Coal Handling Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual
ZAMBIA MAAMBA 2150MW POWER PLANT PROJECT

Client: SEPCO II ELECTRIC POWER CONSTRUCTION CORPORATION
S/N
Fuel Operation and

Maintenance Manual (A)
Total Pages:103
Operation and Maintenance Manual
SEPCO II
Prepared by: Wang Feng
22/07 /2016
Reviewed by: Li Qingtang 22 / 07 /2016
Approved by: Li Mingda 22/ 07 /2016
Name of Variation Order

1
2
3
S/N
Approved on
Contents
System Overview..........................................................................................................................................................4
Chapter I........................................................................................................................................................................7
1 .1DT II belt conveyor and accessory equipment...............................................................................................7
1.1.1Belt conveyor........................................................................................................................................7
1.1.2 Handover inspection and check before start-up................................................................................16
1.1.3 Local Operation Procedures..............................................................................................................16
1.1.4 Notes for Operation...........................................................................................................................17
1.1.5 Accident Handling.............................................................................................................................18
1.1.6 General rules for the safety management of fuel coal handling system...........................................21
1.2 Vibration coal feeder.....................................................................................................................................24
1.2.1Technical Specifications of vibrating coal grates...............................................................................24
1.2.2 Technical Specifications of vibration Coal Feeders..........................................................................25
1.2.3 Shift Inspection and Check Before Start-up......................................................................................26
1.2.4 Local Operation Procedures..............................................................................................................27
1.2.5 Notes during Operation.....................................................................................................................27
1.2.6Common Failures and Handling.........................................................................................................27
1.2.7Maintaining the Vibrating Feeder for Coal........................................................................................28
1.3 Filtering Equipment......................................................................................................................................29
1.3.1 High amplitude vibration screen.......................................................................................................29
1.3.2 double-roll coal crusher.....................................................................................................................32
1.3.3 Fine crusher.......................................................................................................................................36
1.3.4VariabIe speed Coupling.....................................................................................................................39
1.3.5Measures to be taken at standstill periods or at stand by operation...................................................39
1.3.6Maintenance intervals and Measures to be taken..............................................................................40
1.4 Auxiliary equipment.....................................................................................................................................40
1.4.1 unload car unloader...........................................................................................................................40
1.4.2Belt-type electromagnetic iron-separator...........................................................................................42
1.4.3Disk-type electromagnetic iron separator...........................................................................................45
1.4.4Three-way pipe of electric plate.........................................................................................................46
1.4.5DMC bag filter type dust collectors...................................................................................................48
1.4.6Pollution discharge devices................................................................................................................50
1.4.7Sampling device for coal as fired.......................................................................................................53
1.4.8Electronic belt scale............................................................................................................................56
1.4.9cranes & hoists....................................................................................................................................57
1.4.10wiper.................................................................................................................................................62
1.4.11Bridge type grab crane......................................................................................................................63
Chapter II Bucket Wheel Stacker and Reclaimer.......................................................................................................65
2.1 DQ750/750-35 bucket wheel stacker...........................................................................................................65
2.2 Handover Inspection and Check Before Start-up for Bucket Wheel Stack Reclaimer................................66
2.3 Operation mode of bucket wheel stacker.....................................................................................................67
2.3.1 Mode for material piling at the pointed place...................................................................................67
2.3.2 Mode for material rotary piling:........................................................................................................67
1
2.3.3 Long piling method:..........................................................................................................................68

2.4 Stacking Operation Procedure of Bucket Wheel Machine...........................................................................68
2.5 Parking Procedure of Bucket Wheel Machine During the Stacking Operation...........................................69
2.6 Operation Procedure of Reclaiming.............................................................................................................69
2.7 Parking Procedure of Bucket Wheel Machine During the Reclaiming Operation......................................70
2.8 Notes to the Use of Bucket Wheel Machine................................................................................................70
2.9 Causes and Treatment of Common Faults of Hydraulic System.................................................................71
2.10 Maintenance of the Bucket Wheel Machine..............................................................................................73
2.10.1 General Provisions of Lubrication Points and Lubrication.............................................................73
2.10.2 Refueling and Maintenance System for Bucket Wheel Machine...................................................73
2.10.3 Maintenance and Inspection Items of Bucket Wheel Machine.......................................................74
2.10.4 Requirements of Hydraulic System.................................................................................................74
Chapter III Program Control System.........................................................................................................................76
3.1 Control Object...............................................................................................................................................76
3.2 Control Functions.........................................................................................................................................76
3.3 Functions of the Main Screen Buttons.........................................................................................................77
3.4 Automatic Mode...........................................................................................................................................78
3.4.1 Process of Automatic Mode..............................................................................................................78
3.4.2 Manual Operation.............................................................................................................................81
3.4.3 Coal Blending Mode.........................................................................................................................82
3.4.4 Monitoring and Alarm......................................................................................................................82
3.4.5 Inspection and Preparation Before System Shift-Over and Start.....................................................83
3.4.6. Pre-start Check.................................................................................................................................83
3.4.7 Precautions for Programmable Operation and Monitoring..............................................................84
3.4.8 Failure Causes in Programmable Operation and Treatment............................................................85
Chapter IV Loader......................................................................................................................................................89
4.1 Structure and Performance...........................................................................................................................89
4.1.1 Structure.............................................................................................................................................89
4.1.2 Technical Performance......................................................................................................................89
4.1.3 Technical Performance of Diesel Engine..........................................................................................89
4.1.4 Technical Performance of Hydraulic Torque Converter...................................................................90
4.1.5 Gearbox..............................................................................................................................................90
4.1.6 Drive Shaft and Drive Axle...............................................................................................................91
4.1.7 Brake System.....................................................................................................................................91
4.1.8 Steering System.................................................................................................................................91
4.1.9 Electrical System...............................................................................................................................92
4.1.10 Refuel Capacity...............................................................................................................................92
4.2 Maintenance Interval and Period..................................................................................................................92
4.3 Common Troubles and Troubleshooting Methods.......................................................................................93
4.3.1 Drive System.....................................................................................................................................93
4.3.2 Brake System.....................................................................................................................................94
4.3.3 Steering System.................................................................................................................................94
4.3.4 Working Hydraulic System................................................................................................................95
4.4 Maintenance Items........................................................................................................................................96
Chapter V ZD220 Coal Bulldozer..............................................................................................................................97
2
5.1 Main Specification and Technical Parameters.............................................................................................97

5.2 Operation Rules............................................................................................................................................97
5.2.1 Engnie Operation...............................................................................................................................97
5.2.2 Notices for Operation........................................................................................................................99
5.2.3 Troubleshooting.................................................................................................................................99
Chapter VI Fire alarm system...................................................................................................................................106
6.1. Medium speed water spray fire alarm system of coal conveying system.................................................106
6.2 Composition of medium speed water spray system...................................................................................106
6.3 Technical Specifications of the deluge valve.............................................................................................106
6.4 Technical Specifications of the nozzle.......................................................................................................106
6.5 Water curtain system...................................................................................................................................106
System Overview
MAAMBA 2150MW Power Plant Project in Zambia is built by SEPCO Electric Power Construction
Corp.This project is located in Maamba Collieries Maamba ,Sinazongwe Zambia .This project consists of two
150MW circulating fluidized bed boiler coal-fired power units. The design daily coal consumption is 5120.8 t.
Design coal types for # 1 and 2 furnaces are coals providing net calorific value as received basis of Q net,ar=22.59
MJ/kg and moisture as received basis of Mar=7.40%.
This project has two coal source,one is local coal mine.Supply raw coal particle size no more than
500mm.Another is a local coal preparation plant. Respectively supply coal particle size no more than 50mm and
10mm.Mine coal transport by road Unloading way in factory is underground coal hopper.Total set 6
underground coal hoppers.Using vibration coal feeder as coal feeder machineryEach vibration coal feeder rated
output is 250t/hMaximum output is 350t/hfrequency conversion.The underground hopper use vibration coal
grate.coal grate hole500mm.Underground coal hopper is arranged around the movable rails.The coal of coal
Preparation plant transport into the plant through the belt, used underground coal hopper as coal unloading system
.Coal no more than 50mm and less than 10mm each set a underground coal hopper.Using vibration coal feeder as
coal feeder machineryEach vibration coal feeder rated output is 70-250t/hfrequency conversion.
The 2150MW project consists of two coal storage yards.Set the coal storage yards surrounding the
underground coal hopper use to storage coal of coal mine.Coal stack height is not more than 4.5m The coal yard
is trapezoidal Coal reserves can meet the capacity of about 2 days coal consumption of 4 * 150MW
units.Contain a folding type bucket wheel coal yard.Used to store coal after primary crushing.The yard is
equipped with one cantilever bucket wheel stacker reclaimer. Cantilever length is 35m.Its stacking ability and
reclaiming ability are 750 t/h.Maximum stacking ability and reclaiming ability are 900 t/h.Coal stack height is not
more than 9-12m Coal reserves can meet the capacity of about 15 days coal consumption of 4 * 150MW
units.Around the coal yard have a spare underground coal hopper.The coal hopper is equipped with 3 Vibration
coal feeder.Vibration coal feeder rated output is 200-300t/h,frequency conversion.The coal hopper contains
electric gate.Furthermore, the yard is equipped with 3 sets of TY220 coal bulldozers and one ZL-50 loader. 44sets
of KLP-50 sprinklers are provided on both sides of the yard for dust suppression.
This project uses the two-stage screening two stage crushing. Coarse coal crusher room arrangement before
the coal yard, set the coarse coal crusher 2 sets, Rating Q = 800 t/h; Feed particle size 500 mm, Discharging
granularity 50 mm. Finely coal crusher room arrangement after the coal yard, set high amplitude vibrating screen
and reversible hammered coal crusher 4 sets ,each of high amplitude vibrating screen rating Q = 450 t/h; Feed
particle size 50 mm, discharging granularity < 10 mm, The reversible hammered coal crusher rating is Q = 375
t/h, the maximum output is 475 t/h; Feed particle size 50 mm, discharging granularity < 10 mm. Screening
building decorate after finely coal crusher, it has high amplitude vibrating screen machines 4 sets, rating Q = 375
t/h, the maximum output is 475 t/h; Feed particle size 50 mm, discharging granularity < 10 mm. The materials on
the screen returned to the finely coal crusher entrance by belt conveyor. The coal particle size Enter the boiler
meets the requirements.In order to remove the ferromagnetic impurities in the coal, the leading end of #1, #3, #4,
#11belt is equipped with belt de-ironing separator, In the middle of #7 belt installs two disc de-ironing separator
which bandwidth is 1000 mm, 2 sets in total. #1belt A/B,#4belt A/B, #7beltA/B, #11belt central zone each
equipped with 2 sets metal detectors, 7sets in total. In order to ensure the safety of Finely coal crusher, in the
leading end of C6A, B belt is equipped with two sets disc de-ironing separator which model is RCDA - 10 T1; All
4
de-ironing separator have iron falling pipe lead to the ground.

