1.0 - Maintenance

SHANGHAI HEAVY MINING MACHINERY LTD.
FOR KSPL CTG BANGLADESH
INDEX
1.0 MAINTENANCE1
1.1 LUBRICATION..2
1.2 - PREVENTIVE MAINTENANCE..3
1.2.1 - PREVENTIVE MAINTENANCE SCHEDULE3
1.2.1.1 - PREVENTIVE MAINTENANCE CARD..7
1.2.1.2 - GEAR VISUAL INSPECTION..8
1.3 - EXTRAORDINARY MAINTENANCE12
1.4 - MAINTENANCE TOOLS.13
1.5 WEAR OUT PART DRAWING LIST....17
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
Maintenance operators should strictly comply with the safety rules in force in their
country and in the plant.
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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 - LTC 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.
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.
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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(s).
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.
PREVENTIVE MAINTENANCE SCHEDULE
Here below there is a list of the main preventive maintenance operations to be
scheduled for the perfect machine preservation.
1. 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).
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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 motor please see the manufacturers instructions.
2. Fastening elements
Check the tightening of nuts and bolts, in particular the foundation tie rods, and tighten
always with the required torque.
3. 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).
4. Pneumatic system
Air must be filtered and lubricated.
a) Check the filter unit, the pressure regulator and the lubricator, as follows:
- drain the condensed water from the filter cup;
- check the oil level in the lubricator and, if necessary, top it up with the same
oil used in the machine lubrication system: If necessary , regulate the oil
metering;
- check the air pressure and make sure that there is no blow-by.
b) Check the filter cartridge:
- remove and replace it.
c) Disassemble the filter unit, the pressure regulator and the lubricator.
- Thoroughly clean each component and replace the worn-out ones.
- Reassemble the components.
- Finally, check the correct operation and adjust the working pressure.
d) Check the compressed air system.
Check the sealing of pipings and unions:
- if there are leakages in the unions, replace the gaskets and tighten
completely the unions; if this is not enough, replace the unions.
Carry out a visual check of the component integrity. Should the hoses be damaged,
replace them.
Any defect which might be found, must be immediately eliminated.
e) Check the efficiency of pneumatic cylinders.
- Make sure there is no air blow-by through the rod hole; this event is
characterised by a hissing sound.
- Check that there are not anomalies in the motion of the piston.
The presence of these inconveniences indicate wear of sealing gaskets which must
be promptly replaced.
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5. Centralized grease lubrication system

a) During the lubricant pumping phase, carry out the following checks:
- check the correct operation of the feeder checking the movements of the
small rod visible inside the turret;
- make sure that all the points on the lubrication system, particularly the most
distant ones, are being properly lubricated; if necessary, operate on the relative
adjusting turrets on the metering valves provided for each connected unit.
b) Check the grease lubrication system circuit.
- Check the junctions.
If there are leakages in the junctions, tighten completely the junctions. If this is not
enough, replace the junction.
- Carry out a visual check of the component integrity. If the hoses are
damaged, replace them.
Any defect which might be found, must be immediately eliminated.
6. Gear motor
Note: see also the manufacturer's documentation.
a) Make sure that there are not oil leakages from fastening flanges and the
gaskets of the shaft.
b) Check the bolt tightening and the alignment of the connected machines.
c) Check gear noise.
If unusual noise is heard, it may be due to insufficient lubrication or to excessive
wear in the gears.
If necessary stop and lock the machine drives, and then carry out a visual inspection
of the teeth to make sure they are not damaged.
d) During functioning, constantly check the bearings noise.
For an accurate check of bearings it is advisable to use the appropriate device (for
example an electronic stethoscope).
e) Check the bearing temperature which must never exceed 70C.
This check can be carried out with the machine running or immediately after the
machine stop, using the adequate instrument (for example a digital thermometer).
f) Carry out the first change of the lubricant oil.
The following oil change can be carried out at intervals indicated on the lubrication
table.
Note: when check the oil level: if necessary restore the level using the same type
of oil indicated in the technical table.
The oil must be added avoiding the contamination with dirt.
Any leakage towards the inside must be immediately eliminated.
If more than 10% of total oil capacity has to be added, carry out an accurate
cleaning and a careful check of the reduction gear to avoid possible oil leakages.
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7. Pinion, drive wheel, rack

