme.com.cn
ADD5F, 705 Zhongshan North 1Rd. HaiJian Building, Shanghai P.R. China
TEL86-021-51089131 FAX86-021-55396312 E-mail: shmie@vip.163.com
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1.0 - MAINTENANCE
GENERAL INFORMATION
The purposes of any maintenance program are:
to keep the existing plants in good working conditions in order to ensure the highest
output at the best quality and cost ratio;
to prevent failures and breakdowns as far as possible;
to make the intervention times for failures and/or breakdowns as short as possible.
An accurate preventive maintenance (in compliance with the instructions of the relevant
cards) reduces the possibility of immediate interventions during the machine operation.
SHM are at the Customers disposal for any maintenance operation on the machines of
their own construction and supply.
Any request should be sent to:
Shanghai Heavy Mining Machinery Ltd.

6F, 705 Zhongshan North 1st Road, Haijian
Building, Shanghai, P.R.China P.C.: 200083
Tel: +86 21 5108 9131
Fax: +86 21 5539 6312
E-mail: shmie@vip.163.com
Attention:
Maintenance operators should strictly comply with the safety rules in force
in their country and in the plant.
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1.1 LUBRICATION
Lubrication is meant to guarantee the working efficiency of each machine and plant
component, and to prevent breakdowns and failures.
Lubrication operations are listed in the lubrication table of the Lubrication Tables
Collection manual.
The customer is highly recommended to use suitable lubricants according to the
intervals indicated in the Lubrication Tables Collection - LTC manual. As regards the
suppliers of the suggested lubricants, comply with what stated by the LUB manual.
Before using a hand pump, thoroughly clean the grease nipple area and pump in
grease according to the quantities indicated in the lubrication tables. Remove any
excess grease.
Attention:
If not otherwise indicated, the lubrication is to be carried out only with stopped
machine. Make sure that there is no risk of accidental start.
1.2 PREVENTIVE MAINTENANCE

Preventive maintenance includes all those checks and operations necessary to ensure
the plant utmost operating efficiency and to prevent damages or failures.
The above-mentioned operations, based on experience and/or theoretical calculations,
consist in periodical interventions to prevent failures and in thorough inspections to
check the conditions of a machine component.
The inspections are mainly based on operative personnel observations and include:
Visual observation: for fluid leaks and blow-by, vibrations, cracks, wear, etc.
Noise listening: for creaking, hissing, unusual noise, vibrations, etc.
Sensorial detection: for temperature, vibrations, unusual roughness, etc.
Such checks and interventions must be carried out within the pre-arranged terms, as
indicated in the manual for preventive operations. These intervals may vary according to
working conditions.
The operators should report the detected data and their comments upon the integrity
and efficiency of the item in a special register, in order to choose the operation to be
carried out before trouble develops.
Increased inspections by means of special tools or based on the operative personnel's
observations, make it possible to decide whether the operation should be carried out
immediately or postponed until the first programmed stop of the working cycle.
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1.2.1 PREVENTIVE MAINTENANCE SCHEDULE

Here below there is a list of the main preventive maintenance operations to be
scheduled for the perfect machine preservation.
1. Machine cleaning and checks
Before starting all the cleaning operations, set the machine in safety condition, by
pressing the emergency push-button.
The person in charge must carry out the various cleaning operations wearing the
adequate personal protection outfit (goggles, safety shoes, overalls, etc.) and fully
complying with the rules for accident prevention.
Remove any dirt and dust from the machine by means of a special industrial
vacuum cleaner. If there are grease or oil spots, wash with oil-solvents (for
instance, petroleum solvents like gas oil).
Attention! Most solvents are highly flammable and toxic. The utmost care and the
prescribed safety measures must be put into practice when handling and / or using
solvents.
For cleaning the electric motors please see the manufacturers instructions.
2. Fastening elements
Check the tightening of nuts and bolts, in particular the foundation tie rods and the
rotating elements. Always tighten with the required torque.
3. Gear coupling
The accident prevention protections have to be removed only when the machine is
stopped and they must be reassembled before the start up.
a) Check the gear coupling for noise.
If noises develop under operation, check for excessive clearances or other
damages.
b) Check the gear coupling for eventual lubrication leaks.
Leaks coming from seal rings indicate excessive misalignment between shafts. In
this case it's necessary to disassemble the coupling and align the shafts again.
Take this opportunity for making a check of the components and if the seal rings are
damaged, change them.
c) Check that the flanged sleeves of the gear coupling move back and forth freely.
If the flanged sleeves are blocked, it is advisable to perform a maintenance
intervention to check the component integrity.
d) Check the alignment of the connected shafts and gear coupling.
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e) Check, using a dynamometric wrench and proceeding in crossed manner, the