It has 24 sets of belt conveyor in coal conveying system, in addition to the C10, C11 belt conveyor, the other
are the dual arrangement (according to the coal flow direction, the left side is path A , path B is on the right
road),when One path is running, another path standby.C3A belt for two-way reversible belt.
The belt conveyor system of the project is two kinds of specifications.The coal washery coal underground
coal bunker with coal conveyer parameters B=650mm V=1.8m/s Q=200t/h All single road
layout.Parameters of the other belt conveyor.B=1000mmV=3.15m/sQ=750t/hdouble road layout.
Belt conveyor angle can not be greater than 14 degrees.belt machine jetty using closed form.The coal bunker
mobile unloading small fleet raw coal bunker in coal blending
In order to measure coal flow and coal quality into the furnace, two sampling equipment are installed in
sampling building. Sample building located in the central part of C7 landing stage. the whole coal conveying
system has 7 sets of belt scale which are installed in the middle part of C1A/C1B/C3A/C7A/C7B/C10 / C11 belt.
#7 belt A/B has a dynamic circular chain code to check of belt scale, 2 sets in total. Belt scale range: 20%- 120%
of the rated output of belt conveyor, and 100% of overload protection. The accuracy of belt scale: 0.25% range.
To combination system of different operation modes, it has 13 electric baffled t-branch pipes, 3 electric baffled
cross pipes; The coal conveying system adopts hydraulic flushing, It is equipped with 2 sets SLW125-315A type
centrifugal pump in the coal crusher room, one run, one standby. Rinse water first being focused to the transfer
station, coal crusher room, sump of the car coal station and finely coal crasher room, then it is discharged to the
coal water settling pond by 25 sets submerged multi-purpose pump which model is 100 YZ100- 30A. 1 wiper is
equipped On the C3A belt conveyor which used to clear the dropsy on the C3A belt, in order to guarantee the coal
conveying air quality of the space, reduce the dust concentration, The system equipped with 35 sets DMC pulse
mode bag filter. the bag filter (efficiency 99%) is installed in Coarse coal crusher room, finely coal crusher room,
screening building, raw coal bunker, limestone transfer station, the coal falling pipe which has large gap installs
buffer gas lock device, to reduce the coal flow impact, reduce intensity of the dust float in the sky.In coal area
there are three electric crab bucket cranes set above one coal water settling pond and two rain water settling pond
Belt protection device is installed on both sides of the belt conveyor,including pull rope switch belt sway
switches velocity point detector jam signal vibrator Material flow signal temperature measuring
equipmentWhen the vibration signal is received,the coal blocking signal is received,work for 10seconds,If the
coal blocking signal does not lift,reverse coal flow down.Pull rope switch:Along the belt machine on both sides of
each pair of 30 meters.The first and last pair of pull wire switches shall be located within 15 meters of the
head.Belt sway switches:Along the belt machine on both sides of each pair of 50 meters.Speed detector:Each belt
is fitted with 1.Blocking signal and oscillator:Installed in each of the three-electric power.Material flow
signal:Each belt conveyor.Monitoring information is displayed on the simulation screen and input to the
computerized system. The coal handling system uses the interlocking centralized control mode to ensure proper
operation of coal handling devices.
The entire coal handling system is controlled in a centralized manner. The control host is a Rockwell
programmable logic controller (PLC). Three upper computers, two for monitoring and one for management, are
provided. They can completely replace all functions of the console. On the upper computers, you can remotely
control devices of the system except for bridge-type grab and bucket wheel machines (involved in the interlocking
and programmable data input and output).
Chapter I
1 .1DT II belt conveyor and accessory equipment
1.1.1 Belt conveyor
1.1.1.1 Technical Specifications of the Conveyors
NO model Width Rating Inclinat Rollers at Tensioning Rollers at
Motor Motor Motor
Speed
both ends
power voltage current
reducer
Horizontal
Horizontal
kw V A
Model
center
height
distance
distance
mm output ion both ends

t/h
C1
C2
DTII
DTII
C3A DTII
1200
1000
1000
750
750
750
model
A13 A172.370
Vertical A22.315
B13 B172.485
B22.315
14 A45.869
Vertical A9.915
B45.869
B9.915
14 456.987
Carriage
Motor
Y315L1-4
160
380
270.4 PHD9075R3
Belt
Quant Braking Hydraulic
speed ity of device

m/s
belt
2.0
YOXII560
2.8
YOXII450
3.15
-31.5
Y280S-4
75
380
132.3 PHD9060R3
-22.4
Y315S-4 2110
380
188.8 PHD9060R3
-20
C3B DTII
1000
750
12
154.175
Vertical
21.515
coupler
Y315M-4
135
380
226.1 PHD9070R3
YWZ5- YOXIIz50
400/800 0
2.5
3.15
YWZ5-20
3.15
YOTcs560
3.15
YOXII500
3.15
YOXII560
3.15
YOXII560
3.15
YOXII500
YOXII500
-25
C3CD DTII
1000
750
11.5
Spiral
0.185
Y180M-4
18.5
380
34.5 PHA9030R3
-25
C4
DTII
1000
750
12 A197.03
B197.928
C5AB DTII
1000
750
1.6 A186.895
B190.070
C5CD DTII
1000
750
1.6~14 C138.825
C6
C7
DTII
DTII
1000
1000
750
750
Vertical A30.215
B30.231
Vertical A5.22
200
380
3552-4
Y315S-4
Vertical C20.615
D20.615
5~14 A135.675
Vertical A24.321
B135.675
B24.321
9~14 A244.862
Vertical A51.546
21.6 PHD9075R3
-20
110
380
188.8 PHD9060R3
-20
B5.309
D138.825
B244.862
YKK
Y315L
160
380
1-4
Y315L
270.4 PHD9070R3
-20
160
380
1-4
Y315M-4 2132
270.4 PHD9070R3
-20
380
226.1 PHD9065R2
-20
B51.546
C8
DTII
1200
750
A10.4
Spiral
A10.4
B10.4
C9
C10
DTII
DTII
1200
650
750
200
Vertical A5.424
B112.50
B5.424
103.93
18.5
380
33.4
CHHM25-
Vertical
22.63
2.0
2.5
1.8
6190-B-29
B10.4
14~0 A112.50
14
Y220L-4
Y280S-4
75
380
132.3 PHD9060R3
-31.5
Y225S-4
37
380
67
PHA9045R3
-28
C11
DTII
650
200
14
139.95
Vertical
33.648
Y255M-4
45
380
81.1 PHA9045R3
1.8
Name of belt
Name of the roller
Diameter of rollermm
NO of the bearing pedestal
Number of the roller
C1A BELT
C1A-1
800
C1A-1-A
C1A-1-B
C1A-2-A
C1A-2-B
C1A-3
500
C1A-3-A
C1A-3-B
C1A-4
630
C1A-4-A
C1A-4-B
C1A-5
500
C1A-5-A
C1A-5-B
C1A-6
400
C1A-6-A
C1A-6-B
C1A-7
630
C1A-7-A
C1A-7-B
C1B BELT
C1B-1
800
C1B-1-A
C1B-1-B
C1B-2
400
C1B-2-A
C1B-2-B
C1B-3
500
C1B-3-A
C1B-3-B
C1B-4
630
C1B-4-A
C1B-4-B
C1B-5
500
C1B-5-A
C1B-5-B
C1B-6
400
C1B-6-A
C1B-6-B
C1B-7
630
C1B-7-A
C1B-7-B
C2A BELT
C2A-1
800
C2A-1-A
YOX II
400
1.1.1.2 Technical Specifications of the roller and bearing pedestal
400
YOX II
400
-28
C1A-2
YOXII450

C2A-1-B
C2A-2
400
C2A-2-A
C2A-2-B
C2A-3
500
C2A-3-A
C2A-3-B
C2A-4
630
C2A-4-A
C2A-4-B
C2A-5
500
C2A-5-A
C2A-5-B
C2A-6
400
C2A-6-A
C2A-6-B
C2A-7
630
C2A-7-A
C2A-7-B
C2B BELT
C2B-1
800
C2B-1-A
C2B-1-B
C2B-2
400
C2B-2-A
C2B-2-B
C2B-3
500
C2B-3-A
C2B-3-B
C2B-4
630
C2B-4-A
C2B-4-B
C2B-5
500
C2B-5-A
C2B-5-B
C2B-6
400
C2B-6-A
C2B-6-B
C2B-7
630
C2B-7-A
C2B-7-B
C3A BELT
C3A-1
800
C3A-1-A
C3A-1-B
C3A-2
400
C3A-2-A
C3A-2-B
C3A-3
500
C3A-3-A
C3A-3-B
C3A-4
500
C3A-4-A
C3A-4-B
C3A-5
630
C3A-5-A
C3A-5-B
C3A-6
630
C3A-6-A
C3A-6-B
C3A-7
400
C3A-7-A
C3A-7-B
C3A-8
800
C3A-8-A
C3A-8-B

