LARSEN & TOUBRO LIMITED
KANSBAHAL WORKS, SUNDERGARH
ORISSA, INDIA
OPERATION & MAINTAINENCE MANUAL FOR
6024 SSHD ROLL CRUSHER
PLANT: COAL CRUSHING PLANT
LOCATION: WANI WASHERY,
MAHARASHTRA
CUSTOMER: KARTIKAY COAL
WASHERIES PVT. LTD.
ORDER REF: KCW/L&T/WW/03-04/1001
Dt. 24.03.2004
SWO NO.: 75007/00
ASSEMBLED VIEW OF A 6024SSHD ROLL CRUSHER
FROM THE MANUFACTURER’S HOUSE
We have the pleasure in enclosing the Operating & Servicing Instructions
For the Crusher described in the following text. It should be noted that for the efficient performance of the machine strict observance of the instructions is very much necessary.
We would advise you to keep a stock of the essential spare parts as per the list attached, for the trouble free operation.
To enable us to give you efficient and quick service we recommend you the following:
· All orders should include the part number shown in the list of the spares
· A short description of the part required.
Please quote our Works Order Number on your Order form or in any correspondence for this project is 75007/00
Please note our Phone Number: (06624) 280241, 280101, 280123, and 280145
280551, 280552 & 280556.
Fax Number: 06624-280226, 280238,280243 & 280557
And E-mail address: issrao-kbl@kbl.ltindia.com
Tushar_kbl@kbl.ltindia.com
Psm-kbl@kbl.ltindia.com
CONTENTS
SECTION
DESCRIPTION
SECTION- 1
GENERAL INFORMATION
SECTION - 2
INTRODUCTION
SECTION- 3
SAFETY INSTRUCTIONS
SECTION- 4
DESPATCH INSTRUCTIONS AND STORAGE PROCEDURE
SECTION- 5
ERECTION & RECOMMENDATION FOR BELT TENSIONING.
SECTION- 6
DRIVE
SECTION- 7
COMMISSIONING AND OPERATION
SECTION- 8
MAINTENANCE AND TROUBLE
SHOOTING GUIDE
SECTION- 9
ADJUSTMENT & ALIGNMENT ASSLY
SECTION- 10
GEAR BOX
SECTION- 11
LUBRICATION SYSTEM
SECTION- 12
ROLL REPAIR
SECTION- 13
SPARE PARTS
SECTION- 14
LIST OF DRAW INGS
SECTION- 15
O & M MANUAL FOR HYDRO-PNEUMATIC CYLINDER
SECTION - 1
GENERAL INFORMATION
GENERAL INFORMATION
_____________________________________________________________
CUSTOMER’S NAME : KARTIKAY COAL WASHERIES PVT.
LIMITED
CUSTOMER’S ORDER NO. : KCW/L&T/WW/03-04/1001
Dt. 24.03.2004
L&T ORDER NO. : 75007/00
EQUIPMENT TYPE & SIZE : 6024 SSHD
WEIGHT : 10.8 T (APPROX) EXCLUDING DRIVE
CAPACITY : 400TPH
FEED MATERIAL : COAL
FEED SIZE MAX. : -300mm 500mm (Max) Stray Pieces.
END PRODUCT SIZE : - 50mm sq mesh
YEAR OF MANUFACTURE : 2004
MACHINE NO. : 006-573
MOTOR RATING : 90KW, 1000 RPM
CRUSHER RPM : 300 RPM
RECOMMENDED OPERATING : 570
CENTRE DISTANCE
BETWEEN ROLLS
SECTION - 2
INTRODUCTION
INTRODUCTION
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L&T GUNDLACH 6024SSHD is a single stage two Roll Crusher. The General Assembly of the machine is shown in enclosed drawing.
This machine consists of one set of rolls. One roll is stationary and other is adjustable one. The rolls break the feed material to the desired output size with minimum fine generation. The rolls are made of cast steel and hard faced on teeth for extra tough service. These roll are coupling mounted and they can be removed quickly without dismantling bearing and main drive components. These rolls are supported on the antifriction bearings through stub shafts made of alloy steels.
The adjustable roll can be set independently to the desired position by Hydraulic cylinders. The hydraulic cylinders operate with hydraulic oil on one side and inert gas (nitrogen) on other side. The roll position can be changed either by pumping more oil through a hand pump or draining out oil to tank. The inert gas on the other side of the cylinder acts as a spring that allows the adjustable rolls to move back to allow tramp iron / uncrushable material to pass through. For more details please Refer Section- 9.
The flywheel sheaves provide high inertia for crushing large lumps in the feed. Extreme care has to be taken that metal detector and magnetic separator must be installed in the feeding line to prevent damage to the crusher.
The two rolls are housed inside a hopper assembly, which is made in four parts. This construction makes the removal of the worn out rolls and assembly of new rolls extremely easy and fast. The rolls are driven by single motor and specially designed gearbox.
All the moving parts are provided with lubricating facilities. The machine is provided with manual point-to-point lubrication system, with difficult to approach lubrication points connected with pipes, hoses, and brought to conveniently approachable location.
SECTION - 3
SAFETY INSTRUCTIONS
SAFETY INSTRUCTIONS
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Operator’s safety and the safety of others depend upon reasonable care and judgment in the operation of this crusher. A careful operator is good insurance against an accident.
Most accidents, not matter where they occur, are caused by failure to observe and follow simple fundamental rules or precautions. For this reason recognizing hazards can prevent most accidents and taking steps to avoid them before an accident occurs.
Regardless of the care taken in the design and manufacture of this type of equipment, there are conditions that cannot be completely safe guarded and which are prone to accidents.
Basic rules regarding Safety in and around a crusher are outlined in the following list of DOs and DO NOTs:
DO
1. Install the crusher on a structurally sound foundation.
2. Allow the crusher to get up to full speed before loading.
3. Disconnect and lockout the electrical power to the crusher motor (s) before servicing the crusher.
4. Wear proper safety equipment such as safety glasses, safety shoes and hard hats as required as good safety practices.
5. Maintain the crusher at regular and scheduled intervals.
6. Keep the area around the crusher picked up and free from debris, which present tripping hazards.
7. Periodically check and tighten all accessible bolts, nuts and screws.
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8. Use only appropriate qualified persons for operation and maintenance of the crusher.
9. Make sure the crusher inspection doors are closed and locked before operation the crusher.
10. Make sure the crusher is clean & clear before starting.
DO NOT
1. Remove drive guards if the crusher is in operation.
2. Attempt to clear the crusher when in operation. Always disconnect the electrical power to the motor first.
3. Look into the crusher chamber when the crusher is in operation.
4. Insert hands, feet or other body parts into the drive or the crusher when in operation.
5. Start the crusher while fully loaded; unload it before starting.
6. Adjust the roll gaps when crusher is in operation.
SECTION - 4
DESPATCH INSTRUCTIONS AND STORAGE PROCEDURE
DESPATCH INSTRUCTIONS & STORAGE PROCEDURE
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A. DESPATCH
L&T GUNDLACH 6024SSHD CRUSHER is generally dispatched in the following sub-assemblies as per ref. drg. No. CS.1.4-15466.
Ref: “Indicative dispatch particulars drawing” enclosed with manual:
SL. NO.
QTY.
DESCRIPTION
APPROX. DIMENSION
(L X W X H)
APPROXIMATE WEIGHT (Kg)
1
1
6024SSHD Roll Crusher Assembly
3335 X 2438 X 1311
9499
2
1
Belt Guard With Bracket
3261 X 1810 X 380
200
3
1
Fly wheel Sheave
Dia. 1299 X 200
665
4
2
Slide Rails
1200 X 200 X 128
200
5.
1
Lot Loose Items *
-
329
TOTAL=10893 Kg
*Lot Loose Items.
Ring feeder, Cover plate, and Mini bucket grease pump with adapter, Pocket tooth gauge. Torque wrench arm with ½” (M) sq. drive. Converter, Extension piece, Hex. Bit socket Belt tension meter, Roll removal rail installation, Motor pulley, SPC 8V-2360 “ V”-belt, Bolts & Fasteners, N2 Pressure Regulator with adaptors.
B. STORAGE PROCEDURE
I. Pack all Bearing-housing full of grease.
II. Coat all exposed machined surfaces with rust preventive coating.
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III. Pack Pulleys, V-Belts, Nit roil adjustment components in weatherproof ply wood container.
IV. While the Crusher is being kept idle, rotate the drive shafts several revolutions a minimum of once in a week to distribute grease to the bearings and prevent possible corrosion damage.
V. Prior to start up fill the bearings and seals with new grease.
SECTION - 5
ERECTION & RECOMMENDATION FOR BELT TENSIONING
CRUSHER ERECTION
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The machine is generally supplied in completely assembled condition with very few loose items. A list of loose items supplied is given in Section-4.
The erection of the machine should be carried out in the following steps:
IMPORTANT
1. Foundation Plan
The foundation plan should be in accordance with the foundation drawing supplied by LARSEN & TOUBRO LIMITED. The foundation details are to be finalized by the customer.
2. Feed and discharge chute fixing
When attaching a feed and discharge chute, we recommend you to bolt to the hopper and channel extending concrete base respectively using the holes provided on the hopper flange. Welding to the crusher may cause distortion, resulting in failure of the moving parts.
**CHUTES SHOULD BE SELF-SUPPORTING UNITS, NOT DEPENDENT ON THE CRUSHER FOR SUPPORT.
3 Maintenance area
In the event of future maintenance on your crusher (changing gear box parts, roll and bearing), We recommend leaving 1500 mm minimum clear area all around the crusher. If it is absolutely necessary to locate other equipment in this area, we suggest bolted construction so that these items can be removed if required.