correct tightening of nuts and screws.
f) Grease lubricate the gear coupling according to the intervals and with the lubricant
shown in the lubrication card.
Relubrication
On each half coupling are mounted two grease nipples offset at 180 from each other;
proceed as follows:
- clean the two half couplings carefully from all traces of old grease;
- position the coupling so that one of the two grease nipples is turned upward;
- remove the upper grease nipple to allow the bleeding of any air trapped in
the system;
- connect the pump to the lower grease nipple and pump in the correct
quantity of grease;
- remove the pump and install the grease nipple which was previously
removed;
- remove any excess grease.
Changing grease without disassembling
- remove the safety guard from the coupling;
- unscrew the grease nipples;
- discharge the old grease through the grease nipples holes with a jet of
compressed air;
- fill the coupling for about 2/3 of its nominal capacity with very liquid
detergent fluid;
- reassemble the grease nipples and rotate the coupling for about 15 minutes
without load or until the old grease mixed wit the fluid becomes liquid
enough to be discharged through the grease nipples holes;
- if necessary repeat this operation again until old grease is completely
eliminated;
- position the coupling so that one of the two grease nipples is turned upward;
- remove the upper grease nipple to allow the bleeding of any air trapped in
the system;
- connect the pump to the lower grease nipple and pump in the correct
quantity of grease;
- remove the pump and install the grease nipple which was previously
removed;
When the above procedure has been completed, install the guard on the coupling.
Changing grease disassembling the coupling and checking its conditions
- remove the safety guard from the coupling;
- loosen and remove the screws which fasten the flanges;
- uncouple the two sleeve flanges, taking care not to damage the sealing
surfaces. Collect and store any grease which spills out during this operation;
- expose the two geared hubs by sliding the flanges;
- clean all the elements carefully with a suitable detergent or solvent and dry
with compressed air and blotting paper;
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- check the extent of wear of the gear teeth; check also the condition of the
gaskets, and of the calibrated screws. If necessary, replace the worn or
damaged parts;
- check the alignment of the shafts; measure the extent of the errors, if any, in
the alignment and squareness between the two half couplings. To carry out
these checks, refer to the manufacturer's documentation;
- using a putty knife, fill the space between the hub and the flange with
grease;
- spread the coupling surfaces of the flanges with rubber cement of a suitable
type;
- couple the flanges again so that the grease nipples will be offset 180 form
each other;
- install and tighten the screws to the prescribed torque (check the
manufacturer's documentation);
- make sure that the flanged sleeves can move back and forth freely. Refer to
the manufacturer's documentation;
- complete the filling of the coupling:
- remove the grease nipple which is turned upward to allow the bleeding of
the air from the system;
- connect the grease gun to the grease nipple which is turned downward
and inject a correct quantity of grease;
- remove the pump and install the nipple which was previously removed;
When the above procedure has been completed, install the guard on the coupling.
It is recommended to carry out all the assembly and disassembly operations using
adequate slinging devices and fully complying with the safety rules.
When starting up the machine, check that the coupling does not generate noise or
vibration due to faulty installation. If this is the case, immediately stop the machine
and carry out the necessary corrective measures.
4. Grease lubrication
Grease lubricate all the components that require it according to the intervals and with
the lubricant shown in the lubrication table (see in the Lubrication Tables Collection LTC manual).
5. Hydraulic system
a) Check the proper operation of the interlocked cylinders.
- Using a pressure gauge, check the working pressure; if necessary, make
the necessary adjustments.
- Check the efficiency of solenoid valve.
b) Check the condition of the hydraulic cylinders.
- Make sure that oil is not leaking through the passage hole in the piston rod.
- Check that there are not anomalies in the motion of the piston.
The presence of such troubles indicates wear in the seals: schedule the removal of
the cylinder from the machine to replace the sealing gaskets.
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c) Check the hydraulic system circuit.