C3C BELT
C3C-1
800
C3C-1-A
C3C-1-B
C3C-2
400
C3C-2-A
C3C-2-B
C3C-3
400
C3C-3-A
C3C-3-B
C3C-4
630
C3C-4-A
C3C-4-B
C3D BELT
C3D-1
800
C3D-1-A
C3D-1-B
C3D-2
400
C3D-2-A
C3D-2-B
C3D-3
400
C3D-3-A
C3D-3-B
C3D-4
630
C3D-4-A
C3D-4-B
C3B BELT
C3B-1
800
C3B-1-A
C3B-1-B
C3B-2
400
C3B-2-A
C3B-2-B
C3B-3
500
C3B-3-A
C3B-3-B
C3B-4
630
C3B-4-A
C3B-4-B
C3B-5
500
C3B-5-A
C3B-5-B
C3B-6
400
C3B-6-A
C3B-6-B
C3B-7
630
C3B-7-A
C3B-7-B
C4A BELT
C4A-1
800
C4A-1-A
C4A-1-B
C4A-2
400
C4A-2-A
C4A-2-B
C4A-3
500
C4A-3-A
C4A-3-B
C4A-4
630
C4A-4-A
C4A-4-B
C4A-5
500
C4A-5-A
C4A-5-B
C4A-6
400
C4A-6-A
C4A-6-B
C4A-7
630
C4A-7-A

C4A-7-B
C4B BELT
C4B-1
800
C4B-1-A
C4B-1-B
C4B-2
400
C4B-2-A
C4B-2-B
C4B-3
500
C4B-3-A
C4B-3-B
C4B-4
630
C4B-4-A
C4B-4-B
C4B-5
500
C4B-5-A
C4B-5-B
C4B-6
400
C4B-6-A
C4B-6-B
C4B-7
630
C4B-7-A
C4B-7-B
C5A BELT
C5A-1
800
C5A-1-A
C5A-1-B
C5A-2
400
C5A-2-A
C5A-2-B
C5A-3
500
C5A-3-A
C5A-3-B
C5A-4
630
C5A-4-A
C5A-4-B
C5A-5
500
C55A-5-A
C5A-5-B
C5A-6
400
C5A-6-A
C5A-6-B
C5A-7
630
C5A-7-A
C5A-7-B
C5B BELT
C5B-1
800
C5B-1-A
C5B-1-B
C5B-2
400
C5B-2-A
C5B-2-B
C5B-3
500
C5B-3-A
C5B-3-B
C5B-4
630
C5B-4-A
C5B-4-B
C5B-5
500
C5B-5-A
C5B-5-B
C5B-6
400
C5B-6-A
C5B-6-B
C5B-7
630
C5B-7-A
C5B-7-B
10

C5C BELT
C5C-1
800
C5C-1-A
C5C-1-B
C5C-2
400
C5C-2-A
C5C-2-B
C5C-3
500
C5C-3-A
C5C-3-B
C5C-4
630
C5C-4-A
C5C-4-B
C5C-5
500
C5C-5-A
C5C-5-B
C5C-6
400
C5C-6-A
C5C-6-B
C5C-7
630
C5C-7-A
C5C-7-B
C5D BELT
C5D-1
800
C5D-1-A
C5D-1-B
C5D-2
400
C5D-2-A
C5D-2-B
C5D-3
500
C5D-3-A
C5D-3-B
C5D-4
630
C5D-4-A
C5D-4-B
C5D-5
500
C5D-5-A
C5D-5-B
C5D-6
400
C5D-6-A
C5D-6-B
C5D-7
630
C5D-7-A
C5D-7-B
C6A BELT
C6A-1
800
C6A-1-A
C6A-1-B
C6A-2
400
C6A-2-A
C6A-2-B
C6A-3
500
C6A-3-A
C6A-3-B
C6A-4
630
C6A-4-A
C6A-4-B
C6A-5
500
C6A-5-A
C6A-5-B
C6A-6
400
C6A-6-A
C6A-6-B
C6A-7
630
C6A-7-A
C6A-7-B
C6B BELT
C6B-1
800
C6B-1-A
11

C6B-1-B
C6B-2
400
C6B-2-A
C6B-2-B
C6B-3
500
C6B-3-A
C6B-3-B
C6B-4
630
C6B-4-A
C6B-4-B
C6B-5
500
C6B-5-A
C6B-5-B
C6B-6
400
C6B-6-A
C6B-6-B
C6B-7
630
C6B-7-A
C6B-7-B
C7A BELT
C7A-1
800
C7A-1-A
13
C7A-1-B
C7A-2
400
C7A-2-A
C7A-2-B
C7A-3
630
C7A-3-A
C7A-3-B
C7A-4
630
C7A-4-A
C7A-4-B
C7A-5
800
C7A-5-A
C7A-5-B
C7A-6
800
C7A-6-A
C7A-6-B
C7A-7
630
C7A-7-A
C7A-7-B
C7A-8
630
C7A-8-A
C7A-8-B
C7A-9
500
C7A-9-A
C7A-9-B
C7A-10
630
C7A-10-A
C7A-10-B
C7A-11
500
C7A-11-A
C7A-11-B
C7A-12
400
C7A-12-A
C7A-12-B
C7A-13
630
C7A-13-A
C7A-13-B
C7B BELT
C7B-1
800
C7B-1-A
C7B-1-B
C7B-2
400
C7B-2-A
C7B-2-B
12
13

C7B-3
630
C7B-3-A
C7B-3-B
C7B-4
630
C7B-4-A
C7B-4-B
C7B-5
800
C7B-5-A
C7B-5-B
C7B-6
800
C7B-6-A
C7B-6-B
C7B-7
630
C7B-7-A
C7B-7-B
C7B-8
630
C7B-8-A
C7B-8-B
C7B-9
500
C7B-9-A
C7B-9-B
C7B-10
630
C7B-10-A
C7B-10-B
C7B-11
500
C7B-11-A
C7B-11-B
C7B-12
400
C7B-12-A
C7B-12-B
C7B-13
630
C7B-13-A
C7B-13-B
C8A BELT
C8A-1
800
C8A-1-A
C8A-1-B
C8A-2
400
C8A-2-A
C8A-2-B
C8A-3
400
C8A-3-A
C8A-3-B
C8A-4
800
C8A-4-A
C8A-4-B
C8B BELT
C8B-1
800
C8B-1-A
C8B-1-B
C8B-2
400
C8B-2-A
C8B-2-B
C8B-3
400
C8B-3-A
C8B-3-B
C8B-4
800
C8B-4-A
C8B-4-B
C9A BELT
C9A-1
800
C9A-1-A
C9A-1-B
C9A-2
500
C9A-2-A
C9A-2-B
C9A-3
500
C9A-3-A
13

C9A-3-B
C9A-4
630
C9A-4-A
C9A-4-B
C9A-5
500
C9A-5-A
C9A-5-B
C9A-6
400
C9A-6-A
C9A-6-B
C9A-7
630
C9A-7-A
C9A-7-B
C9B BELT
C9B-1
800
C9B-1-A
C9B-1-B
C9B-2
500
C9B-2-A
C9B-2-B
C9B-3
500
C9B-3-A
C9B-3-B
C9B-4
630
C9B-4-A
C9B-4-B
C9B-5
500
C9B-5-A
C9B-5-B
C9B-6
400
C9B-6-A
C9B-6-B
C9B-7
630
C9B-7-A
C9B-7-B
C10 BELT
C10-1
630
C10-1-A
C10-1-B
C10-2
315
C10-2-A
C10-2-B
C10-3
400
C10-3-A
C10-3-B
C10-4
500
C10-4-A
C10-4-B
C10-5
400
C10-5-A
C10-5-B
C10-6
315
C10-6-A
C10-6-B
C10-7
500
C10-7-A
C10-7-B
C11 BELT
C11-1
630
C11-1-A
C11-1-B
C11-2
315
C11-2-A
C11-2-B
C11-3
400
C11-3-A
C11-3-B
14

C11-4
500
C11-4-A
C11-4-B
C11-5
400
C11-5-A
C11-5-B
C11-6
315
C11-6-A
C11-6-B
C11-7
500
C11-7-A
C11-7-B
1.1.2 Handover inspection and check before start-up