4. Hoisting
Enclosed GA drawing shows the designated points to attach hook or chain. Never lift unit by handle attached to hopper. Extreme care must be taken when hoisting the crusher
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REFER FOLLOWING DRAWINGS
1. General Assembly of 6024SSHD
2. General Assembly with Drive Arrangement for 6024SSHD
3. Dispatch particulars
The erection to be done in following steps:
A. ERECTION OF THE MAIN BODY
1. Check that the foundation plan is made as per the drawing furnished.
2. Place the crusher over the foundation. Install the foundation bolts but DO NOT TIGHTEN THEM.
3. Check the alignment of the machine.
4. Level the machine. Leveling should be checked at bearing housing pad. Standard shims can be employed at foundation bolts as required. The shims should be tack welded with base frame after unit is leveled.
5. Fine grout (non shrinkable type) to be done. Incase of civil foundation.
6. Foundation bolts to be tightened lightly.
7. After curing of the fine grout, the levels should be checked again.
8. Tighten the foundation bolts completely.
9. Assemble the flywheel sheave on the main drive shaft.
B. ERECTION OF DRIVE ARRANGEMENT
1. Check the foundation plan for the drive arrangement.
2. Place the slide rails, make sure that the slide rails are parallel to each other and to the axis of crusher. The relative position of the Slide Rails with respect to the machine is to be maintained.
3. Level the slide rails. The height of slide rail top with respect to machine axis should be maintained.
4. Shim provided for leveling should be tack welded with slide rail base.
5. Foundation bolts to be inserted in position and tightened lightly.
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6. Non- Shrinkable type Grout is to be provided under the slide rails in leveled condition.
7. After curing of fine grout the levels should be checked again.
8. Tighten the foundation bolts.
9. Place the motor over the slide rails.
C. INSTALLATION OF OTHER LOOSE ITEMS
Install the hoses, nitrogen pressure regulator and other items of hydraulic adjustment assembly sent loose as shown in our drawing no. CS.1.2 – 2545.
D. CHUTES
1. Feed Chute
In order to obtain the maximum through - put capacity of the crusher, the feed chute should satisfy the following conditions:
i) The feed conveyor should run perpendicular to the length of the roll.
ii) The sealing arrangement between the feed chute and the top of the crusher to be provided.
iv) The feed chute should be self-supporting type i.e., the weight of the feed chute should not be transferred to the machine.
2. Discharge Chute
Discharge chute should be so designed that material does not build up at the discharge of crusher.
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E. MAINTENANCE FACILITIES
In order to provide proper maintenance to the crusher and its drive, sufficient space should be allocated. The minimum space required for maintenance purpose is shown in G. A. with drive drawing.
To facilitate installation of crusher, portable crane of capacity approx. 15T. will be needed. To facilitate maintenance of various components, like rolls of a monorail of approx. 1.8 T. will be needed.
IMPORTANT
ROTATE DRIVE SHAFT A MINIMUM OF ONCE PER WEEK WHILE CRUSHER IS NOT BEING OPERATED TO DISTRIBUTE LUBRICANT TO THE BEARINGS AND PREVENT POSSIBLE CORROSION
SECTION - 6
DRIVE
DRIVE
________________________________________________ _____________
DRIVE COMPONENTS
The crusher is provided with one drive design of rolls.
The Motor Pulley is directly mounted on the motor shaft through key whereas the driven pulley is mounted on the roll shaft through Ring Feeder locking assemblies.
The detail of drive components are given below:-
1. MOTOR
90KW, 1000-RPM TEFC Squirrel Cage Induction Motors.
Frame Size: 315
2. PULLEYS
Motor Pulley - PCD - 394 mm
8V SECTION.
Driven Pulley - PCD - 1294 mm
8V Section
3. BELTS - 5 Nos. - 8V 2360, Make - PIX
Supplier’s address : PIX Transmission Limited
J 7, MIDC, Hingna Road
Nagpur - 440 016
4. RING FEDER LOCKING ASSEMBLY.
Size - 140x190 RfN 7012, Qty - 2 Nos.
Supplier’s address: M/s. Ring Feeder, GmbH
D-415, Krefeld, GmbH, West Germany.
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INSTALLATION AND OPERATION OF BELT DRIVES
TROUBLE SHOOTING
Small cracks on V - Belt side and base
Generally caused by excessive heat and chemical fumes. The heat may be generated by a shortage of belt tension.
V - Belt swelling or softening
Caused by excessive contamination by oil, certain cutting fluids or rubber solvent.
Whipping during running
Usually caused by incorrect tensioning, principally on long center drives. If a slightly higher (or lower) tension does not cure the problem there may be a critical vibration frequency in the system, which requires redesign or a banded belt. Consult Fenner/Pix.
ALIGNMENT
Good alignment of pulleys is important otherwise the belt flanks will wear quickly.
Conversion Constants
Length: Inches X 25.4 = Millimeters
Inches X 0.0254 = Meters
Feet X 0.30480 = Meters
Yards X 0.91440 = Meters
Force: Kilogram force (kgf) X 9.81 = Newton (N)
Pounds force (lbf) X 4.45 = Newton (N)
Note: The kilo pound (kp) is an alternative name for the kilogram force (kgf).
Torque: Kilogram force meter X 9.81 = Newton meter (Nm)
Pounds feet (lbf) X 1.36 = Newton meter (Nm)
Pounds inches (lbfin) X 0.113 = Newton metre (Nm)
Power: Horse power (hp) X 0.746 = Kilowatt (kw)
Cheval - vapeur (CV) X 0.735 = Kilowatt (kw)
Pferdestarke (ps) X 0.735 = Kilowatt (kw)
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TORQUE AND POWER EQUIVALENTS
The kilowatt (kw) is the common unit of mechanical power, i.e., the rate of doing work Torque is a turning movement or twisting effort and is expressed in Newton metres (Nm).
KW = (Nm x rev/min) / 9550 Nm = (kW X 9550) / (rev/min
GENERAL METHOD FOR TENSIONING V- BELT DRIVE
The best tension for a V- belt is the lowest tension at which the belts will not slip under the highest Load condition.
Check the tension on a new drive frequently during the first day of operation.
Check the drive tension periodically.
Too much tension shortens the bearing and the belt life.
Keep belts and sheaves free from any foreign materials, which may cause slip.
If a V-Belt slips tighten it.
Narrow Wedge Belt
PROFILE
SMALL PULEY
FORCE IN Kgf
SPZ/3V
63-89
1.1-1.6
90-114
1.2-1.8
115-152
1.3-2.2
SPA
90-125
1.7-2.6
126-200
2.1-3.2
201-250
2.3-3.3
SPB/5B
178-229
3.8-4.8
230-305
3.4-5.8
306-406
3.7-6.7
8V
418-432
8.1-15.0
433-610
12-17.6
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RECOMMENDATION FOR TENSIONING OF BELTS
As per the guide lines available for tensioning, all new belts during installation should be tensioned to the HIGHER VALVE (refer TENSIONING FORCES in the enclosed Installation & Maintenance instructions) to allow for the normal drop in tension during running in period. Use Belt Tension Indicator / Tester to check belt tension.
The tension of the belts to be very closely monitored and checked with tester everyday for one week after installation and running. This is to ensure satisfactory performance of the belts and avoid twisting and jumping of belts. After one week of operation the belts should get stretched. However, if sagging is observed, proper tensioning to be out immediately. At this stage the tensioning should be done towards the lower value. This has to be checked at least twice - a - week regularly.
It may be emphasized that proper tensioning of belts will result in a efficient drive system and better performance of the belts.
It is recommended that a drive which is to stand for a prolonged period ( say more than one week ) before use should have the tension relaxed to prevent the belt taking a permanent set on the pulleys. Before a drive is started up, it is essential that be re tensioned.
PIX TRANSMISSIONS LTD
J-7, M-I-D-C, HINGNA ROAD,
NAGPUR - 440 016
PIX V - BELT TENSION TESTER
GENERAL GUIDELINES FOR TENSIONING OF V-BELTS:
1. Ideal tension is the lowest tension at which the belt will not slip under
Peak load conditions.
2. Check tension frequently during the first two days of operation.
3. Over tensioning shortens belt and bearing life.
4. Keep belts free from foreign material, which may cause slip.
6. Make V-drive inspection on a periodic basis. Adjust tension when
Slipping. Never apply belt dressing, as this will damage the belt and cause
Early failure.
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TENSION MEASUREMENT PROCEDURE
The length of the span should be measured in millimeter (refer sketch). At the center of the span a force is to be applied with a tension tester in a direction perpendicular to the span, until an amount equal deflects the belt from the normal to 0.015 mm for every millimeter of span length. For example, the deflection for a span of 1m is (1000 x 0.015) mm, i.e. 15mm.
The force required for this deflection should be noted and compared with the value of P given in the Table A.
In all cases, it is essential that the pulley centers be fixed and that the larger pulley be then rotated at least four times before making measurement. The belt tension should be such that the measured force falls within the value given in the table A. A measured force below the value indicates under tensioning while a measured force above the value indicates over tensioning. Some difficult drives may need a tension towards the higher value to be maintained, such drives usually having one or more of the following properties:
a. High Belt speed
b. Low Belt speed
c. Small arc of contact
d. High overload on start-up
e. Frequent high torque start-up
All belt drives should be watched carefully during the running in period of 2 days after initial start-up. Re-tensioning should be carried out by the above procedure when necessary.