Check the proper condition of the trolley pinion and drive wheel and of the trolley power
takeoff pinion and rack.
Carry out a detailed visual inspection of teeth to make sure they are not damaged.
In case of doubts, check the areas involved with penetrants, in order to find out small
cracks or pitting.
8. Positioning of trolley and stopper plate
Check the blocking and the proper position of the trolley and the bumper.
9. Conditions of link works
Check the supports, lever mechanisms, transmissions, joints, stop plates and all the
parts most subject to wear.
10. Pivots, joints and bushes
Check the pivots and bushes and the ball joints.
11. Limit switch
With the machine stopped and power to it cut off, check the limit switch.
Remove the cover, taking care to avoid damaging the gasket.
Remove any traces of oxidation from the terminal clamps and spray them with a
suitable protective liquid.
Check the correct tightening of the screws on the terminal clamps.
Reinstall the cover, taking care to position the gasket properly.
Note: for further information and details see the manufacturer's documentation.
12. Junction boxes
With the machine stopped and power to it cut off, check the junction boxes.
Remove the cover, taking care to avoid damaging the gasket.
Check the correct tightening of the screws on the terminal clamps.
Reinstall the cover, taking care to position the gasket properly.
13. A.C motors
a) With the machine in operation:
- check the temperature of the motor frame;
- check the bearing noise, in particular the bearings placed on the drive
coupling side;
- check the cooling fan noise, which may be due to impacts or accidental
damages.
b) With the machine stopped and power to it cut off:
- 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.
c) With the machine stopped and power to it cut off:
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- 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. Welds
Check the welded joints in order to find out possible cracks.
If necessary, make a new weld, and keep into account the possible thermal expansion and shrinkage.
PREVENTIVE MAINTENANCE CARD
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1
2
3
4
4.a
4.b
4.c
4.d
4.e
5
5.a
5.b
6
6.a
6.b
6.c
6.d
6.e
6.f
7
8
9
10
11
12
13
13.a
13.b
13.c
14
Cleaning and checks

Fastening elements
Grease lubrication
Pneumatic system
Filter and lubricator unit
Filter cartridge
Component integrity
Circuit integrity
Pneumatic cylinder
Centralized grease
lubrication system
Feeders
Circuit integrity
Gear motor
Leaks
Tightening and the
alignment
Gear noises
Bearings noise
Bearings temperature
First change of the
lubricant oil
Pinion, drive wheel, rack
Positioning of trolley and
stop plate
Conditions of link works
Pivots, joints and bushes
Limit switches
Junction boxes (J.B.)
Electric motor (A.C.)
Temperature and noise
Windings
Grounding of drive motor
Welds
S
S
S
10000
4800
2400
1200
X
X
#
See Lubrication Table Collection
S
X
S
S
M/S
M/S
#
X
#
#
#
X
X
#
M/S
M/S
M/S
S
M
M
M
400
160
80
NAME OF THE UNIT AND /OR M/S

COMPONENT
(*)
16
PREVENTIVE MAINTENANCE PROGRAM
OPERATIONS
X
X
#
X
X
#
M/S
See Lubrication Table Collection
M/S
S
S
S
M
S
S
S
#
#
X
X
X
X
X
X
X
X
(*) M = Moving;
S = Stopped; M/S = Stopped machine and moving device

X = First maintenance operation; # = Following operations
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GEAR VISUAL INSPECTION