1.1.2.1 Anchor bolts of the motor, reducer, roller, and bearing pedestal are fixed and free of breakages.
1.1.2.2 Leads and ground wires of motors and other electrical equipment are intact.
1.1.2.3 Speed reducers and hydraulic couplers are free from oil leakage. Oil levels and colors are normal.
(Under normal circumstances, the appropriate oil depth at the oil probe bottom is 10 - 20mm.) Couplers
connecting bolts are fixed, shields are intact and secure, and there is no jam phenomenon.
1.1.2.4 All rollers and tension devices are free from axial displacement and incline. The cast rubber of rollers
does not suffer adhesive failure. The balance weight is free from jam due to contact with the ground. There are no
coals and foreign articles around tension devices.
1.1.2.5 The rubber covering on the rubber belt and edge rubber do not have new wear, scratches, and cracks.
Joints are intact and free from adhesive failures.
1.1.2.6 Various carrier rollers do not have wear and shedding phenomena. Supports are fixed and free from
incline and deformation.
1.1.2.7 Coal guide troughs and coal chutes do not suffer coal leakage and are free from foreign articles. Coal
guide trough sheaths are intact and coal chutes are clean and free from accumulated coals. Vibrators are intact.
1.1.2.8 Sweepers, non-return devices, belt-type iron separators, brakes, and flat bag-type dust removers are
complete and in readiness.
1.1.2.9 Blades of electric plough unloaders are smooth and free from sharp burrs that may affect the belt safety.
Coal ploughs are set properly according to coaling or coal blending demands. Pay attention to coal level in the
coal bunker.
1.1.2.10 Railings at belt holders, pass bridges, coal chute platform and other structures are complete and intact.
1.1.2.11 Baffle locations are correct according to operation modes.
1.1.2.12 Pull-chord type emergency switches and switch buttons on the power control box are intact and their
locations are correct. Belt conveyors do not bear load and are free from foreign matters. No persons work nearby
the conveyors.
1.1.2.13 Field lighting is good and emergency lamps are ready. There are no water and debris on the ground.
Health standards are met.
1.1.2.14 Field camera lens and ancillary equipment are in good condition and complete.
1.1.2.15 Sewerage devices are operating properly and standby devices are in good conditions.
1.1.3 Local Operation Procedures
Devices of the system are generally controlled from the program control room. Under special circumstances,
15
they can be operated locally only after approval of team leaders or on-duty centralized control personnel. Before
starting the system, on-duty personnel shall report check results to the on-duty personnel in the control room and
obtain approval for starting. (Note: During local control, the interlocking function is not supported.)
1.1.3.1 Start-up operation
1.1.3.1.1 To start the whole system, belt conveyors shall be started orderly in the reverse direction of the coal
flow.
1.1.3.1.2 Switch the control mode switch on the local control box to local position.
1.1.3.1.3 Press the On button on the power box to start the conveyors.
1.1.3.2 Stop operation
1.1.3.2.1 Stop the conveyors orderly in the direction of the coal flow.
1.1.3.2.2 When there is no coal on the conveyors, press the "Stop" button to stop operation of the conveyors.
1.1.4 Notes for Operation
1.1.4.1 Carry out check frequently during operation. Anchor bolts of motors must be fixed. Motors do not have
abnormal noises and burning smell. The temperature of motor shells does not exceed 80 and axial movement
does not exceed 2 mm. Vibration values do not exceed the values in the following table:
Rated Rotation
Speed
(r/min)
3000
1500
1000
750 and
below
Vibration (mm)
0.05
0.085
0.1
0.12
1.1.4.2 Speed reducers should run smoothly and do not have abnormal noises. Anchor bolts and connecting
bolts are fixed. There are no oil leakage, vibration and overheating. The temperature does not exceed 80. Axial
movement does not exceed 2 mm and vibration does not exceed 0.1mm.
1.1.4.3 Each roller bearing is free from overheating, vibration, crack and abnormal noises. The temperature
does not exceed 80 and vibration should not exceed 0.1mm.
1.1.4.4 Rollers and carrier rollers of conveyors shall rotate smoothly and free from axial displacement, falling
off, jam, and vibration. Tightening bolts of bearing pedestals and carrier roller supports are secure.
1.1.4.5 Pay attention to belt operation laws. They should be free from cuts, adhesive failures, breakages and
other abnormal wear.
1.1.4.6 Regularly check coal chutes for coal adhesion during operation. If coal adhesion is severe or blockage
occurs, start vibrators or stop the system. Take reliable safety protection measures to remove coals in coal chutes.
1.1.4.7 Observe whether the belts suffer slipping, off-tracking, and jam. Make adjustments to fix problems in a
timely manner.
1.1.4.8 Coal guide troughs and coal chutes do not suffer coal dropping. There are no accumulated coals under
each roller.
1.1.4.9 If belts are off tracking during operation, operators shall use the adjusting roller to perform adjustments.
If the problem cannot be solved and operation is severely affected, stop the conveyor immediately. It is forbidden
to use sticks to adjust off-tracking belts.
1.1.4.10 Observe whether coal guide troughs and coal chutes drop off sharp objects and whether there are large
foreign matters in the coal flow that affect equipment safety. If problems cannot be solved during operation, stop
equipment to solve problems to avoid damages to equipment.
1.1.4.11 When using coal ploughs, do not press the belt too tight so as to avoid wear. The bunker should not be
fed too many coals to prevent coal leakage.
1.1.4.12 During operation, do not step over belts and do not clean, lubricate, adjust and repair rotating
16
equipment.
1.1.4.13 During operation, enhance communications. Under normal circumstances, do not start and stop
equipment with load.
1.1.4.14 During operation, if conveyors stop due to tripping, find out the cause and report it to the shift leader.
After problems are solved, start the conveyors.
1.1.4.15 During operation, it is forbidden to clean coals adhered to rollers or rotating carrier rollers.
1.1.4.16During operation, do not step over belts and deliver tools and do not clean, lubricate, adjust and
repair rotating equipment.
1.1.5 Accident Handling
1.1.5.1 In case of minor failures during operation, operators on duty shall promptly handle failures and report
situations to shift leaders. If operators cannot solve problems, they shall report them to shift leaders immediately
and obtain handling suggestions from leaders and notify relevant personnel to take appropriate measures.
1.1.5.2 Emergency shutdown conditions: when a device is running, in case of the following conditions, stop the
device immediately without needing to consult the shift leader and leading operator on duty. However, a detailed
report shall be submitted subsequently.
1.1.5.2.1 Belts suffer severe tear or serious off tracking.
1.1.5.2.2 Belts suffer severe slipping or foreign articles jam belts.
1.1.5.2.3 Motors and speed reducers have abnormal noises, excessive temperature or vibration.
1.1.5.2.4 Motors suffer phase break.
1.1.5.2.5 There are large iron matters and detonators on belts or other risks that may damage belts.
1.1.5.2.6 Coal chutes are severely blocked and blockage is not eliminated.
1.1.5.2.7 Couplers are badly damaged.
1.1.5.2.8 Fire and human injury accidents occur.
1.1.5.2.9 The safety of personnel and equipment is endangered.
1.1.5.3 Accident handling
1.1.5.3.1 During start-up, the motor buzzes and cannot reach rated speed of rotation or does not rotate.
Causes:
a. Start with a large load.
b. The motor bearing is damaged or rotating parts are jammed.
c. Motors suffer two-phase operation.
Handling:
a. Immediately stop the belt conveyor. Report the situation to the shift leader. Take measures to prevent the belt
conveyor from running and then clean accumulated coals on the belt to reduce load.
b. Comprehensively check all devices of the system to confirm whether rotating parts are jammed.
c. For problems caused by mechanical or electrical failures, notify maintenance personnel to solve the
problems.
1.1.5.3.2 Motors have abnormal noises and vibration or excessive temperature.
Causes:
a. Load is too large.
b. The voltage is low and there is friction between running parts and statistic parts.
c. The bearing is faulty or misalignment is large and anchor bolts are loose.
Handling:
17
a. In case of large load, report it to the shift leader and reduce the coal feeding volume of the coal source device.
b. Stop the equipment immediately, report the situation to the shift leader, and notify electrical personnel to
solve problems.
c. Report the situation to the shift leader and strengthen monitoring. Stop the equipment after all coals on the
belt are conveyed. Notify maintenance personnel to solve problems. If the situation is severe, stop the equipment
immediately.
1.1.5.3.3 The speed reducers have abnormal noises and vibration or excessive temperature.
Causes:
a. Anchor bolts are loose.
b. The bearing is damaged or transmission shafts are deformed.
c. Gears do not mesh well or gears are severely worn.
d. The coupling center is not aligned.
e. Lubricating oil is insufficient or too much or deteriorates.
Handling:
Find out the cause and report the situation to the shift leader. Notify maintenance personnel to solve problems.
If the situation is severe, stop the equipment immediately.
1.1.5.3.4 Rollers do not run or bearings are overheated.
Causes:
a. Rollers are jammed by foreign articles.
b. The bearing is damaged.
e. Lubricating oil is insufficient or deteriorates.
Handling:
a. Report the situation to the shift leader and remove foreign articles.
b. Stop the equipment and find out the cause. Report the situation to the shift leader, and notify maintenance
personnel to solve problems.
1.1.5.3.5 Belts are off tracking.
Causes:
a. Steel structures are deformed or belt joints are not aligned.
b. Coal dropping points are not aligned or material loading is unbalanced. Coal guide troughs are not aligned.
c. Coals are adhered at rollers and carrying rollers.
d. Axes of rollers and carrying rollers are unparallel. Tensioning rollers are inclined.
e. Adjusting rollers do not work or work reversely.
Handling:
a. Notify maintenance personnel to adjust steel structures.
b. Remove coals adhered in coal chutes. Adjust coal dropping points and check tension devices. Notify
maintenance personnel to adjust coal guide troughs.
c. Stop the equipment and remove coals adhered to rollers. If joints are not aligned, notify maintenance
personnel to re-connect belts.
d. Notify maintenance personnel to adjust axes of rollers and carrying rollers to parallel. Adjust inclined rollers.
e. Correctly use adjusting rollers. If they do not work and belts are severely off-tracking, report it to the shift
leader, stop the equipment and notify maintenance personnel to solve problems.
1.1.5.3.6 Belts are slipping. Main rollers smoke and have abnormal smell.
Causes:
a. Load is too large.
b. There is water on non-working surface of the belt.
18
c. The cast rubber of rollers is severely worn or suffers adhesive failure. Friction is small.
Handling:
a. Report it to the shift leader and notify the coal source personnel to reduce load.
b. Stop operation. Remove water and then start operation.
c. The balance weight contacts the ground or is loose. Tension structures are jammed. Notify maintenance
personnel to solve problems.
1.1.5.3.7 Belts are scratched and torn.
Causes:
a. Belts suffer severe off tracking and hit brackets so that belts are jammed between the roller and bracket.
b. Adjustment plates and liner plates come off or are impaled and cut by sharp metal items.
c. Foreign matters (coal, stone, or iron) are jammed between the belt and roller.
d. Belt joints are loose, rubber covering on the belt suffers adhesive failures, coal ploughs and wipers have
sharp burrs or rollers have foreign matters.
e. Iron plates of coal guide troughs contact belts.
Handling:
Stop the equipment immediately. Report the situation to the shift leader. If you find out the cause and cannot
solve problems, notify maintenance personnel to solve problems.
1.1.5.3.8 Belts are broken.
Causes:
a. The quality of belt joints is poor. There is severe wear and adhesive failure.
b. Operate with overload or start with load.
c. Coals are blocked in coal chutes. Materials are involved in return belts. Belts are jammed by foreign articles.
d. Height gap is too large and coals are too large so that belts are broken and torn.
Handling:
Stop the equipment immediately and find out the cause. Report the situation to the shift leader, and notify
maintenance personnel to solve problems.
1.1.5.3.9 Belts are worn partially and abnormally.
Causes:
a. Materials of large sizes pose impact on belts.
b. Belts are slipping or lump materials drop to return belts and are brought to rollers at the tail or are jammed
between the belt and roller.
c. Plastic baffles of coal guide troughs are too tough and there are foreign articles between the plastic baffle and
belt.
d. The pressure between the coal plough and belt is too large and belt quality is not qualified.
Handling:
Eliminate slipping or off tracking. Appropriately set rising and dropping degrees of coal ploughs. In case of
severe situations, stop the equipment, report it to the shift leader, and notify maintenance personnel to solve
problems.
1.1.5.3.10 Coal chutes are blocked.
Causes:
a. Coals have high viscosity.
b. There are large foreign articles or too many accumulated coals in the coal chutes.
c. Belts are slipping or belt speed is too slow.
d. Belt conveyors are overloaded and coal-retaining sheaths of the coal guide troughs are too wide so that flow
is reduced.
19
e. Front belt conveyors fail. They stop and do not work with rear conveyors.
f. The baffle is not in the correct position.
Handling:
Start vibrators immediately to eliminate blockage. In case of severe problems, stop the equipment immediately,
report it to the shift leader, and clean the coal chutes to operate with reduced load. In case of equipment failures,
notify maintenance personnel to solve problems.
1.1.6 General rules for the safety management of fuel coal handling system
1.1.6.1 Fire precaution measures of coal handling system
1.1.6.1.1 Strictly implement management standards of operating shift change, equipment routine inspection, and
equipment regular test and alternation, if there is coal leakage or powder leakage, it needs to clean up in time to
prevent spontaneous combustion. The floor of coal handling site should be flushed once each day. Coal handling
system which has not been used for long time, including accumulated coal and accumulated powder of belt
conveyor, coal chute and precipitator, should be clean up each shift; there should not be coal accumulated on the
belt to avoid spontaneous combustion of accumulated coal and powder.
1.1.6.1.2 There should be quarantine measures for flame operation above or near the coal conveyor belt.
1.1.6.1.3 Each shift should check whether fire water sprinkler, fire water curtain and deluge valves is lost or
damaged and record them. It must not use fire water to flush and remove ash.
1.1.6.1.4 When detonator is found on the coal conveyor belt, measures need to be taken to clean, if detonator can
not be cleared away, it should stop the belt and then handle it and avoid explosion accident caused by collision,
falling, extrusion or heat of detonator.
1.1.6.1.5 For the accumulated coal and powder which is cleaned to conveyor in coal handling site civilized
production, should start the equipment on time, accumulated coal and powder cleaned in civilized production
should not be cleaned to standby (overhaul) conveyor, and should not stay on the conveyor for more than 24 hours
to avoid spontaneous combustion caused by the cleaned accumulated coal and powder stack on the conveyor for
long time and avoid endangering the safe operation of coal handling system.
1.1.6.2 Prevention of coal pulverizing system explosion and coal dust explosion
1.1.6.2.1 Make sure the granularity of as fired coal is within the specified value range and monitor the quality of
as fired coal change within the design value range.
1.1.6.2.2 Monitor and prohibit untreated spontaneous combustion coal in coal yard to enter coal handling system
and raw coal hopper.
1.1.6.2.3 Put de-ironing separator into operation in accordance with the provisions to reduce and prevent against
as fired coal containing detonators. If a detonator is found on the last stage of coal conveyor belt, the belt should
be stopped immediately for treatment and avoid explosion accident caused by collision, falling, extrusion or heat
of the detonator.
1.1.6.3 Prevention of dam-failure, plant flooding and plant collapse
1.1.6.3.1 Strictly implement flood control, prevention and other relevant provisions of the country where the
project is located, each department of flood control organization should take its own duty strictly. It should check
before the flood season, prepare scientific, specific and realistic flood prevention plan; make summary timely after
the flood season, eliminate the hidden danger and report to the higher competent department.
1.1.6.3.2 Actively take effective measures to improve the predictability of flood control as well as the electric
equipment ability of defending and resisting floods.
1.1.6.3.3 Sewage pumps in the pits of all low zone pumps should be tested routinely to ensure they are in good
20
conditions.
1.1.6.3.4 In flood seasons, appropriate temporary sewage pumps should be prepared in the pits of all low zone
pumps and tested routinely to ensure they are in good condition.
1.1.6.3.5 Prepare enough necessary equipment and supplies for flood control and rescue.
1.1.6.3.6 Seriously check before flood season and focus on prevention of trestle water and drainage facilities of
component below zero meter, as well as plugging of all possible water channels. If there is leakage in above sites,
it should be reported and handled promptly.
1.1.6.4 Prevention of personal injury and death
1.1.6.4.1 Safety measures of works or workplaces must comply with the relevant requirements of Working
Regulation of Power Safety and Regulation of Safety Operation in Power Engineering Construction (DL5009.192).
1.1.6.4.2 Managers should pay great attention to personal safety, fulfill their security responsibilities seriously,
grasp various security measures and requirements of works seriously and comply with the safety rules and
regulations in an exemplary way. Have the courage to bear their responsibilities and exercise management no
matter what others might think, strictly require working personnel to implement safety rules and regulations and
strictly respect the labor principles, as well as regularly inspect in depth site to identify problems and make
rectification in time.
1.1.6.4.3 Safety and technical training of personnel should be provided to the staff routinely to improve their
security level of technical protection.
1.1.6.4.4 Strengthen the safety management of various contracted projects, define security responsibilities,
rigorously enforce management, improve security measures and strictly assess in accordance with relevant
regulations.
1.1.6.4.5 In preventing electric shock, fall, machine damage, burn, scald and etc. accidents, security organizational
measures and technical measures should be complement seriously, safety equipment and protective equipment
with high reliability qualified by national or provincial and ministerial level quality inspection agency should be
equipped. Improve security protection facilities of equipment to create reliable conditions for the safe operation in
measures and equipment. Eliminate unqualified apparatus and protective equipment to improve the safety level of
work.
1.1.6.5 Prevention of personal electric shock accident
1.1.6.5.1 Strictly implement worksheet system, operation permit system, operation guardianship system as well as
operation interruption, transfer and termination system.
1.1.6.5.2 Once the electrical equipment has been charged with electricity, the visible and correct electrified sign is
done, anyone on site should not shift or move the safety measures without permission.
1.1.6.5.3 If power failure occurs suddenly in charged operating process, the equipment should be regarded as
charged.
1.1.6.5.4 Strengthen the management of temporary power for maintenance and construction. There must be a firm
and safe low-voltage power pack, casual connection and wiring are prohibited and the case ground device of
electrical equipment must be qualified.
1.1.6.6 Prevention of personal injury and death in coal transport.
1.1.6.6.1 Strictly implement the system of two sheets, three systems and strictly forbid work without sheet.
1.1.6.6.2 Working personnel entered work site should dress as required with overalls up to the standard of threetight and helmet worn to be standard.
1.1.6.6.3 Regularly check fences, covers, ladders, holes of work site, once the breakage is found, it should be
repaired in time and appropriate safety precautions should be taken.
1.1.6.6.4 No spanning belt or crossing belt from underpart.
21
1.1.6.6.5 Take technological transformation measures to prevent the belt deviation, using wooden sticks or iron
bars to calibrate operating deviation belt is prohibited.
1.1.6.6.6 The start signal bell of coal conveyor belt must be loud and rings twice according to the caution, each
time is not less than 10 seconds, the interval of two bells is 30 seconds and equipment can be started after 10
seconds of the last bell.
1.1.6.6.7 In the emergencies that might happen and already have happened, endangering personal and safe
operation of equipment, anyone is entitled to issue a stop signal to ships and various vehicles entering the coal
handling and production areas and demand an immediate traffic halt.
1.1.6.7 Prevention of high-altitude drop and injury accidents of lifting and machinery.
1.1.6.7.1 High-altitude operation personnel must be in good health and start to work after getting three degree
safety education and medical qualification. High-altitude operation personnel must not drink and must have good
mental state before operation.
1.1.6.7.2 High-altitude operation must have a guardian.
1.1.6.7.3 When higher and lower parts of high-altitude operation conduct vertical cross-operation, there should be
tight security isolation measures between layers, security protection facilities should be checked and approved by
department and then put into operation.
1.1.6.7.4 Climbing operation must use the specified channel. Climbing in breach of regulation, standing on
unstable components to operate or move and sitting on the edge of holes to rest are strictly forbidden.
1.1.6.7.5 The shield of rotating machinery should be complete and sound.
1.1.6.7.6 Cleaning, wiping and lubricating the machine rotating and moving parts in operating process as well as
put hand into fences are prohibited.
1.1.6.7.7 When cleaning the fixed part of operating machine, the personnel must not wrap rag around hands or
figures to use it. Only when the rotating parts are no danger, the working personnel can refuel the bearing by oiler
and not to refuel in rotating.
1.1.6.7.8 Do not scatter rosin and other objects on belt by hand directly when the belt is rotating.
1.1.6.7.9 Install shield or fence for rotating parts of belt conveyor. Set fence on both side of the belt and cover the
exposed shaft end to avoid twisting clothes. Shields or other protective equipment is not allowed to remove from
the coupling and drive pulley in belt conveyor rotation.
1.1.6.7.10 Before the complete stop of the belt conveyor, maintenance is not allowed. The power supply of
equipment must be cut off before overhaul and hang a nameplate of No Switch on on the operating handle.
1.1.6.7.11 When manually sample coal on operating belt, there must be a specified personnel to monitor, working
personnel cuffs should be fastened in case twisting by the belt.
1.1.6.8 Prevention of burning and scalding accident.
1.1.6.8.1 Cotton overalls, cotton gloves and masks must be put on when connecting with or switch onto the hightemperature hot body and equipment might blow out high-temperature airflow and flame.
1.1.6.8.2 Do not stay at the high-temperature steam-water pipes, flanges and door levers for long time, and do not
stay at the blast doors and access openings for boiler flame for long time.
1.1.6.8.3 Do not overhauling or disassembly electrical equipment and heating facilities or equipment.
1.1.6.9 Prevention of significant environmental pollution accident
1.1.6.9.1 To prevent significant environmental pollution accident, laws, regulations, rules of the project country
should be conscientiously implemented.
1.1.6.9.2 Strengthen the supervision of each environmental protection facilities to make sure the perfectness ratio
is 95% and input ratio is 100% in case significant environmental pollution accident.
1.1.6.9.3 Regular water spray in the coal yard to prevent coal dust pollution, based on coal storage and external
environment.
22
1.1.6.9.4 Supervise and inspect the clean of operating environment (such as waste oil, waste water, waste material,
etc.) after overhaul and keep cleaning.
1.2 Vibration coal feeder