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DEFLECTION FORCE REQUIRED FOR MEASURING BELT TENSION IN WEDGE & V-BELT DRIVES:
TABLE `A’
Type of Belt
Belt Cross
Section
Smaller pulley
Diameter (mm)
Required deflection force P
At the center of Span (in N*)
Belt Speed Range, m/sec
1-10
11-20
21-30
New
Used
New
Used
New
Used
A
80 - 140
141 & above
18
27
12
18
15
22
10
15
12
18
8
12
V - BELTS
B
125 - 200
201 & above
36
54
24
36
30
45
20
30
24
38
16
24
C
200 - 400
401 & above
72
110
48
72
60
90
40
60
48
72
32
48
D
355 - 600
601 & above
140
210
96
140
120
180
80
120
96
140
55
96
SPZ/3V
67 - 95
96 & above
18
26
12
18
16
24
10
16
14
22
8
14
SPA
100 - 140
141 & above
32
48
22
32
26
40
18
26
22
34
15
22
WEDGE BELTS
SPB/5V
160 - 265
266 & above
56
72
38
56
50
64
32
50
42
58
28
42
SPC
224 – 355
356 & above
102
132
72
102
90
120
60
90
80
110
50
80
8V
330 – 520
521 & above
160
250
122
160
135
210
102
135
110
170
84
110
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INSTALLATION INSTRUCTIONS
RINGFEDER LOCKING ASSEMBLIES
Rfn 7012 & 7012 - IN
The RINGFEDER LOCKING ASSEMBLY is a keyless shaft - hub connector providing mechanically the same characteristics as a shrink fit. It is, however, easily adjustable and removable thus facilitating assembly and disassembly. Since torque is transmitted by contact pressure and friction between functional surfaces, condition of contact surfaces and proper tightening of the locking screws are of great importance.
IMPORTANT: To insure satisfactory performance and easy installation read first and then follow all instructions carefully.
INSTALLATION
1. Clean and slightly oil shaft, hub bore and Locking Assembly. Make sure to always oil thread and under the head of cap screws. (Never Use Molybdenum Disulphide “MOLYKOTE” or other similar lubricant).
2. Slip Locking Assembly and hub onto the shaft and bring them to desired position.
3. Tighten locking screws evenly and in several stages following diametrically opposite sequence.
Stage 1: Tighten by hand until a slight positive contact is established. Make final alignment and adjustment to connection.
Stage 2: Tighten screws to approx. half the specified tightening torque (MA) shown in table on page. Do this by extended key or torque wrench.
Stage 3: Tighten screws to full tightening torque (MA) using a torque wrench.
Stage 4: Check and make sure that no screw will turn any more by applying specified torque (MA).
4. Allow assembly to stand for 1/2 to 1 hour.
SECTION - 7
COMMISSIONING AND OPERATION
COMMISSIONING AND OPERATION
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A. PRIOR TO COMMISSIONING
1. Check that all the bolts are tightened properly. All loose tools/tackles should be removed. All the tack welds, clamps and similar things employed during installation to be removed.
2. Check that the electrical connections and interlocking has been done properly.
3. Purge all the bearings with new grease to remove the old grease. For proper grade and quantity of grease refer Section-10.
4. Ensure that all the grease lubrication line joints are leak proof. Solidified grease in the pipe may prevent the flow of grease.
5. Ensure that all the start up instructions related to motor and other related equipment is followed.
6. Check and ensure that all the joints of hydraulic and nitrogen lines are leak proof.
7. Fill to proper level the gearbox with new oil. For proper grade and quantity of oil refer Section-11
B. COMMISSIONING
1. Rotate the motor manually for rotations to ensure that it rotates freely.
2. Run the motor alone for some time.
3. Rotate the rolls manually by rotating the flywheel to ensure there is no fouling anywhere.
4. Adjust the gap between the rolls to the desired specified values.
5. Ensure that the grease is filled up to the required level in the respective reservoirs.
6. Connect the V-belts and tighten them up to the required tension. For proper tensioning of the belts, follow instructions given as a part of this manual.
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7. Install the belts guards and its supports properly.
8. Pressurize the nitrogen side of the cylinder to approximately 12 bars. Resetting can be done if required. For detail instruction, refer Section-9.
9. Inch the motor and ensure that rolls are rotating in proper direction. The direction of rotation of stationary roll should be clock wise when viewed from flywheel end.
10. Run the Crusher without load for few hours. Make observation on -
- Bearing temperature.
- Any unusual Vibration.
- Load on drive motor, power consumption etc. and record for future reference.
11. In case the running of crusher is normal, the no load trial can be continued for a period of 6 to 8 hours and the bearing temperature should be checked at regular intervals for any undue rise in temperature.
C. OPERATION
1. After no load run, stop the crusher and tighten all the fasteners of machine and its drive. Check the belt tensions & readjust if necessary.
2. Check ancillary equipment, Inter locking of the complete system.
3. Set the roll center distance at the operating center distance given in the General Information Section.
4. Start feeding material slowly and evenly and gradually bring the Crusher up to full load in 8 - 12 hours time.
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IMPORTANT
v It is essential that the feed is distributed evenly over full length of Rolls and it should fall centrally between the rolls.
v Readjust the gap.
v Check the motor load.
v Check the bearing temperature.
v The distance between the rolls determines the Product Size. Product size can be varied to a certain extent by changing the distance. To change this distance follow the procedure outlined in Section-9.
v The nitrogen pressure of the Nitroil cylinder should be set at a lower pressure to prevent the Adj. Roll from bouncing during normal crushing. Normal operating pressure should not exceed 200-300Psi.
SECTION - 8
MAINTENANCE AND TROUBLE SHOOTING GUIDE
MAINTENANCE
______________________________________________________________
Maintenance of the Crusher and its drive components consists of regular inspections, lubrication and replacement of worn out parts. Minimum down time will result if properly scheduled inspection is carried out.
IMPORTANT
Disconnect the electrical power to the motor first before doing any maintenance to crusher.
1. INSPECTION
A. STRUCTURAL INSPECTION
To maintain the structural integrity of the crusher regular inspections are a must. Check all bolts and nuts with a Wrench minimum of once a day during the first week of operations. After the first week of operations, the inspection interval can be increased as experience indicates.
B. INTERNAL INSPECTION
The interior of the crusher should be inspected a minimum of once a day during the first week of operation. The wear on the rolls` teeth should be observed. Uneven wear in any area of the roll is indication of non-uniform feed distribution across the roll width. A change in the feed pattern to evenly distribute the feed material across the roll width will increase the life of the rolls.
C WEAR PLATES
The hopper slope plates are lined with CD plates. These wear plates are plug-welded to the slope plates. Use E 8018G, 4 Dia. Electrodes for welding.
2. LUBRICATION SYSTEM
A) GEAR BOX
The gearbox on the crusher is a special enclosed type gearbox. The gears operate in an oil bath. The drive gears to the idler gears carry The lubricant. The lubricant is distributed to the gear plate bearings and idler gear bearings by gravity flow. An oil level indicator is provided on the housing of the gearbox. Check the oil level of the gearbox.
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Refer to the lubrication section of the manual for the type and quantity of oil required for the gearbox.
B) MAIN BEARINGS
Each rolls of the crusher are supported on one number of Main bearing on either side. These bearings are double row spherical roller bearings. The bearings are mounted in machined bearing blocks and sealed with labyrinth type seals to keep out of dust and moderate amount of moisture. These bearings should be lubricated every 1000 hrs. Of operation the labyrinth seals should be lubricated once every 8 hrs. Of operation. Since adjustable bearing block slides over the frames, a lubrication point is also provided for lubricating the base. Grease should be applied a minimum of once per week to assure proper lubrication of the base. See the lubrication section of this manual for the recommended lubrication.
C) ADJUSTMENT & ALIGNMENT ASSEMBLY.
The adjustment and alignment system is equipped with a Nitroil cylinder for roll adjustment and tramp iron relief. The cylinder is connected to a hand operated pump. The reservoir of the hand pump should be filled with oil up to required level.
The alignment shaft housings are equipped with grease fittings. Grease should be applied a minimum of once a week to assure proper operation. See the lubrication section of the manual for recommended lubricants.
3. REPLACEMENT AND REBUILDING OF THE WORN OUT PARTS ROLLS
A) To rebuild the rolls while in the crusher, use the following procedure:
Remove the end section of the hopper.
Attach the welding machine ground wire directly to the roll to eliminate the possibilities of electric arc damage to the bearing.
Apply the hard facing material on the worn out teeth. Refer roll repair section on the manual for the hard facing procedure.
Roll removal rail installation - CS.1.3-3156
The crusher is supplied with Chisel tooth type rolls. The rolls are cast / fabricated type with special wear resistant hard faced teeth for extra tough service.
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As the hard facing material wears away, new hard facing material should be deposited on the teeth. The teeth can be rebuilt with in the crusher, however it may be more convenient to remove the rolls from the crusher.
To replace the rolls from the crusher, use the following procedure:
1. Remove the end section of the hopper and dribble chute.
2. Remove six coupling bolts from each hub of the roll / shaft coupling flange. Rotate the roll so that the bolt-removed holes are towards the base frame.
3. Refer Drg. no. CS.1.3-3156, insert the roll removal rail, item 1 in the mounting bar, item 3, passes the pin, item 2, through the slots.