ASPECT
Abrasive wear
Presence of ridgings on
the tooth side, with
orthogonal direction with
respect to the contact line
Excessive wear
Removal of great particles
from the tooth surface, with
consequent tracks having
orthogonal direction with
respect to the contact line.
Scratch
Long and linear grooves in
the contact direction of the
teeth. Their intensity is less
marked at the pitch
diameter.
Seizure
Seizure usually starts on a
small surface near the
tooth top or bottom; it can
be noticed because of
grooves in the skimming
direction.
Should seizure stratch over
a large part of the tooth
sides, the gear will have a
considerable vibration and
noise degree.
CAUSE
Presence of small
particles in suspension in
the lubricating oil (scale
deposits, sand, rust, etc.).
Hard particles trapped on
the surface of the tooth
sides.
Big hard particles in the
lubricating oil.
REMEDY
Improve the filtering degree
of the filtering cartridge.
Replace the oil with a more
viscous one. Improve the
filtering degree of the
filtering cartridge.
Excessive modification of
the tooth profile due to
continuous abrasive wear.
Replace the gear.
Hard projections on the

tooth side.

Lubricating film breakage

between the sides, which
causes a localized
welding.

Check the oil flow rate.
Check the efficiency of the
oil sprayers.
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Chemical corrosion
Very fine pitting on the
whole surface of the tooth,
often accompanied by redbrown traces of oxidation
near the active part of the
tooth side.
Carry out an immediate and

careful analysis of the oil
residue to determine the
Surface deterioration due type, quantity and origin of
to the action of chemical
the contaminating chemical
agents. This type of wear
agents.
can continue until the gear Then take the necessary
becomes unsuitable for
measures to prevent the
further use.
recurrence of the problem.
Should the pitting have a
considerable extent, replace
the gear.
Oxidation
Red-brown pitting in the
skimming area.
The damage mainly
interests the inner and
stationary toothings
(couplings and clutches).
Repetition of small
movements of a contact
surface over another, with
consequent production of
oxides and abrasive
action.
Make sure that the gear

axial displacements are
within the allowed limits.
Carry out the oil chemical
analysis.
Chipping
Spot-shaped swellings on
the tooth sides.
During the operation

under load, power is
initially transmitted
through these swellings,
which rapidly acquire a
metallic polish.
Check the maximum load

on the tooth.
Check the sprayer flow rate
and efficiency.
Improve the filtering degree
of the filtering cartridge.
ASPECT
Overheating
The area subject to
overheating is characterized
by:
- colour typical of the
tempering
process
- frequent furrowed areas
- signs of plastic deformation.
Cavitation
The sides of all the teeth show
a localised uniform chipping.
In other cases, the whole tooth
surface appears as if it was
sanded.
CAUSE
REMEDY
Presence of high-frequency
vibrations.
Check the sprayer

flow rate and
efficiency.
Check the oil
condition.
Improve the filtering
degree of the
Check the condition
of the bearings and
the installation
backlashes.
Check the backlash
between the teeth.
Check the bearing
backlashes.
The lubricating oil is

contaminated by water, air or
other gases.
Carry out the oil

chemical analysis
and act accordingly.
Excessive temperature due to

improper lubrication.
Excessive temperature
bacause of insufficient
backlash due to possible
external yieldings.
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Hydraulic erosion
The eroded part shows a
porous area which, as the
damage worsens, increases in
size and takes on a squashed
elliptical form with the main
axis parallel to the direction of
the tooth.
Electrical erosion
The discharge produced by an
electric arc between the tooth
sides produces many craters
on their surface. Occasionally,
there can be extensive areas
with evident signs of burning
(colour typical of the tempering
effect).
Erosion due to the action of a

liquid jet containing air or fine
metal particles.
This type of damage is found
particularly on gears operating
at high speed.
Check the sprayer

positioning and
efficiency.
Check the oil
condition.
degree of the
Current passage due to

losses for parasitic currents or
to faulty insulation.
Check the insulation

of the main motor
basement or of any
electrical equipment
located near the
machine.
Presence of projections on the