1.2.1Technical Specifications of vibrating coal grates
Picture of vibrating coal grates

Raw coal hopper underground vibrating coal grates
Vibrating of coal grates
Specifications Model
ZMBZXB-
Capacityt/h
6000t/h
Grates surface sizemm
54503950
Grates hole sizemm
500500
Weightkg
4167.51
Maximum exciting
forceKN
50KN
tilt angle
Vibrating motor model
VB-50234-W
23
Maximum Motor
PowerKW
2.25KW
Motor Speedr/min
1450r/min
1.2.1.1Use and Maintenance

1.2.1.1.1 Regular checks whether there is loosening fasteners, if locked in time.
1.2.1.1.2 Constant attention to moving parts and a fixed combination of office if there are anomalies.
1.2.1.1.3Spring is damaged, it shall promptly replace the springs, so as to avoid the accident generation.
1.2.1.1.4 Periodic inspection vibrating motor fastening bolts loosening and timely fastening.
1.2.2 Technical Specifications of vibration Coal Feeders
Raw coal emergency coal hopper underground vibration Coal Feeders

NO
name
Parameter
model
GZM-350
Material diameter
0500raw coal hopper

underground
050emergency coal hopper
underground
mm
Double amplitude
58
mm
Vibration frequency
16
Hz
Groove angle
10
Capacity
350
t/h
Motor
Unit
Model
Y132S-6 F
power
23
kw
voltage
400
Single maximum Dynamic load
3000
Single static load
10000
crude coal fine coal hopper underground vibration Coal Feeders

NO
name
parameter
model
GZM-250
Material diameter
050
24
Unit
mm
Double amplitude
58
mm
Vibration frequency
16
Hz
Groove angle
15
Capacity
250
t/h
Motor
Model
Y132S-6
power
23
kw
voltage
400
3000
Single static load
10000
Unit
Limestone coal hopper underground vibration Coal Feeders

NO
name
parameter
model
GZM-150
Material diameter
040
mm
Double amplitude
25
mm
Vibration frequency
25
Hz
Groove angle
15
Capacity
150
t/h
Motor
Model
YZO-17-4
power
20.75
kw
voltage
400
3000
Single static load
8000
25
1.2.3 Shift Inspection and Check Before Start-up

1.2.3.1 Check motor, vibration bottom of fastening bolts should be no loose, Motor leads and grounding wires
are firmly fixed.
1.2.3.2 Fastening bolts on couplers and bearing pedestals are complete and tight. Coupler shells are intact.
1.2.3.3 Check the electric hydraulic valve should be in the open position
1.2.3.4 Coal hoppers of feeders are not blocked. Coal drop pipe should be in good condition and there is no coal
leakage.
1.2.3.5 Change-over switches on the control box shall be complete and at the right position and buttons are
intact.
1.2.4 Local Operation Procedures
1.2.4.1 Switch the Remote-Local switch on the control box to Local position.
1.2.4.2 Press the start button on the control box to start the coal feeder.
1.2.4.3 Starting must start from static state. After shutdown, to make the operation of the vibration coal feeder shut
down completely, then start again.
1.2.4.4 Stop feeding and have enough time to make the feeding system of material from the eduction in coal
feeder, and then, again close coal feeder.
1.2.5 Notes during Operation
1.2.5.1 When coal feeder is running, check the status of material flow. The base must be spread evenly across the
wide range of the tub.
1.2.5.2 When run coal feeder, to check whether there is loose phenomenon in bolt or components. Before adjust
loose bolts or components, must make coal feeder stop operation, to avoid possible personal injury.
1.2.5.3 To check whether there is leakage in the coal feeder side or back, whether there is a chute blocking
phenomenon.
1.2.5.4 Check the spring, and whether there is material gathered around the spring coil, if necessary, can only
after downtime and disconnect power feeding system for too much out of the material, if the coal feeder each side
of the spring compression is not equal, check whether there is spring individual damage phenomenon.
1.2.5.5 Coal hoppers are not jammed and blocked. There is no coal leakage. There is no coal leakage due to break
of welded joints of hoppers. To regularly check the tub and clear adhesive material, in a timely manner to
complete the repair or replacement before failure occurred.
1.2.5.6. When running, check if there is a noise in exciter
1.2.5.7. Check if there is any loosen at the motor fastener,
1.2.5.8. Check whether there is motor bearing noise or too high working temperature.
1.2.6Common Failures and Handling
1.2.6.1 The coal feeder motor fails to rotate when start button is pressed
Causes:
aThere is no power supply.
26
bControl circuit wiring or fuse is damaged.

cOverload
Handing:
Check and startup by Light load. Report it to the shift leader and notify maintenance personnel to recover
failures.
1.2.6.2 Abnormal noise gradually obvious
Causes:
aThe bolt looseness
bBearing lack of grease or damaged
cSieve plate frame fracture
Handling:
Fasten the bolt Stop the coal feeder. Report it to the shift leader and notify maintenance personnel to
recover failures.
1.2.6.3 Coal feeder abnormal vibration
Causes:
a. Damper spring fatigue or damaged
Handling: Stop the coal feeder, Report it to the shift leader and notify maintenance personnel to recover
failures.
1.2.6.4Electric hydraulic gate no action
Causes:
a. Motor fault
b. Electric hydraulic gate pushrod fault
Handling: Stop the coal feeder, Report it to the shift leader and notify maintenance personnel to recover
failures.
1.2.7Maintaining the Vibrating Feeder for Coal
1.2.7.1The Vibrating Feeder for Coal is running at the burdensome conditions. And the running periods are
more than million times, and the material has a characteristic of abrasion and corrosion, so it is necessary that you
should repair any default or stoppage of equipment.
1.2.7.2You should comply with the Routine Checking Every Day and System Checking for 200 hours, so that
you can reduce the maintenance costs, reduce the production loss and increase the Working gains of equipment.
1.2.7.3Generally speaking, if it is running for 1000 hours, then you should check all the fastening bolts
whether they are loose or not.
1.2.7.4Generally speaking, you can use the bolts and nuts only one time, throw away the used fasteners, and
assemble the new bolts ,nuts and washers.
1.2.7.5 You should replace the composite springs in time.
1.2.7.6 The Vibrating Feeder for Coal should not be maintaining when it is running, or else, it will happen out
stoppage, so the checking schedule is not determined at the starting stage, however you should check them
frequently until you make a available checking schedule.
1.2.7.7 If storing the Exciter more than 6 months, you must change a new lubrication grease
1.2.7.8 If the exciter is working at the high temperature or the grease is dirty, then you can lubricate the exciter
or replace a better grade lubrication grease according to the Table .
1.2.7.9 If you shorten the lubrication periods or reduce the volume of grease, then you can extend the lifetime
27
of Exciter.
Table Check List of Lubrication Grease
Lubrication Type
1# molybdenum
lubricating grease
Importing Lubrication Grease Type
SHELL
MOBILUX EP2
Supplying Grease Periods
50 h
Lubrication Grease Volume/Set
800 g
disulfide
ALVANIA
Li+
grease
2/MOBIL
1.3 Filtering Equipment

1.3.1 High amplitude vibration screen
1.3.1.1Technical Specifications of High amplitude vibration screen

1
Model
GFS-X-500
feeding size
50
mm
Discharge size
10
mm
Screen surface inclination
25
Capacity
500
t/h
Screen holes
10
mm
motor
model
Y180L-8 IP55 F class
power
113
kw
turn
730
r/min
voltage
400/230
NO
amplitude
15-25
mm
Maximum weight lifting
3000
kg
Maximum single weight maintenance
2200
kg
570623962275
mm
Maximum single size
1.3.1.1.2Technical Specifications of High amplitude vibration fine screen

1
Model
GFS-X-500
28
feeding size
10
mm
Discharge size
10
mm
Screen surface inclination
20-22
Capacity
500
t/h
Screen holes
10
mm
motor
model
Y180L-8 IP55 Fclass
power
113
kw
turn
730
r/min
voltage
400/230
NO
amplitude
15-25
mm
Maximum weight lifting
3000
kg
Maximum single weight maintenance
2200
kg
570623962275
mm
Maximum single size
1.3.1.2 Shift inspection and check before start-up

1.3.1.2.1 Fastening bolts on bases of motors and vibration exciter must be secure. Motor leads and grounding
wires are firmly fixed.
1.3.1.2.2 Fastening bolts on couplers and bearing pedestals are complete and tight. Coupler shells are intact.
1.3.1.2.3 Open the inspection door to confirm that there are no accumulated coals on the screen surface. The
screen shall be intact and screen shaft is not jammed.
1.3.1.2.4 Coal chutes are free from severe coal adhesion. Baffles are in correct positions and can be operated
flexibly. Each limit switch is intact.
1.3.1.2.5 Change-over switches on the control box shall be complete and at the right position and buttons are
intact.
1.3.1.3 Local operation procedures
1.3.1.3.1 Switch the control mode switch over to local control mode.
1.3.1.3.2 After the coal crusher operates normally, press the "Start" button to start the vibration screen.
1.3.1.3.3 After operation, press the "Stop" button to stop the vibration screen.
1.3.1.4 Local operation notice
1.3.1.4.1 During normal operation, the vibration screen is controlled from the control room. Without the
approval of the shift leader, and chief attendant or no emergency circumstances threatening personal safety, do not
stop the vibration screen through local operation arbitrarily.
1.3.1.4.2 When the operating system is running, vibration screen should start after the coal crusher starts and
before the belt conveyor starts. It should be stopped 5 minutes after c4 belt conveyor stops.
1.3.1.4.3 The vibration screen should not start with load. If there are coals on the screen surface, manually
29
remove coals before operation.