- Check the sealing of piping and unions.
- If there are leakages in the unions, replace the gasket and tighten
completely the union. If this is not enough, replace the union.
- Carry out a visual check of the components integrity. If the hoses are
damages, replace them.
Any defect which might be found, must be immediately eliminated.
6. Rollers
Check the condition of the rollers for possible deformations, failures and wear.
It is a recommended practice to check all the rolls whenever there is a pause in
production.
7. Aprons
a) Check the condition of the aprons for possible failures and wear.
It is a recommended practice to check all the aprons whenever there is a pause in
production.
For regeneration of partially worn aprons see the chapter "Extraordinary
Maintenance".
b) Check the simultaneous movement of the aprons and the alignment of all the
aprons in upper, lower and intermediate position.
If necessary, adjust the position of the aprons to obtain the most correct alignment,
see the chapter "Extraordinary maintenance".
8. Bushes and ball joints
Check the wear of the bronzes and the ball joint of the arm articulations and of the
cylinder articulations.
9. Junction boxes (J.B.)
With the machine stopped and power to it cut off, check the junction boxes.
Remove the cover and be careful not to damage the gaskets.
Check the correct tightening of the screws on the terminal clamps.
Install the cover again and make sure that the gasket is positioned in the right way.
10. A.C. motor
a) With the machine in operation:
- check the temperature of the motor casing;
- check the noise from the bearings, particularly the one at the coupling end.
- check the cooling fan for noise which may be due to impacts or accidental
damage.
b) With the machine in operation:
- check the efficiency of the frequency regulating unit.
c) With the machine stopped and power to it cut off:
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- Check the windings with a tester: the values between the phases must be
identical to each other. If abnormal conditions are found, determine whether
the motor should be immediately replaced or whether the checks should be
increased in frequency, and plan for the replacement of the motor.
d) With the machine stopped and power to it cut off:
- check the grounding of the drive motor.
To do this, disconnect the ground cable in the junction box and, using a tester,
measure the impedance between the end of the cable and a grounding bar of the
junction box: the value must be ~0. If this is not the case, check the fastening of the
ground clamp on the motor and/or the ground cable for any interruptions.
Note: for further information and details about the electric motor and the instruments
used for the checks, see the Manufacturer's documentation.
11. Welded joints
Check the welded joints in order to avoid any crack.
If necessary, carry out a new welding, taking into account the possible expansion or
shrinkage due to thermal variations.
1
2
3
3.a
3.b
3.c
3.d
3.e
3.f
4
5
5.a
5.b
5.c
6
7
7.a
7.b
8
9
M
S
S
S
S
S
S
M
M/S
M/S
S
10000
4800
2400
1200
S
S
400
Machine cleaning and checks

Fastening elements
Gear coupling
Noise
Grease leakage
Flanged sleeves
Alignment
Tightening of screws and bolts
Gear coupling lubrication
Grease lubrication
Hydraulic system
System operation
Hydraulic cylinder
Hydraulic circuit integrity
Rollers conditions
Aprons
Failures and wear
Movement and alignment
Bushings and joints
Junction boxes (J.B.)
160
M/S
(*)
80
NAME OF THE UNIT AND /OR

COMPONENT
16
PREVENTIVE MAINTENANCE PROGRAM
OPERATIONS
1.2.1.1 PREVENTIVE MAINTENANCE TABLE
#
X
X
#
#
X
X
#
X
X
See Lubrication Table Collection
See Lubrication Table Collection
X
S
M/S
S
S
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#
#
#
#
X
X
X
X
X
X
#
X
#
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10
10.a
10.b
10.c
10.d
14
A.C. motor
Temperature and noise
Frequency regulating unit
Windings
Grounding of drive motor
Weldings
M
S
S
S
S
X
X
X
X
#
(*) M = Moving; S = Stopped; M/S = Stopped machine and moving device

X = First maintenance operation; # = Following operations
1.3 EXTRAORDINARY MAINTENANCE

GENERAL INFORMATION
Extraordinary maintenance includes all those operations for the replacement of faulty
components subject to unexpected breakdowns or worn-out components that,
according to proper preventive maintenance standards, no longer guarantee their
perfect operation.
This chapter describes the normal assembly/disassembly operations of the units or
components which require particular procedures for their replacement.
1.3.1 APRONS VERTICAL ALIGNMENT
For the vertical alignment of the aprons it is necessary to act on the tie rod screw
connecting the lever to the apron.
Proceed as follows:
loosen the left and right locking nuts;
by means of an hexagonal wrench, rotate the tie rod screw until the alignment
as been attained;
tighten the left and right locking nuts.
1.3.2 REMOVAL/ASSEMBLING OF THE TRANSPORT ROLLERS
(see fig. 4.3.2.a)
REMOVAL
To remove the transport rollers from the roller table with aprons, proceed as follows:
interrupt the electric supply to the driving motors, from the control pulpit;
disconnect the electric feeding wires from the terminal board of the motor;
hook the motor by means of an eyebolt to an adequate lifting device;
remove the screws and the relative washers (1) (2) which secure the roller to
the roller table frame;
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very carefully extract the roller from its housing and place it on the working
bench;
remove the screws and the washers (4) (5) taking out the head washer (3) to
allow the extraction of the driving shaft roller;
using an adequate tie-rod puller, extract the roller (6) from the shaft.
ASSEMBLING
To assemble the transport rollers to
Fig. 4.3.2.a - Transport roller. the roller table with aprons, proceed
as follows:
insert a new roller on the driving
shaft by means of the head washer
(3) and the washers and screws (4)
(5). Proceed with extreme accuracy
so as to insert the roller correctly,
without causing damages, until its
complete insertion;
hook the roller using an adequate
lifting device and place it again in its
housing in the roller table frame;
secure the roller by means of the
screws and the washers (1) (2) to
the roller table frame;
connect the electric feeding wires to
the terminal board;
start the rollers at low speed and
check if they rotate freely and in the
right direction;
Note: in case of rolls surface partial
wear, rotate it of 180, before
its replacement.
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1.3.3 APRONS REMOVAL/ASSEMBLING