contacts of the tooth sides.
Initial pitting
Often, when the projections
Small craters thinly distributed have been eliminated by the
No intervention is
around the area of the pitch
pitting and the load is
necessary.
diameter.
redistributed, there is no
further damage and the pitting
stops.
Check the oil
condition.
Check the sprayer
The initial pitting on the teeth
flow rate and
can occur at the beginning of
efficiency.
Initial pitting
the operation, after a period of
Replace the oil with
operation with reduced
a more viscous one.
loads.
degree of the
Progressive pitting
The affected areas are
a more viscous one.
increasingly more extensive
Material fatigue caused by the Improve the filtering
and deeper. The more
overcoming of hertzian
degree of the
extensive pitting develops
pressure often due to external filtering cartridge.
around the pitch diameter
overloads.
of the gears, while on the tooth Vibrations.
Check the bearing
crests there may be small
backlash.
craters (almost striations).
Micropitting
High loads with small
Check the maximum
thickness of the oil film.
load on the tooth.
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If the area affected

by this defect widens
and the size of the
micro-craters
increases:
replace the oil with a
more viscous one.
degree of the
It consists in very thick microcraters and/or superficial

micro-cracks.
ASPECT
Scale-type pitting
Detachment from the side of the
tooth of small steel scales which
create cavities on the tooth
contact surface, with the form of
an overturned triangle of
constant depth.
Flaking
Detachment of metal fragments
with irregular shape in the
hardened toothing area. This
type of defect mainly occurs on
superficially hardened gears
(casehardened or nitrided).
Breakage of the hardened
layer
This defect appears as a wide
area of hardened material which
comes off the tooth side, thus
leaving a cavity on the surface.
The line of the superficial break
usually follows the direction of
the contact line.
Plastic deformation due to
rolling
The material creeps from the
pitch diameter of the pinion
towards the outside of the tooth,
CAUSE
REMEDY
Defects found on the

forged material.
Replace the gear.
Heavy overloads.
Check the maximum

load on the tooth.
Replace the oil with a
more viscous one.
degree of the filtering
cartridge.
Heavy overloads on all

the teeth.
Replace the gear.

Check the maximum
load and determine
the causes.
Propagation of the
cracking area along the
transition area between
the hardened superficial
layer and the hardened
and tempered zone as a
result of both a faulty
superficial hardening and
of heavy overloads.
Load exceeding the
material elastic limit.
This deformation is
permanent.
CopyrightSHMM
Replace the gear.

If the break is due to
overloads, check the
maximum load and
determine the causes.
Replace the gear.
Before installing the
new gear, check the
maximum load and
determine the causes.
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thus forming a metal ridge. The

material of the conjugate
gearwheel deposits along the
pitch diameter. In this manner, a
groove forms on the drive gear,
while a metallic ridge forms on
the driven one.
Poor lubrication with

subsequent temperature
increase on the side of
the tooth above the
temperature at which
plasticization starts.
Presence of foreign
Riveting
bodies between the teeth,
A more or less marked
with equal or greater
depression with a notched aspect
hardness than the gear
on the edges of the tooth side.
material.
Hammering
Slight grooves on tooth sides on
the contact line.
Strong impulsive
phenomena due to
abnormal vibrations
extending over a long
time.
Waviness
Slight ridging on the tooth sides
perpendicularly to the skimming
direction.
The damages occur on a limited
number of teeth and in different
positions.
Plastic deformation which

occurs after a great
lapping of the sides.
CopyrightSHMM
Replace the gear.