1.3.1.4.4 Stop the equipment with heavy load is not allowed except in special cases. If you have to stop the
equipment in special cases, stop feeding first.
1.3.1.5 Notes for operation
1.3.1.5.1 When the screen is running, check the status of coal.Primer must be evenly spread over the full width
of the sieve. After the equipment stops, personnel on duty shall immediately check whether the screen is jammed
by foreign articles. If it is jammed, remove foreign articles.
1.3.1.5.2 When the screen is running, check whether the bolt or component loosening. Before adjusting the
loose bolt or member, the screen must stop running, Avoid possible personal injury
1.3.1.5.3 Check if the sieve side and back have coal leakage or block . The screen shaft should be flexible and
run smoothly. There is no abnormal noise and vibration. During operation, if the screen shaft does not run
smoothly or is jammed and there are severe abnormal noises, stop the equipment immediately for check. After
failures are recovered, restart the equipment.
1.3.1.5.4 Check the spring, around the spring if there are coal gathered, If necessaryClear up the coal After
shutdown and power off the system If each side of the compression spring inequality, check whether the
individual damage spring phenomenon.
1.3.1.5.5 When operating, check if the exciter noise.
1.3.1.5.6 During operation, the motor mount is firmly fixed and there is no abnormal vibration and noise. The
motor housing is free from overheating and noise.If the vibration screen or coal crusher fails, open the bypass
door immediately and release interlocking. Then stop the vibration screen or coal crusher. This aims to prevent
belt conveyors from being stopped due to overload.
1.3.1.6 Cause and handling of faults
1.3.1.6.1 The motor fails to rotate when the start button is pressed
Causes:
Causes:
a. Power line barrier.
b. Motor is blocking
c. The load is over
d.The motor is faulty.
Handling:
a. Press the stop button. Report the situation to the shift leader, and notify maintenance personnel to solve
problems.
b. Clear off the blocking
c. Start it in a light load
d. notify maintenance personnel to solve problems.
1.3.1.6.2the sizes passed the screen meshes are larger than the common size.
Causes:
a. Wear the screen meshes badly.
b. The connecting sections of screen decks had been worn badly.
Handling:
Report the situation to the shift leader, and notify maintenance personnel to solve problems.
1.3.1.6.3 The abnormal noise is louder and louder
Causes:
a. The bolts are loose
b. The bearing are short of grease of worn out
30
c. The screen decks are broken

Handling:
a. screw the bolts again
b. add the lubrication grease or change them
c. Repair the screen decks or change them
1.3.1.6.4the vibration screen vibrates abnormally
Causes:
a. The insulating springs are fatigued or broken
Handling:
a.Report the situation to the shift leader, and notify maintenance personnel to solve problems.
1.3.2 double-roll coal crusher
1Motor 2Coupler cover 3Reducer 4Coupling cover 5Base 6Hydraulic coupler 7Dry oil
pump 8Coupling 9Side rack 10Adjusting mechanism of the lower toothed rollers 11Bearing pedestal
of the rollers 12Flipping oil tube 13Distributing device
HLPMB0510-800 Double Roller Crusher
1.3.2.1 Technical specifications of the equipment
Model
HLPMB0510-800
Capacity
Granularity of feeding material
800
500
Granularity of discharging material
mm
mm
50
Material to be crushed
rollers
t/h
coal
Lubricating system
model
Automatic refueling
Distributor model
Straight plate
diameter
840
31
mm
length
Truss plate
motor
1500
material
mm
High manganese steel
life
10000
Interferences value
6000
static load
25000
Kg
Dynamic load
30000
Kg
connection
bolt
model
Y3-315L1-4WF2
power
160
KW
Synchronous speed
1480
r/min
voltage
400
current
270.4
Hydraulic
coupler
model
YOXE560
Speed reducer
model
H2SH10-18
crusher
shape
565026422642+1530
mm
weight
About 25000
Kg
1.3.2.2Handover inspection and check before start-up

1.3.2.2.1First in the oil tank of the oil pump to join the right amount (80% capacity) grease, check whether the
normal operation of the lubricating oil pump.Check whether screws of the crusher, motor base, and baffle are
loose and broken.
1.3.2.2.2Check the main motor rotation direction, check all sensors are sensitive, various electric instrument
display is normal. Check whether motor wiring and grounding is good.
1.3.2.2.3Check the crusher work cavity and the moving parts, make sure there are no installation or maintenance
waste retained inside the equipment, manual move teeth roll at least once, to ensure no scratch and jam
phenomenon. Note: to remove legacy waste, to prevent possible damage to crusher equipment or accessories.
1.3.2.2.4Check reducer oil level is in line with the requirements; Check whether the connecting bolt fastened.
1.3.2.2.5Check the oil level flip station tank meets the requirements; If there is a oil leakage; Start the oil pump
check the direction of rotation is correct. Flip area must be determined no person before flip! When first turning,
cylinder rod cavity must exhaust, Or else side frames will flip the impact damage.
Note: the joint bolt of side frame must first be removed before reverse, after flip connecting bolts must be put
back!
1.3.2.2.6Buttons and change-over switches on the local control box shall be complete and at the right position
with indicating lamp free of damage.
1.3.2.3Local operation procedures
1.3.2.3.1Put this local/commissioning/remote control switch to "Local"position, close the circuit breaker, (if have
the power on /off button, then need to press the power button), indicating lamp of power source on, indicating
lamp of local on,and the system is ready.
1.3.2.3.2Before start the crusher, first need to start the crusher discharging system, after starting finish and running
normal ,then start the crusher. After the crusher discharging system run in normal, press the 1 # start button of
32
main crusher control, system go in 1 # motor in mot start, after start a certain time automatically switch to run full
pressure (if directly start then direct to full pressure) and 1 # motor running indicator on; Then press the start
button # 2 , the system go into the 2 # main motor start, start after a certain time automatically switches to run full
pressure (if directly start then direct to full pressure)) and 2 # main motor running indicator on, 1 #, 2 # main
motor after normal operation, press the charge distributor start button, the charge distributor run indicator on,
crusher entered into a state of normal operation.
1.3.2.3.3Outage process : "charge stop" "2 # main motor stop", "1 # main motor stop", every operated
indicator lights off, after crusher roller full stopped, (if have the power on /off button, it need to press the stop
button), cut the power supply, power indicator light off, crusher machine stop. Note: A,if 1 motor breaker, startstop, no 2 # host and related description; B, mechanical configuration has vibration charge distributor, the case is
related to the charge distributor start-stop and related description.
1.3.2.4.5It is strictly prohibited in the operation of the sieve plate to adjust clearance, it is forbidden to open the
de-ironing gate and the inspection door, it is forbidden to Start/Stop the coal crusher with load, it should not stay
near the inspection door and de-ironing gate. It Is not allowed to have large metal block with more than 150 mm
in diameter in the coal .
1.3.2.4.6During the running with load should be gradually increase the amount of material to achieve the rated
capacity, this machine is not allowed to randomly change the speed of the rotor, shall not exceed the rated output,
don't increase the coal flow.
1.3.2.4.7During the operation of equipment, not allowed to make any adjustment, shall not be used rods or
other similar tool dial feed port and discharging port and the materials crushing cavity. Operation of equipment or
not to cut off the power supply equipment, are not allowed to climb, across, or standing on the equipment, not
allow for any form of repair work. it should pay attention to the motor shell and bearing temperature in the
operation ,it should not exceed 80 , coal crusher vibration should be below 0.1 mm, the rash move below 0.5
mm.
1.3.2.4.8Pay close attention to feed particle size and feed rate during equipment operation, large materials are
not permitted to enter and overload operation. Discharge size shall conform to specified requirements (30 mm) or
less.
1.3.2.4.9Unless abnormal shutdown, it should according to the program to stop feeding, after crushing cavity
material crushed then to stop the crusher. after Abnormal shutdown, should through open side of hydraulic
pressure flip system, inching inversion tooth roller, discharge the crushing cavity material, so that next time can
normal start device, connecting bolts must first be removed before side frame flip , it must be installed fastening
bolts after side frame reset If found have abnormal situation in operating, endangers personal and equipment
safety, should immediately press the "stop" button on the operation box, emergency stop coal crusher .
1.3.2.5Cause and handling of crusher faults
1.3.2.5.1crusher heavy vibration during operation
Causes
aAnchor bolt looseness.
bMotor and reducer are not concentric.
cTeeth roll and coupling are not concentric .
handling : nut tightening around the foot, adjust the motor and reducer concentric, adjust the tooth roll and
coupling of concentric, if in critical condition, should immediately stop the coal crusher operation.
1.3.2.5.2Bearing temperature is high
Causes
a. Badness lubrication
b.Teeth roll and coupling are not concentric
33
c.Overlord
Processing: check to ensure good lubrication of the bearing, adjust the tooth roll and reducer concentric, ensure
not overload operation. Pay close attention to the equipment situation, stop running when necessary, notify the
maintenance personnel processing.
1.3.2.5.3Teeth roll locked-rotor (motor convertible, toothed roller not turn) :
Causes
a. The larger between teeth roll were not broken foreign bodies (like iron).
b. Incoming material is too large, overload.
c. Equipment loading start.
Removal treatment: flip side frame, and flip side frame, remove material accumulation, the clear material, no-load
startup.
1.3.2.5.4Equipment running internal sound
Causes
a. The superhard between teeth were foreign body.
b. Broken tooth plate is loose.
c. Tooth plate and the broken tooth brush touch
Processing: removal, tighten the connecting bolt at the broken tooth plate, work under the adjustment of vice.
1.3.2.5.5Discharging granularity:
Cause
a. Broken tooth plate wear too much.
b. Downside broken tooth wear is too big.
c. Downside auxiliary work position is too low
Handing:Replace the broken tooth plate, replace the broken toothAdjust and rise the downside auxiliary work
position
1.3.2.6Routine maintenance
1.3.2.6.1 Inspect the connecting bolts often and fasten them in time. Inspect the connecting bolts of the crushing
teeth regularly (every month) to make sure that there wont be loose and falling phenomenon for the crushing
teeth causing equipment failures and safety accidents.
1.3.2.6.2Inspect regularly whether each sensor is sensitive and each electrical instrument is in good condition or
not.
1.3.2.6.3Inspect regularly (every week) whether lubrication oil in the oil bunker of the automatic lubricating dry
oil pump is enough or not. Replenish it in time or change the lubrication oil according to the temperature. See the
lubricating chart.
1.3.2.6.4Inspect regularly (every month) the left volume of the lubrication oil of the reducer. Change the oil
according to the requirements of the operation instructions of the reducer.
1.3.2.6.5Inspect regularly (every month) the oil level of the oil bunker of the flipping oil station. Inspect whether
theres oil leaking at each connection of the oil pipe.
1.3.2.6.6Inspect and adjust regularly to make sure that the concentricity of the spindle of the crusher, input shaft of
the motor and reducer meets the requirement.
1.3.2.6.7When you hear an unusual sound from the machine, you should shut it down first for careful examination
to determine the original position of it. The machine could be restarted only when the unusual sound is eliminated.
1.3.2.6.8Inspect the lubrication system regularly to ensure its normal work.
1.3.2.6.9When the equipment is running or the power hasnt been cut off, any overhaul job is forbidden.
1.3.2.6.10After debugging and overhauling, try no load test running at first, and then the equipment can run again.
Note: in normal condition, after 5000 hours running, the bearings and bearing pedestals should be washed
34
completely with kerosene. Then, add about half of the volume of the bearings new lubrication oil in (according to
the lubrication oil chart).
lubrication chart
Lubrication position
Lubrication oil
Standard
number
Major bearing
lithium
grease
GB7324-2010
base
code
Lubrication
period
Lubrication
method
300hours
by
oil
pump/grease gun
1.3.3 Fine crusher