4. By rail turning the adjustment screw item 4, raise the rail until the raise touching the rolls.
5. Install wooden blocks under the shafts to prevent the shafts from pivoting and damaging the seats.
6. Remove the remaining shaft / coupling bolts
7. Pry the stub shafts away from roll.
8. The roll along with the removal rail and hoist out of the crusher. The roll weighs approximately 300 kg.
9. Remove the center section of the hopper and follow above procedure to remove the remaining roll.
10. To install rolls use reverse procedure.
______________________________________________________________
WEAR PLATES
Refer wear plates drg. Enclosed with the manual. The hopper slope plates are lined with TISCRAL wear plates. These wear plates are plug welded to the slope plates. Use E 7018 3.15Dia electrode for welding.
4. REPLACEMENT OF MAIN BEARING GEAR BOX SIDE OF CRUSHER:
Refer Gear Box Drg. enclosed with the manual.
1. Drain oil from gearbox.
2. Remove gearbox cover.
3. Scribe a line across end of both gearbox shafts. Center punch, the inside edge of lines on both the shafts. This is to keep the gearbox in time when you reassemble.
4. If the adjustable or stationary main bearing needs to be replaced, remove the complete gear assembly. Now remove the gearbox back plate by removing the bolts from the stationary and adjustable gearbox support tubes on the backside of the gearbox back plate. Next remove the stationary or adjustable gearbox support tube from the main bearing that needs to be replaced.
5. Remove the slide bar from the top of the adjustable and stationary main bearing. Reference drawing in the adjustment and alignment section of the manual.
6. If the bearing to be replaced is on the adjustable roll, remove the clevis bracket of the adjustment system
7. If the bearing to be replaced is on the stationary roll, remove the screws that connect the block to the base frame.
8. Block up rolls to remove weight from the bearings when replacing bearings, use roll removal rails to support rolls.
9. Remove the bearing block / shaft assembly from the crusher.
10. Remove the bearing seal housing and spacer rings.
11. Slide the shaft / bearing assembly, out of the bearing block.
12. Remove the bearing from the shaft. A torch may be used to cut the bearing off the shaft, but be careful not to damage the shaft.
______________________________________________________________
13. Clean all parts with solvent and apply a thin layer of light oil to the bearing block bore and the shaft.
14. Install a new bearing on the adapter sleeve.
Main Bearing: Spherical Roller Bearing SKF 24130 CCC3/W33
With H322 Adapter sleeve or equivalent FAG.
15. Install the bearing / shaft assembly into the bearing block.
16. Apply a thin layer of super gasket GK to the seal housing and the tube support.
17. Install the seal housing, tube support and spacer rings on the bearing block.
18. Install the bearing block assembly on the crusher.
19. Use reverse procedure, step 1 through 7 to reinstall block assembly on the crusher. Assume that notches in flanges are aligned before installing coupling bolts.
20. When assembling the gearbox, make sure the scribe lines and center punch marks are lined up as in disassembly procedure, step 3.
5. REPLACEMENT OF MAIN BEARING DRIVE SIDE OF CRUSHER:
1. Remove the flywheel from the shaft if the stationary main bearing needs to be replaced.
2. Continue removal of main bearing by following step 5 through 15 in preceding sheet gearbox side of crusher.
______________________________________________________________
TOOLS
For maintenance of the machine, following tools / gauges may be kept.
1. Complete spanner set for M6 to M48.
2. Hook spanner for bearing lock nuts size KM 22.
3. Hex bit socket with one end male hex S=14 mm other end female square drive 1/2”.
4. Hex bit socket with one end male S=10 mm other end female square drive 3/8 “.
5. Converter with one end 1/2” female square drive and other end with 3/8” male square drive.
6. Torque wrench with 1/2” male square drive, torque range 250 Nm
7. Torque wrench with 1/2” male square drive, torque range 125 Nm
GAUGES
Chisel tooth gauge – CS.1.4-15438
NOTE
I. Tools Sl. no. 3 & 6 required to be used for tightening taper lock bushing screws.
II. Tools Sl. no. 4, 5, 6 & 7 required to be used for tightening Ring feeder-locking assembly of flywheel.
III. Tools Sl. no. 4, 5, & 7 with gauge are supplied along with the machine as special tools. All other tools to be arranged by customer.
______________________________________________________________
BEARING MAINTENANCE
Crusher bearings are antifriction, spherical self-aligning roller bearings with a cylindrical bore. To prevent axial movement, the bearing on the drive side of the crusher is non-expansion in the bearing housing by distance rings.
The expansion (free) bearing housing on the side opposite the drive is to allow equal axial movement of the roller bearing in both directions. This compensates for the expansion and contraction of the roll.
Although termed non expansion and expansion, the bearing housing are basically identical. The non-expansion bearing housing can be converted to the expansion bearing housing by removal of the distance rings. Normal bearing maintenance consists of keeping the area in and around the bearing housing clean. The bearings must be lubricated in accordance with instructions.
CHANGING BEARINGS
Thoroughly clean all rust preventive from the new roller bearing with a solvent, when completely clean, wipe dry.
Before fitting a new bearing, clean the shaft and the point of assembly thoroughly. It is not necessary to wash out new bearings; nothing but pure Vaseline has been used as a protective against rust. If old bearings are fitted, these must be washed out. Use turpentine, petrol or benzene. Kerosene or paraffin must not be used as they contain acids and promote the formation of rust. After cleaning, regrease the bearings at once. Check the shaft for roundness and correct tolerances.
Lubricate each bearing before start-up. Even a short trail run without lubricating the bearing damages it.
Before making a trial run, check the bearings by turning lightly by hand. After starts up & before coming up to full operating speed, check that the bearings are running properly. The noise of rough, uneven running indicates that some fault is present (dirty bearings, foreign bodies, faulty or insufficient lubrication, jamming).
Do not attempt to modify the bearings:
Grooves, holes, and beveling will release tension and cause the races to become egg-shaped.
______________________________________________________________
Warning
When carrying out welding on Crusher, always ensure that the welding current does not pass through the bearings. If this happens the roller may become cold-welded to the races.
BEARING AND SEALS
The crusher is fitted with self-aligning roller bearings. The bearing housing is open at both sides and fitted with covers and labyrinth rings as shown in Bearing Assembly Drawing. Grease is pumped in to the bearing housing and space between labyrinth rings by lubrication pump at regular interval of time. Labyrinth rings should be lubricated every 8 hours of operation to prevent dust entry to bearings.
BEARING INSTALLATION
Bearing should be installed in a clean environment free of dust, moisture or metal particles.
1. Refer drawing No.CS.1.1-2698 & CS.1.1-2699.
2. Clean the bearing block, labyrinth rings, spacer rings and shaft using filtered water free Kerosene or similar solvent and apply a light oil lubricant to the bearing block bore.
3. Install spacer ring (item no.6) for non-expansion side.
4. Heat the bearing to 200 degree F to 225 degree F to expand the inner race so that the bearing can be slipped freely over the shaft.
5. Install the bearing on the shaft and allow it to cool to room temperature.
6. Install lock washer and lock nut (Item no.3)
7. Install bearing block (Item No.1) on the bearing. Ensure that the hole for lubrication is in line with Center of the bearing.
8. Install spacer ring i.e. locating ring (Item no.11) for non-expansion bearing.
9. Install labyrinth ring and labyrinth cover (Item 4 & 5) for all the bearing housing.
______________________________________________________________
10. Install labyrinth cover in case of tender side.
11. Install labyrinth ring and labyrinth cover in case of drive side.
12. Ensure a minimum gap of 5 mm between labyrinth grooves.
13. Ensure that loctite is applied for Grub Screw and on inner surface of labyrinth as indicated in drawing.
BEARING REMOVAL
Reverse the procedure described for bearing installation.
MOUNTING OF SPHERICAL ROLLER BEARINGS WITH TAPERED BORE
===============================================================
BEARING NO. 24130 CC C3 W33
===============================================================
Radial internal clearance of Min 0.170 mm
Bearing as received from Max 0.220mm
Manufacturer (C3)
----------------------------------------------------------------------------------------------------------------
Reduction in Radial Min. 0.076 mm
Internal clearance: Max. 0.100 mm
---------------------------------------------------------------------------------------------------------------- Mininmun Permissible residuals Min. 0.090mm
---Clearance after mounting
Bearing with initial clearance C3.
--------------------------------------------------------------------------------------------------------------
______________________________________________________________
ROUTINE CHECKS ON 6024SSHD ROLL CRUSHER
CLIEN: M/s. Kartikay Coal Washeries Pvt. Ltd. YEAR OF COMMISSIONING: 2004
SITE: Wani Washery, Maharashtra MATERIAL: COAL
MACHINE NO. 006-573 FEED SIZE: (-) 300MM
END PRODUCT: 95%( -) 50 MM
SERVICE ENGINEER’S CAPACITY: 400 TPH (Rated)
NAME: ____________________________
& DATE OF INSPECTION:
CHECK/ INSPECTION
FREQUENCY
OBSERVATION
RECTIFICATION DONE
A. CRUSHER BODY
1. Gap between Hopper & Roller
Fortnightly
2. Condition of Hopper Plates
Weekly
3. Spillage from Dribble Chute
Daily
4. Tightness of Hopper Bolts
Weekly
5.Tightness of Foundation Bolts
Quarterly
6. Clearance between Hopper wall & Feed Chute
Weekly
B. ROLL BEARINGS & HOUSINGS
1. Tightness of bearing outer race
Yearly
2. Grease reaching all the bearings and Labyrinth Rings.
Daily
3. Condition of the Labyrinth Cover and Ring
Fortnightly
______________________________________________________________
4. Tightness of the bearing block holding bolts, and labyrinth grub screws.
Weekly.