Check oil conditions.
Check sprayer
efficiency.
Check the oil
conditions.
cartridge.
Check the sprayer
efficiency.
If the damage
interests at least 40%
of the tooth surface,
replace the gear.
Check the proper
tightness of the
anchoring screws.
Check the bearing
backlashes.
Check the axial
backlashes of
connecting devices
such as couplings and
spindles.
Check the oil
conditions.
cartridge.
Check the sprayer
efficiency.
Check the damage
progressiveness at
regular intervals (200
hours); if the damage
progresses, replace
the gear.
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ASPECT
Striations
Formation of marked ridges in the
tip speed direction.
This type of damage can be found
on toothings with a low tip speed
and with a significant component
due to the skimming in the
direction of the contacts
(hypoid gears and worm screws).
Fragile break
Break along the sliding
intercrystalline planes or along the
separation line of the grains; this
type of break is characterised by
the absence of visible plastic
deformation.
CAUSE

Contemporary presence
a more viscous one.
of plastic deformation and Improve the filtering
wear.
degree of the
If the striations are
very deep and
mainly localised
towards the tooth
Very hard materials with
bottom, replace the
high contact stresses.
gear.
Check the maximum
load and determine
the causes.
Overloads, even of minor

degree, with oxidation.
Overload.
Ductile break
Brake surface with opaque and
fibrous appearance characterised
by the presence of visible plastic
deformation.
Breakage of tooth end

Surface characterized by ridges
(towards the tooth end) with
orthogonal direction with respect to
the tooth longitudinal one, followed
by a wide area with superficial
granulation (similar to a
sandblasting).
REMEDY
Overload and fatigue at

the same time.
Load concentration.
CopyrightSHMM
Replace the gear.

new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
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Breakage of the end part of the

toothing (both cylindrical and
conical).
Load concentration.
Breakage with signs of pitting.
Great and constant

overloads on the final
part of the tooth side.
Very severe overloading.

Tooth breakage and cutting
When the teeth are completely
sheared, the sheared surface is
similar to a machined surface.
This damage only regards the
gears between gear wheels with
very different strength values.
Modification of the load

distribution on the
meshing due to external
factors (bearing yielding,
external axial loads, etc.).
Replace the gear.

new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
Replace the gear.
new one, check the
maximum load and
determine the
causes.
Moreover, check the
bearing condition
and backlashes.
EXTRAORDINARY MAINTENANCE
It is not necessary to describe particularly the operations for the substitution of inside
parts to the machine, considering that are intuitive entirely and of simple execution.
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.
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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

Shanghai Heavy Mining Machinery Ltd.

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

FOR KSPL CTG BANGLADESH

5. Centralized grease lubrication system

FOR KSPL CTG BANGLADESH

7. Pinion, drive wheel, rack

FOR KSPL CTG BANGLADESH

- check the grounding of the drive motor.

PREVENTIVE MAINTENANCE CARD

FOR KSPL CTG BANGLADESH

Cleaning and checks

NAME OF THE UNIT AND /OR M/S

PREVENTIVE MAINTENANCE PROGRAM

SHANGHAI HEAVY MINING MACHINERY LTD.

See Lubrication Table Collection

S = Stopped; M/S = Stopped machine and moving device

FOR KSPL CTG BANGLADESH

GEAR VISUAL INSPECTION

Replace the gear.

Hard projections on the

Replace the oil with a more

Lubricating film breakage

Replace the oil with a more

FOR KSPL CTG BANGLADESH

Carry out an immediate and

Make sure that the gear

During the operation

Check the maximum load

Check the sprayer

The lubricating oil is

Carry out the oil

Excessive temperature due to

FOR KSPL CTG BANGLADESH

Erosion due to the action of a

Check the sprayer

Current passage due to

Check the insulation

Presence of projections on the

FOR KSPL CTG BANGLADESH

If the area affected

It consists in very thick microcraters and/or superficial

Defects found on the

Replace the gear.

Check the maximum

Heavy overloads on all

Replace the gear.

Replace the gear.

thus forming a metal ridge. The

FOR KSPL CTG BANGLADESH

Poor lubrication with

Plastic deformation which

Replace the gear.

FOR KSPL CTG BANGLADESH

Replace the oil with

Overloads, even of minor

Breakage of tooth end

Overload and fatigue at

Replace the gear.

FOR KSPL CTG BANGLADESH