(See Fig. 4.3.3.a)
Fig. 4.3.3.a - Apron removal.
REMOVAL
To remove the lifting aprons,
proceed as follows.
Operating in the "manual
mode" from the control
pulpit put the aprons in
"low" position.
Disconnect the hydraulic
feeding
system
and
discharge
the
accumulators to make
sure that the cylinders do
not start.
Sustain the apron to be
replaced
by
wooden
wedges and supports (1),
operating on the side of
the
motorized-rollers
motors.
Take out the splin pin of
the side of the apron to be
changed (2) and partially
extract the pins (3) until
the apron is free.
Using a jack, lift the apron
until
it
leans
out
compared to the others
and it is possible to hook
it by an adequate lifting
device.
Very carefully extract the
apron.
ASSEMBLING
To assembling the lifting aprons, proceed as follows.
By means of an adequate lifting device, hook the new apron (or regenerated
one) and insert it slowly and with great attention in the housing.
Put the apron on the jack.
Lower the jack slowly until the apron is on the supports used for the removal.
Reinsert the pins (3) and lock them by splin pins (2).
Check the apron vertical alignment; for the correct procedures see the
relevant paragraph.
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Connect the hydraulic feeding system and make sure that there are no fluid
leaks.
Operating in the "manual mode" from the control pulpit move the aprons to
make sure that the new piece can freely move in its housing.
1.3.4 REGENERATION OF PARTIALLY WORN APRONS

Aprons which present wear damages due to bar sliding (grooves, etc.) can be used
again carrying out an adding of material directly on the apron without removing it.
To carry out this operation, proceed as follows:
clean accurately, using a grind, the parts to be regenerated;
carry out a "base coating" using electrodes "Castolin 2-25";
complete the "coating" using electrodes "Castolin 6006" (60 HCR);
using a portable grind, remove the material in excess and level the surface
accurately.
1.4 - MAINTENANCE TOOLS

To carry out an efficient maintenance service, the operators should be provided with
suitable and efficient tools, which can be divided into:
1. routine equipment;
2. special equipment.
Routine Equipment
The routine equipment available on the market consists in wrenches, screwdrivers,
hammers, thickness gauge, etc.
Special equipment
For a thorough preventive maintenance, the operators should be provided with the
following equipment.
temperature meters for bearings;
vibration meter for bearings.
1.5 WEAR-OUT PART DRAWING LIST
See KSPL Cooling Bed & Finished Area Wear-out Part List.
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SHANGHAI HEAVY MINING MACHINERY LTD.

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

to prevent failures and breakdowns as far as possible;

Shanghai Heavy Mining Machinery Ltd.

FOR KSPL CTG BANGLADESH

1.2 PREVENTIVE MAINTENANCE

FOR KSPL CTG BANGLADESH

1.2.1 PREVENTIVE MAINTENANCE SCHEDULE

FOR KSPL CTG BANGLADESH

e) Check, using a dynamometric wrench and proceeding in crossed manner, the

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

c) Check the hydraulic system circuit.

FOR KSPL CTG BANGLADESH

Machine cleaning and checks

NAME OF THE UNIT AND /OR

PREVENTIVE MAINTENANCE PROGRAM

1.2.1.1 PREVENTIVE MAINTENANCE TABLE

FOR KSPL CTG BANGLADESH

(*) M = Moving; S = Stopped; M/S = Stopped machine and moving device

1.3 EXTRAORDINARY MAINTENANCE

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

1.3.3 APRONS REMOVAL/ASSEMBLING

FOR KSPL CTG BANGLADESH

1.3.4 REGENERATION OF PARTIALLY WORN APRONS

1.4 - MAINTENANCE TOOLS

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