5.Temperature of the bearings.
Daily
6. V-Belt tension
Daily
7. Labyrinth clearances and grub screw fixing the labyrinth on the shaft for its tightness.
Weekly
8. Tightness of Ring Feeder
Quarterly
9. Wear on Adj. Bearing block base
Half yearly
C: ROLLS
1. Condition of the tooth with the help of template.
Weekly
2. Check if any uneven wear out on teeth
Weekly
3. Rebuilding of tooth
As per requirement
4. Tightness of Stub Shaft bolts
Monthly
5. Roll body to be checked for any crack of other damage
Monthly
6. Gap between Roll and Dribble chute plate.
Weekly
D: ENCLOSED GEAR BOX
1. Check the oil level
Daily
2. Oil temperature
Daily
3. Position of the wiper seal
Daily
4. Accumulation of particles between shaft and wiper seal holder
Daily
5. Condition of the gears
Monthly
6. Condition of the bearings
Quarterly
7. Condition of adjustable seal side guides
Quarterly
________________________________________________________________________________
E: NITROIL SYSTEM
1. Leakage in the Nitroil hose joints
Daily.
2. Leakage from Cylinder.
Daily.
3. Freeness of the adjustable roll assembly
Weekly
4. Gap setting
Daily
5. Check to ensure that all the lubrication hydraulic and Nitrogen lines are not leaking.
Daily
6. N2 pressure setting
Daily
7. Operate the Cylinder through full stroke 1-2 times to ensure the proper functioning of hydro-pneumatic system and to lubricate cylinder seals.
Weekly
8. Oil level in the hand pump
Weekly
9. Check the N2 pressure of the charged bottle through the pressure gauge provided with regulator. Replace the bottle with new charged bottle if the bottle pressure
Has fallen below (P+2) bar. P=Regulator setting
Daily
______________________________________________________________
TROUBLE SHOOTING GUIDE
FOR: 6024SSHD CRUSHER
GENERAL SECTION
SYMPTOM: UNIT PLUGS AND / OR STALLS
CAUSES: REMEDY:
1
2
3
4
5
6
7
Motor badly or Motor heater blown.
Belts loose or burned off.
Rolls jammed with a non-crushable.
Exceeding rated capacity or feed size too large.
Plug in discharge area that backs up in to crusher.
Gear box locked up
Rolls worn out. Teeth too worn to grab material.
1
2
3
4
5
6
7
Replace Motor or Motor heater.
Tighten or replace belts.
Remove non - crushable and check crusher for possible damage.
Reduce feed rate and / or feed size to acceptable level.
Remove blockage.
Remove gearbox cover. Replace damaged gearbox components.
Rebuild or replace rolls.
______________________________________________________________
GENERAL SECTION (CONT’ D)
SYMPTOM: CRUSHER WON’T MAKE PRODUCT
CAUSES: REMEDY:
1
2
3
4
Rolls gap not adjusted properly and / or uneven roll gap.
Roll teeth worn out and not crushing properly.
Rolls out of time; broken taper lock bushing and sheared key in gearbox, gears have excessive backlash or gears not timed properly.
Worn out housing slope plates, allowing oversize to pass behind roll.
1
2
3
4
Re - adjust Nitroil adjustment assemblies or cylinders.
Replace or rebuild rolls.
(Note: - If welding while rolls are in unit, be sure to ground directly to the rolls to prevent bearing damage.)
Replace broken taper lock bushing, sheared key and replace worn gears Re-time rolls.
Replace slope plates.
ROLL SECTION
SYMPTOM: ROLLS WON’T GRAB FEED MATERIAL
CAUSES: REMEDY:
1
2
3
Teeth worn out.
Material feed size entering unit is too large.
The rolls may be set to allow proper material reduction.
1
2
3
Rebuild or replace rolls.
Check feeding equipment for any damage. Reduce feed rate and /or feed size of crusher to acceptable level.
Re-adjust rolls gap to achieve desired product.
______________________________________________________________
ADJUSTMENT & ALIGNMENT SECTION
SYMPTOM: MANUFACTURING ADJUSTS WILL NOT MOVE
CAUSES: REMEDY:
1
2
3
4
Adjustment assembly rusted due to lack of lubrication.
Rusted alignment shaft, due to lack of lubrication.
Bent slide bar preventing bearing block from moving.
Slot closure attached to bearing block jammed.
1
2
3
4
Dis-assemble, clean, re - assembles, lubricate and re - adjust.
Remove shaft. Slide brackets back, clean and re - grease.
Replace or straighten slide bar.
Re - adjust or replace slot closure.
NITROIL SYSTEM
A. SYMPTOM: ROLLS CLOSE WHILE CRUSHING
CAUSES: REMEDY:
1
2
3
Hydraulic control valves on manifold open or leaking.
Leaks in hose or fittings.
Leaking Nitroil Cylinder rod bushings.
1
2
3
Close or replace valve(s).
Replace hose and fittings or tighten as needed.
Rebuild Nitroil cylinder.
B. SYMPTOM: ROLLS OPEN WHILE CRUSHING
CAUSES: REMEDY:
1
2
3
4
Leak in Nitrogen lines or fittings.
Nitrogen leaking to oil side of cylinder past piston seals.
Leak in bleed valve.
Leak at Nitrogen tank regulator.
1
2
3
4
Re - seal or replace lines / fittings as needed. Check lines with soapy water.
Rebuild Nitroil cylinder.
Tighten or replace bleed valve and / or connections.
Tighten or replace Nitrogen regulator.
________________________________________________________________________________
C. SYMPTOM: ROLLS KICK OR MOVE CONTINUOUSLY
REMEDY: Use more Nitrogen Pressure to around 220 - 300 PSI.
NOTE: Only use enough pressure to hold rolls fixed while normally crushing yet allowing uncrushable to pass. System maximum working pressure is 1000 PSI. Which may not be required to use. At this higher pressure Adjustable side can become unnecessary rigid.
GEAR BOX SECTION
SYMPTOM: FAILURE, EXCESSIVE HEAT AND NOISE
CAUSES: REMEDY:
1
2
3
4
5
6
7
Lack of lubrication.
Bent roll stub shaft.
Gear plate or idler bearing failure in gearbox.
Excessive backlash in gears.
Contamination from main bearing failure.
Broken taper lock bushing and sheared key has rolls out of time, causing rolls to hit.
Mis-alignment of adjustable roll.
1
2
3
4
5
6
7
Rebuild gearbox, replace seals and keep proper oil level.
Replace roll stub shaft.
Rebuild gearbox.
Replace gears as required.
Replace main bearing and rebuild gearbox.
Replace taper lock bushing and key and check rolls for damage. Re - time rolls.
Re - adjust roll gap for consistent roll gap across full length.
________________________________________________________________________________
BEARING SECTION
SYMPTOM: BEARING FAILURE
CAUSES: REMEDY:
1
2
3
4
5
6
7
Lack of bearing lubrication.
Bent stub shaft or roll hub.
Roll out of balance.
Roll out balance.
Material pack behind and around bearing causing contamination.
Bearing O. D. loose in bearing block, causing bouncing and false brine ling.
Damaged bearing from welder grounding through bearing.
1
2
3
4
5
6
7
Lubricate properly and periodically.
Replace Shaft or Hub.
Make sure roll rebuild and hard facing is applied evenly.
Make sure roll rebuild and hard facing is applied evenly.
Flush out this area to remove material.
Replace bearing block.
Replace bearing and make sure that welder grounds to his work.
LARSEN & TOUBRO LIMITED
CRUSHER EQUIPMENT START - UP AND INSPECTION REPORT
FOR SERVICE ENGINEER
DATE: _____________________ UNIT S/N: ______________________
COMPANY: ____________________ PLANT: ______________________
LOCATION: ______________________________________________________
OTHER CONTACTS: ______________________________ PHONE: __________
REASON FOR CALL: ________________________________________________
DOES OPERATION HAVE MANUAL? YES _______ NO _______
REVIEWED W / CUSTOMER? YES _______ NO _______
Xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
APPLICATION
MATERIAL: ______________ SEAM (S) __________________ H. G. ________
FEED SIZE: ______________ % ROCK ____________ PRODUCT SIZE _____
OPEN CIRCUIT: ___________ CLOSED CIRCUIT: ______________ TPH: ___
OF NEW FEED: _______________________ OR OF TOTAL FEED: __________
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
MOTOR & DRIVE INFORMATION
STATIONARY MOTOR ADJUSTABLE MOTOR
H.P. _____ RPM ____ FRAME SIZE ______
NAME PLATE AMPS ______VOLTAGE____
MOTOR MANUFACTURER _____________
DR. SHEAVE ______ DRN. SHEAVE _____
BELT SIZE __________________________
H.P. _____ RPM ____ FRAME SIZE ______
NAME PLATE AMPS ______VOLTAGE____
MOTOR MANUFACTURER _____________
DR. SHEAVE ______ DRN. SHEAVE _____
BELT SIZE __________________________
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
INSTALLATION
HOW IS UNIT FED - TYPE & SIZE: _________________________________
DISCHARGE - TYPE & SIZE: _________________________________
TRAMP PROTECTION - MAGNET: ____________ METAL DETECTOR: ___
OTHERS: _________________________________
FEED - PARALLEL: ______________ OR PERPENDICULAR: ____________
TO SHAFT OR ROLLS.
DISCHARGE - PARALLEL: __________ OR PERPENDICULAR: ____________
TO SHAFT OR ROLLS
UNIT INSPECTION
CHECK LUBRICATION FOR CONTAMINATION AND THAT UNIT HAS BEEN LUBRICATED
BEARINGS __________________ LABYRINTH RINGS ____________________
HYDRAULIC SYSTEM ____________ DRIVE CHAIN ______________________
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
CHECK LIST BEFORE START - UP
CHECK AROUND UNIT AND ROTATING PARTS FOR FOREIGN OBJECTS THAT MAY INTERFERE OR DAMAGE UNIT OR CAUSE INJURY TO PERSONNEL DURING OPERATION __________________
CHECK INSIDE OF UNIT FOR FOREIGN OBJECTS ________________________
CHECK FEEDER AND DISCHARGE AREAS FOR FOREIGN OBJECTS OR OBSTRUCTION _______________ ROTATE UNIT BY HAND ________________
CHECK MOTORS FOR PROPER ROTATION _____________________________
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
OPERATION DATA
NO LOAD RUNNING AMPS _____ CRUSHING AMPS _____ AT ____ TPH _____
ROLL SETTING UPPER ________ TYPE ROLLS _________ LOWER _________
TYPE ROLLS ______________ NITROGEN PRESSURE ________________ PSI.
FEED SPREAD ON ROLLS ___________________________________________
xxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxxx
CALL STATUS : COMPLETE / INCOMPLETE / UNDER OBSERVATION / WKG SOLN PROVIDED.
COMMENTS : (L & T SERVICE ENGINEER)______________________________________________________________________________________________________________________________________
CUSTOMER’S FEED BACK: PLEASE GIVE YOUR VALUABLE FEED BACK BY RATING THIS CALL
VERY SATISFIED SATISFIED AVERAGE
CUSTOMER’S REMARK:
__________________________________________________________________
__________________________________________________________________
__________________ ____________________________
SIGN. OF CUSTOMER SIGN. OF L & T REPRESENTATIVE
SITE DATA SHEET OF COAL CRUSHING PLANT
01. L & T SWO NO. :
02. NAME PLATE DETAILS:
MACHINE NO. & YEAR OF
MANUFACTURER
03. CLIENT:
04. SITE OF INSTALLATION:
05. MACHINE TYPE / MODEL:
06. RATED CAPACITY IN OPEN /:
CLOSED CIRCUIT
7A. RECOMMENDED FEED SIZE:
OF MATERIAL
7B. ACTUAL FEED MATL. ANALYSIS:
WITH % OF FRACTIONS
7C. ANY PREVENTIVE MEASURES:
ADOPTED TO CONTROL FEED SIZE
08. IF CLOSED CIRCUIT, GIVE FLOW:
DIAGRAM AND RECIRCULATION
LOAD AND FRESH FEED RATE (TPH)
09. RATING OF MOTOR KW / RPM
a) RECOMMENDED KW / RPM:
b) INSTALLED KW / RPM:
10. PULL OUT TORQUE OF MOTOR
a) RECOMMENDED PULL OUT:
TORQUE
b) ACTUAL PULL OUT TORQUE:
12. ACTUAL RPM ROLLS NO LOAD ON LOAD
a) UPPER:
b) LOWER:
13. WHETHER SPEED SENSOR:
INSTALLED & WORKING
14A. ROLL BEARING TEMPERATURE UPPER LOWER
T.S D.S T.S D.S
14B. WHETHER B.T.D INSTALLED:
15. MOTOR NAME PLATE DETAILS
a) SETTING DETAILS OF MOTOR:
PROTECTION RELAY
b) L&T’s RECOMMENDED MOTOR:
DATA SHEET
c) CUSTOMERS MOTOR PO. NO.:
d) MOTOR Manufacturer’s:
DATA SHEET & CHAR. CURVES
16. a) MOTOR LOAD AMPS / KW :
b) AVERAGE AMPS:
c) RATED AMPS AT FULL LOAD:
d) KICK LOAD; DURATION &:
FREQUENCY / MIN
17. TYPE & SIZE OF FEEDING EQPT. :
18. FEED CONTROL BY:
19. PROPERTIES OF COAL
a) HGI:
b) % OF MOISTURE:
c) % OF CLAY:
d) % OF ASH:
19. DATE OF PERFORMANCE TRIALS:
21. PERFORMANCE DETAIL
a) TOTAL HRS OF TRIALS:
STOPPAGE DUE TO:
b) MECHANICAL REASONS:
c) ELECTRICAL REASONS:
d) CHOKING:
e) WANT OF FEED:
f) ANY OTHER CAUSE:
22. EFFECTIVE RUNNING HOURS:
ON LOAD [a-(b+c+d+e+f)]
23. TOTAL TONNAGE OF MATL. FED:
DURING TRIAL
24. WEIGHT OF SAMPLES COLLECTED
FROM 1 METRE LENGTH OF
DISCHARGE CONVEYOR (kg)
a) Sample 1:
b) Sample 2:
c) Sample 3:
d) Sample 4:
e) Sample 5:
25. SIEVE ANALYSIS OF SAMPLES WEIGHT IN PERCENTAGE
SQUARE / ROUND MESH I II III IV V
+75:
+50:
+40:
+25:
+20 to +25:
+15 to +20:
+10 to +15:
-10:
26. MAGNETIC SEPARATOR / METAL:
DETECTOR PROVIDED
27. INCIDENTS OF ENTRY:
OF UNCRUSHABLES
28. IF ROLLS, BRGS. :
CHANGED BY CLIENT AND WHEN
SECTION - 9
ADJUSTMENT & ALIGNMENT ASSEMBLY
ADJUSTMENT ALIGNMENT ASSEMBLY
______________________________________________________________
Reference Drawings: CS.1.1-2250, CS.1.1-02777
Principle of operation
The crusher is equipped with an oil / nitrogen adjustment assembly that provides movement for adjustable roll. Oil is directed to the cylinders through a manually operated hydraulic pump and three valve manifold. The oil is directed to the rod end of the cylinders. The volume of oil in the cylinder positions the roll, therefore determines product size. The nitrogen gas in the cap end of the cylinder functions as a spring to allow uncrushable objects to pass between the rolls and minimize damage to the crusher. If the uncrushable object enters the crusher, the nitrogen gas compress and allows the adjustable roll to move away from the stationary roll. After the object passes through the crusher, the adjustable roll returns to its original position as determined by the volume of oil in the cylinder.
The alignment system provides a rigid connection between the adjustable bearing blocks and assures a uniform distance between the rolls as the adjustable rolls are positioned.
OPERATION INSTRUCTIONS
Reference Drg. CS.1.2-2545
Sl. No. Description Valves Release Hand Nitrogen
6A 6B valve on pump Pump circuit
1. Rolls move away Open open Close Running Not
From center Pressurized
2. Rolls move Open Close Open Stopped Pressurized
Towards center
Note: -
During operation of the crusher valve 6A & 6B must be closed and nitrogen circuit must be pressurized. Be sure that N2 bottle valve is open all the way during crushing.
SECTION - 10
GEAR BOX
GEAR BOX
______________________________________________________________
INSTRUCTIONS FOR THR INSTALLATION OF THE ENCLOSED GEARBOX ASSEMBLY
Before the new gearbox assembly is installed, the stationary & adjustable roll hub flanges must be clean, especially the roll coupling alignment boltholes and the flange faces.
The new gearbox assembly is to be lifted and mounted in the crusher with the aid of two lifting eyes. (Drg. No. CS. 4-1981)
Set the stationary and the adjustable roll center distance as specified in section-1
Maneuver the enclosed gearbox assembly into the crusher, making sure the notch marks on the roll flanges line up with the ones on the enclosed gearbox stub shaft flanges. This is very important for the timing of the rolls.
Install and tighten the three roll coupling alignment bolts in the adjustable and stationary rolls.
Bolt stationary bearing block in place with 4 M24 Bolts.
Remove the enclosed gearbox support bracket (Drg. No. CS. 4-1981).
The rolls may now be unblocked or the roll removal rail removed. Install and tighten the remaining roll coupling alignment bolts.
Reference drawing in the adjustment and alignment section of this manual. Install the slide bar on the top of the stationary and adjustable bearing block. Two M20 bolts on the top of the thrust block and two M20 bolts for the stationary main bearing hold this in place.
Install the adapter plate (on hydraulics adjustment crushers) to the adjustable main bearings.
Install the alignment bar, this is held in place by 2 pins, one pin in the crank arm and other in the alignment clevis.
Install the Dribble Chute Assembly.
Check that all grease lines and all fasteners are installed and tighten properly. See lubrication section of this Manual for connecting lubricating points.
______________________________________________________________
Now your enclosed Gearbox is ready for operation. Before startup check the following two things:
Check enclosed Gearbox oil level. See lubrication section of this manual.
Check the timing of the rolls by tuning them by hand box section of this section.
INSTRUCTIONS FOR THE REMOVAL OF THE ENCLOSED GEARBOX ASSEMBLY (CS. 1.1-02514)
Remove the Dribble Chute on the gearbox side of the crusher.
Set the rolls center to center as specified for the gearbox assembly that is being replaced.
Disconnect all grease lines to the bearing blocks on the gearbox side of the crusher.
Remove the top 3 roll coupling alignment bolts from the shaft and roll flanges on the stationary and adjustable roll.
Rotate the rolls so that the last 3 roll coupling alignment bolts are now on the top.
Remove the slide bar from the top of the stationary and adjustable bearing block. Two M20 bolts on the top of the thrust block and 2 M20 bolts on the top of the stationary bearing block hold this in place.
Install the gearbox support bracket. This is bolted to the top of the stationary bearing block with 2 M20 bolts and to the adjustable bearing block with 2 M12 bolts. (CS. 4-1981)
Block up the rolls to remove the weight so that last roll coupling alignment bolts may be removed (when replacing the gearbox assembly, the rails to be used to support the rolls weight).
Reference drawing in the Adjustment and the Alignment section of this manual. Remove the alignment bar, which is connected by 2 locking plates, one in the crank arm and other in the alignment clevis.
Support the gearbox by 2 lifting eyes.
Disconnect the adapter plate from the adjustable main bearing.
______________________________________________________________
Remove the four M24 bolts in the stationary main bearing
Now the enclosed gearbox assembly is ready to be removed. Use extreme caution when removing the gearbox assembly. Keep hands and feet away from the assembly.
INSTRUCTIONS FOR DISASSEMBLY OF ENCLOSED GEAR BOX REFERENCE DRAWING (CS.1.1-02514)
1. Be sure all power to main drive of crusher is shut off.
2. Drain oil from gearbox by removing drain plug located on lower side of cover (item-1).
3. Remove gearbox cover (item-1), which is held to the back plate by fasteners.
4. Remove the four (4) jam nuts (item-23) fro the idler pins (item-20).
5. Remove the front side plate (item-21) from the idler pins (item-20)
6. Remove the four (4) hex head screws (item-26) that run through the gear plates (items 2) and spacer (item-25).
7. Pull off either of the front gear plates (item-2) by using wedges between the gear plate and drive gear (item-15) or by using a two-leg puller.
NOTE: - Use caution when removing the gear plates. These plates may be used again by reversing them to have the new set of teeth in mesh. The bearings (item-22) and bushings may be replaced if they’re not damaged. If the plates do not pull, you may cut the cage and rollers or balls of the shaft. Do not cut gear plate.
8. Remove the idler gear (item-17) and idler pin (item-20) as a unit.
9. Remove the drive gear (item-15) by tightening the screws in the taper lock bushing (item-16)
NOTE: - If the gears have turned on the bushing, try turning gear back for enough to free the screws by driving gear teeth with a hard wood block and hammer. If this fails, cut through the gear and remove.
10. Remove the keys from the shaft and pull off back gear plates (item-2). Use
same procedure as outlined in step-7.
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INSTRUCTIONS FOR REASSEMBLY OF ENCLOSED GEAR BOX REFERENCE DRAWING (CS.1.1-02514)
Push gear plates on the shaft.
NOTE:
A: Gear plates should have either new or good bearings and bushing.
B: One plate must have two teeth and opposite plate three teeth in mesh.
C: A pusher may be helpful in pushing plates on the shaft.
Push Bearing and back gear plate onto the stationary shaft so that the plate is 1.6mm past the keyway.
Push the gear plate and bearing onto the adjustable shaft in the same manner paralleling the two gear plates with a straight edge.
Place fiber washers on shafts, place keys in shaft and install drive gear and taper lock bush.
TO INSTALL BUSHING
A: Slip bushing into gear matching bushing half holes to threaded half holes in the gear.
B: Slip bushing and gear onto shaft lining up with keyway. Insert screws in half threaded holes of the gear.
C: The bushing should be about 3mm to 1.5mm from the back of the key. Start tightening Hex Socket Head Cap Screw, Drive bushing, Gears, and retighten the setscrews. Continue above until bushing and gear are flush with end of the key.
D: Hammer against large end of bushing using hammer and block or sleeve. Tighten screws again and repeat hammering until bushing large end is flush with gear face.
4. Torque set screws to 250 N-m.
5. Assembly spacer 2 idler bearings and idler gear on idler shaft. Place fiber washers on shaft and slip shaft assembly into bushing on the gear plate. Be sure to place fiber washers between all gears and gear plates (8 washers in total)
6. When putting front gear plate on the shaft be sure to insert 4 spacers’ b/w front and back gear plates.
7. Before placing side plate on the idler shaft, check timing of the rolls. If the roll teeth are out of proper mesh separate idler gears and rotate them until proper mesh is attained.
8. Install the side plates and place washer & nuts on the idler shaft. Install 4 Hex Head Cap Screws making sure spacers are in place.
9. Check all nuts and screws.
10. Before replacing the cover, place a new gasket around the cover.
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11. Fill the gearbox using OIL Servo mesh Sp320 of IOC or Equivalent. See lubrication section of this manual. Approx. 15 Liters of oil is required. Check the oil level with oil level plug on the side of the gearbox cover.
INSTRUCTION FOR RE-TIMING CRUSHER ROLLS (L&T-GUNDLACH ENCLOSED GEAR BOX)
Before re-timing a pair of GUNDLACH Crusher rolls, make certain all electrical and hydraulic lines to crushers are shut off.
1. Drain oil from gearbox.
1. Do not damage gasket when removing gearbox cover.
2. Unlock four (4) lock washers and unscrew four (4) hex nuts, which retain side plates at the front and rear of the assembly. See illustrations A of Drg. No. CS. 4-1982.
3. Remove side plate from assembly.
4. Move adjustable roll until there approximately 25 mm of clearance between adjustable and opposing roll.
5. Spread apart idler gears, at the upper end of the assembly. Then position both rolls to locate the teeth of one roll or the void between teeth of the opposite roll. See illustration B of Drg. CS.4-1982.
6. With the rolls positioned as in step 6, bring the idler gear together. Check the position of the gear plates, making certain they rest as shown per illustration A.
7. Load two (2) side plates and secure with four (4) lock washers and hex nuts.
8. Bolt cover into position.
10. Add 30 liters of servo mesh SP320 of IOC or equivalent.
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______________________________________________________________
SECTION - 11
LUBRICATION SYSTEM
LUBRICATOIN SYSTEM
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Reference Drawing No.CS.1.1-2779
The crusher is equipped with a point-to-point lubrication system for greasing main bearings and its labyrinths. The requirement of grease for various lubrication points is given below:
1. MAIN BEARINGS
There are 4 main bearings on the crusher. The bearings are double row spherical roller bearings mounted in machined cast steel bearing blocks and sealed with labyrinth type seals. All bearings and labyrinth rings should be lubricated as per lubrication schedule. Labyrinth rings should be lubricated every 8 hours of operation to prevent dust entry to bearings.
2. ADJUSTMENT & ALIGNMENT ASSEMBLY
All the linkage where rotation is there between two links is provided with grease nipples. These points to be lubricated with 1 kg. Of grease every 1000 hrs. Of operation to permit free movement. Recommended grease for the system is SERVOGEM 3 of IOC.
GEAR BOX
Quantity of oil for gear box 30 liter
Type of oil servo mesh SP 320 or equivalent
OIL LEVEL
The oil level should be visible through the oil level indicator provided on the casing
HYDRAULIC HAND PUMP
Quantity of oil - 13 liters
Type of oil - servo system 68 of I.O.C.
Above lubrication schedule is indicated in tabular form.
NOTE:
1. In all cases of bearing and seal lubrication, the amount of grease is estimated. Actual amount required will depend upon the application of crusher and the operation environment.
2. Grade of lubricant indicated is that of I.O.C. make. Equivalent grade of grease of reputed make may be used.
3. Over filling/over greasing will cause unwanted temperature rise, foaming and leakage.
4. Change of bearing grease every 1000 hours of operation.
5. Check for abnormal sound and temperature of main bearing housings at the end of every shift. Any increase in temperature/abnormal sound may be due to inadequate/excess lubrication or due to contamination of lubricant.
6. If machine remains idle for long period old grease/lubricant to be pumped out
And refilled with fresh grease.
LUBRICATION SCHEDULE
KARTIKAY COAL WASHERIES PVT. LIMITED, WANI
(USE IOC BRAND NAME ONLY)
EQUIPMENT NO.: 006 - 573 MODEL NO.: 6024SSHD ROLL CRUSHER
MAKE:L & T GUNDLACH WEIGHT OF EQUIPT. : 10.8T
SL
NO
LUBRICATION POINT
(INCLUDING DRIVE)
SPECN. OF LUBRICATION
(USE IOC BRAND
NAME ONLY)
FIRST FILL QTY
LTR / KG
PER UNIT EQPT.
CHECK -
INTERNAL
UP
TOP-UP QTY
FIRST
CHANGE
FREQUENCY
OF CHANGE
REMARKS
1
2
3
5
6
MAIN BEARING HOUSING
LABYRINTH RING
LINKAGE
GEAR BOX
HAND PUMP
SERVOGEM – 3
SERVOGEM – 3
SERVOGEM-3
SERVOMESH SP320
SERVO SYSTEM - 68
3 KGS.
2 KGS
2 KGS
30 LITRES
13 LITRES
BIWEEKLY
DAILY AFTER
EVERY 8
HOURS OF
OPERATION
- DO -
DAILY AFTER 8 HOURS OF OPERATION
- DO -
4.0 KGS
1.0 KGS
1.0 KG
AS & WHEN
REQUIRED
- DO -
AFTER 250 HRS. OF OPERATION OR ONE MONTH WHICHEVER IS EARLIER.
AFTER
EVERY 500 HRS OF OPERATION OR TWO MONTHS WHICHEVER IS EARLIER.
CHECK FOR ABNORMAL SOUND AND TEMPERATURE OF MAIN BEARING HOUSING (SL. NO. 1) AT THE END OF EVERY SHIFT. ANY INCREASE IN TEMPERATURE / ABNORMAL SOUND MAY BE DUE TO INADEQUATE / EXCESS LUBRICATION OR DUE TO CONTAMINATION OF LUBRICANT APART FROM OTHER REASONS.
INITIALLY TANK SHOULD BE FLUSHED BEFORE CHARGING THE FRESH OIL.
- DO -
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OPERATION AND MAINTENANCE MANUAL FOR LUBCON MINI BUCKET PUMP
OPERATION:
LUBCON MINI BUCKET PUMP IS MANUAL, LEVER OPERATED DOUBLE ACTION PISTON TYPE LUBRICANT DISPENSER.
THE OPERATION OF THE PUMP IS SIMPLE. A FOOT STABILISER IS PROVIDED WITH PUMP TO STEADY THE SAME WHILE OPERATING.
A SCREW TYPE RELIEF VALVE IS PROVIDED NEAR THE OUTLET NOZZLE. THIS VALVE IS USED TO BLEED THE LINE FREE OF ANY POSSIBLE AIR POCKETS.
BEFORE OPERATING THE PUMP, IT IS TO BE ENSURED THAT THE LUBRICANT IS SELF - COLLAPSIBLE (I.E. OIL OR UPTO NLGI - 2 CONSISTENCY OF GREASE) AND THE LEVEL OF LUBRICANT IS ADEQUATE ENOUGH TO KEEP THE SUCTION PORT UNDER LUBRICANT LEVEL. BEFORE OPERATING THE “RELIEF” VALVE SCREW IS TO BE CLOSED FIRMLY.
NOW THE PUMP IS READY FOR OPERATION.
CAUTION:
1. THE LUBRICANT USED SHOULD BE FREE FROM ALL CONTAMINATION LIKE BARS, JUTE, and COTTON WASTE ETC.
2. THE PUMP SHOULD NOT BE USED FOR DISPENSING CHEMICALS, CORROSIVE SUBSTANCES.
3. WHEN NOT IN USE, WIPE CLEAN LUBCON MINI BUCKET PUMP AND STORE IN A DRY PLACE.
IT IS POSSIBLE TO EXPERIENCE SOME PROBLEMS THE REMEDIAL MEASURE ARE SUGGESTED BELOW:
A. PUMP NOT DISCHARGING LUBRICANT WITH ENOUGH PRESSURE/QUANTITY
IT IS POSSIBLE THAT AIR POCKETS HAVE FOUND THEIR WAY IN THE LUBRICANT. SLOWLY, OPERATE THE LEVER AND GO ON LOOSENING THE RELIEF VALVE. A FEW TURNS TILL AIR IS EJECTED AND UNINTERRUPTED FLOW OF LUBRICANT IS ACHIEVED. THE RELIEF VALVE, THEN, TO BE TIGHTENED AND THE PUMP TO BE OPERATED NORMALLY.
BE SURE THAT LUBRICANT LEVEL IN THE CONTAINER IS ENOUGH
(I.E. AT LEAST HALF - TANK)
________________________________________________________________________________
PUMP NOT DISCHARGING LUBRICANT
TAKE OUT THE PUMPING ELEMENT FROM THE CONTAINER. DISMANTLE THE FOOT VALVE AND CLEAN WITH KEROSENE OIL. REMOVE THE IMPURITIES LIKE, JUTE, AND SAND. ASSEMBLE THE UNIT AND START OPERATION.
LUBCON MINI BUCKET PUMPS ARE RIGOROUSLY TESTED FOR PERFORMANCE BEFORE DESPATCH AND WILL RENDER YEARS OF TROUBLE FREE SERVICE, IF CAREFULLY MAINTAINED.
SECTION - 12
ROLL REPAIR
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______________________________________________________________
IV.REHARD FACING
1. Recommended Electrode Eutectrode 2 - EWAC make.
2. Weight of Electrodes required for one Roll - 60 kgs.
3. Welding parameters.
a) Process - SMAW
b) Position - 1G
c) Current - D.C/A.C.
d) Polarity - Positive in D.C
e) Amperage - 120 - 150 A
f) Speed - 6” to 8”
g) Voltage - 24-26 V
h) No. of Layers - 2 to 3(7 layers for grab
Teeth)
i) Pre-heating - 75 Deg.C - 100 Deg.C
j) Inter-pass temperature - 200 Deg.C.
4. Ear thing should be made directly to the roll to avoid arc-thru in main bearings.
Weld not more than 4 teeth of a row at a stretch to avoid warp age of the roll.
5. Build up the hard faced layer by the electrode mentioned in (1) by following the parameters given in (3) to the height of 4-5 mm.
6. Check the hardness on the hard faced surface, which should be Rockwell C-53-57
7. Check the profile with the gauge made as per enclosed drawing. Gauge/template supplied with the machine.
In case the tooth is worn out considerably or broken, it should be replaced. For replacement procedure given below should be followed.
________________________________________________________________________________
I. Cut tooth off completely from body off the roll, ground smooth the cut surface.
II. Weld new tooth of High Tensile Weld able Steel (ST 55 HTW/TATA LA55) as shown in sketch at next page.
III. For welding use electrode E 8016C2 2.5 Dia (Root run) and E 8016C2 3.15 Dia (Subsequent run) follow the welding parameters given in point.8
8. Welding parameters (for tooth welding)
Electrode
E 8016C2 E 8016C2
2.5 Dia. 3.15 Dia
------------- -------------
a) Process SMAW SMAW
b) Position 1G 1G
c) Polarity Reverse Reverse
Polarity Polarity
d) Amperage 100-120A 120-140A
e) Voltage 18 - 22 V 20 - 24 V
f) Preheating 300 Deg.C (min) 300 Deg.C (min)
g) Inter pass temperature 175°C 175°C
9. Incase the tooth is worn out considerably /broken, it should be repaired.
For repair given below procedure should be followed.
I. Cut tooth off 12 mm (approx) and ground smooth the cut surface.
II. Build up new tooth as shown in sketch below and building up of the tooth should be made of high tensile weld able steel (ST 55 HTW) TATA LA55) as per the dimensions given in the sketch on next page.
III. Teeth body to be build up by E-710, 4 Dia of cosmic fontech or E-7018 4 Dia.
IV. Teeth body can also be build by Duroid (spl) of IOL
SECTION - 13
SPARE PARTS
LIST OF SPARE PARTS
______________________________________________________________
DRAWINGS RELATED TO SPARE PARTS
SLNO.
DESCRIPTION
DRAWING NO.
1
GENERAL ASSEMBLY
CS.1.1-02883
2
Gear Box Assembly
CS1.1-2514
3
LUBRICATION System
CS.1.2-2346
4
Stationary & adjustable Bearing Assly
CS.1.2-3880
5
Hyd. Adjustment & Alignment Assly
CS.1.1-2250
6
Hyd. Piping Arrangement
CS.1.1-02779
LIST OF COMMISSIONING SPARES
SLNO.
DESCRIPTION
QTY.
SHT/ITEM
1
Hyd. Pneumatic Cylinder Seal Kit
1set
27/42
2
Hyd. Hand Pump Seal Kit
1set
27/5
______________________________________________________________
RECOMMENDED LIST OF SPARES FOR TWO YEARS TROUBLE FREE OPERATION
SL NO.
DESCRIPTION
QTY.
ITEM
REF. DRG. NO.
1
FIXED BEARING ASSLY
2
3
GEAR BOX ASSLY
2
BEARING FOR IDLER GEAR
4
21
-do-
3
FIBRE WASHER FOR DRIVE GEAR
4
47
-do-
4
FIBRE WASHER FOR IDLERGEAR
4
46
-do-
5
DRIVE GEAR
2
17
GEAR BOX ASSLY
6
IDLER GEAR
2
19
-do-
7
TAPER LOCK BUSHING
2
18
-do-
8
GEAR PLATES
4
2 & 16
-do-
9
GEAR BOX STUB SHAFT
2
5
-do-
10
BEARING FOR GEAR PLATE
4
24
-do-
11
MAIN DRIVE SHAFT
1
7
CS.1.3-5584
12
GIB HEAD KEY
2
17
CS. 1.102777
13
ALIGNMENT SHAFT
1
9
-do-
14
SLIDE BAR
2
43F
-do-
15
Hyd. Hand Pump
1
1
CS. 1.1-02779
16
Hose Assly. With Adapters
1
18
-do-
17
Pipe Connector With Check Valve
1
19
-do-
18
Hydo-pneumatic Cylinder
2
34
-do-
19
N2 Pressure Regulator
1
40
-do-
20
Locking Assly.
2
12
CS. 1.1-02883
21
8V- Belt
1 set
26
1.1-02883
SECTION - 14
LIST OF DRAWING
______________________________________________________________
LIST OF DRAWINGS
Sl. No.
Description
Drawing No.
1
General assembly with drive arrangement of 6024SSHD
CS.1.1-02883
2
Gear box Assembly
CS.1.1-2514
3
Adjustment Alignment Assembly
CS.1.1-2250
&
CS.1.1-0277
4
Stationary & Adjustable Bearing Assembly
CS.1.2-3880
5
Lubrication System
CS.1.2-2346
6
Hydraulic Piping Arrangement
CS.1.1-02779
7
Roll Removal Rail Installation
CS.1.3-3156
8
Hydraulic Cylinder
CS.1.4-14646
9
Wear Plate Arrangement
CS.1.4-15537
10
Chisel Tooth Gauge
CS.1.4-15438
______________________________________________________________
______________________________________________________________
_____________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
______________________________________________________________
SECTION - 15
O & M MANUAL FOR HYDRO-PNEUMATIC CYLINDER
______________________________________________________________
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