Picture of fine crusher
1.3.3.1 Technical specifications
SPM-1618
unit
375
50
10
1600
1800
t/h
mm
mm
mm
mm
60(can be adjust)
30
m/s
kN
productivity
Granularity of feeding material
Granularity of discharging material
diameter
Rotor
Breaking length
Line speed
Interferences value
hammerhead
columns
quantity
weight of the fine crusher
shape
model
12
84
25800
3358*3700*2150
YKK4503-4
35
kg
mm*mm*mm
motor
Hydraulic coupler
power
speed
voltage
type
speed
Power range
effectiveness
560
1486
6.6
YOTchj650
1500
290-760
95%
kW
rpm
kV
rpm
kW
1.3.3.2 Handover inspection and check before start-up

1.3.3.2.1 Check whether the crusher is maintained and whether there are warning signs on the local operation
box.
1.3.3.2.2 The ground wire of the motor shall be intact and the anchor screws shall be secure.
1.3.3.2.3 Check whether connecting bolts are loose.
1.3.3.2.4 There are no foreign articles in the screen of the fine crusher. There are no sundries nearby the air
outlet of the motor. The observation door is intact and tightly closed.
1.3.3.2.5 There are no foreign articles and accumulated coals on the fixed inclined surface.
1.3.3.2.6 Indicators on the field control box are intact and the option switch is switched to correct positions
(in case of programmable control or manual operation under programmable control, the option switch is switched
to Programmable control and the starting switch is switched to the Stop position).
1.3.3.2.7 The fabric baffle shall be at the "Coal Crusher On" position.
1.3.3.2.8 The oil level at all lubricating points is normal and the oil quality is qualified.
1.3.3.2.9 Safety doors and observation holes are closed tightly.
1.3.3.2.10 Working places are clean, the illumination is sufficient, and all devices are in good condition.
1.3.3.3 Local operation procedures
1.3.3.3.1 Switch the control mode switch on the local control box to local position.
1.3.3.1.2 Press the local Start button of the fine crusher.
1.3.3.1.3 Manually stop operation.
Press the local "Stop" button of the fine crusher to stop the fine crusher.
1.3.3.4 Precautions for operation and maintenance
1.3.3.4.1 Without the permission of the Assistant Chief Engineer, do not disable safety protection devices of
the fine crusher. Otherwise, it is forbidden to start the crusher.
1.3.3.4.2 Observation holes at joint surfaces of the fine crusher shall be free from coal leakage and powder
leakage.
1.3.3.4.3 Each time the equipment is stopped after operation, take necessary safety protection measures to
clean accumulated coals, iron articles and stones inside the equipment.
1.3.3.4.4 Coal feeding is uniform. No large metal blocks, wooden blocks and other sundries are allowed in
the crusher.
1.3.3.4.5 During operation, carefully observe indications of the ammeter of the fine crusher. The bearing
temperature should not exceed 80 degree. Vibration should be within the normal range.
1.3.3.4.6 Do not start the crusher with load. Load coals only after the fine crusher reaches the speed of
service. In case of shutdown due to overload (shutdown due to faults) during operation, remove accumulated coals
inside the equipment to avoid damages to the equipment.
1.3.3.4.5 It is forbidden to open inspection doors during operation. Do not clean the equipment during
operation. Do not clime on or stand on the body of the operating equipment.
36
1.3.3.4.6 When you need to clean the inside of the fine crusher, you should go through formalities for power
outage overhaul.
1.3.3.4.7 Material feeding of the fine crusher should be uniform. Otherwise, the wear of the rotor is not
uniform. This will cause unbalance and vibration.
1.3.3.4.8 During the operation of the crusher, the iron separator must run properly to separate iron well.
Therefore, iron articles cannot enter the crusher, thereby avoiding damages to the equipment.
1.3.3.4.9 The inner of the fine crusher shall have a micro positive pressure and the dust remover must run
properly to ensure civilized production on site.
1.3.3.5 Under the following conditions, stop the equipment immediately.
1.3.3.5.1 The fine crusher has a coal jam.
1.3.3.5.2 The fine crusher has loud metal crash sounds and the fine crusher suffers severe overcurrent.
1.3.3.5.3 The vibration of the fine crusher exceeds limits.
1.3.3.5.4 The temperature of the fine crusher bearing and motor bearing exceeds limits.
1.3.3.6 Cause and handling of common faults
1.3.3.6.1 The fine crusher vibrates abnormally.
1.3.3.6.1.1 Causes:
a. Feeding is not uniform so that the hammer ring loses balance due to uneven abrasion. The hammer ring
and collared shaft lose balance.
b. Unbalance occurs due to other reasons.
1.3.3.6.1.2 Handling:
a. Adjust the coal feeding device.
b. Find out the cause and solve problems.
1.3.3.6.2 Bearing temperature exceeds 80.
1.3.3.6.2.1 Causes:
a. Clearance between rolling bearings is too small.
b. The lubricating grease is dirty.
c. The lubricating grease is insufficient.
1.3.3.6.2.2 Handling:
a. Change a bearing with big back lash.
b. Fasten screws on the bearing pedestal.
c. Fill in lubricating grease.
1.3.3.6.3 There are continuous tapping sounds in the coal crusher chamber.
1.3.3.6.3.1 Causes:
a. Foreign matters not easily crushed enters into the chamber.
b. The bearing wears to a great extent.
1.3.3.6.3.2 Handling:
a. Remove foreign matters.
b. Replace the bearing.
1.3.3.6.4 The yield significantly decreases.
1.3.3.6.4.1 Causes:
a. Feeding is not uniform.
b. The screen plate holes are blocked.
1.3.3.6.4.2 Handling:
a. Readjust the feeding mechanism.
b. Clean the screen plate mesh and check contents of moisture and ash in the coal.
37
1.3.3.6.5 The motor current exceeds limits.

1.3.3.6.5.1 Causes:
a. Coals have high viscosity.
b. There are foreign articles or accumulated coals in the equipment.
c. The outlet is blocked.
1.3.3.6.5.2 Handling:
a. Reduce the output.
b. Stop the equipment and remove foreign articles or accumulated coals in the equipment.
c. Clear the outlet.
1.3.3.7Lubricating Grease, Lubricating Cycle and Lubricating Grease Fill
1.3.3.7.1Brand of Lubricating Grease: No. 3 MoS2 lithium-based lubricating grease (type of replacement
grease: SHELL,GADUS,S3V460D2 or other equivalent lubricating grease with same performance indexes).
1.3.3.7.2Lubricating grease must be clean. The lubricating grease in the bearing seat should be replaced for
every 3 6 months. Grease refill is approximately 1/3 2/3 space of grease chamber. In case that the bearing
temperature in replacement cycle rises gradually, it is allowed to refill 500g lubricating grease for one time.
1.3.4VariabIe speed Coupling
1.3.4.1The whole machine should be ok and all the protect cover have finished.
1.3.4.2To check the oil level is in Max level
1.3.4.3check the coupling
1.3.4.4As the rotation direction has been determined during assembly the motor&working machine must be
checked to rotate at the same direction at the first time of start up
1.3.4.5To check the flexibility and accuracy of electric actuator
1.3.4.6The input&output shaft is not allowed to vibrate during rotation
1.3.4.7leakage is not a11owed at any parts
1.3.4.8To open the water valve of coo1er ensuring the water flow speed is higher than 0.8m/s
1.3.4.9The scoop tube must be adjusted to 0% when the coupling is started or stopped
1.3.4.10 When running and the load is centrifugal,if out-put speed reach 60 70% of the in-put speed,The
max thermal load will appear;if the load is constant torque,the thermal load will be maximum when the out-put
speed is minimum.
1.3.4.11The working temperature of coupling must be between 45C~88C It is not allowed to exceed 88C
The best working temperature is 70C5C To se1ect cooler according to the above figure so that the
temperature of oil drained by scoop tube doesnt exceed 95C on The max thermal load To observe the oil
temperature until leve1 off
1.3.4.12\Record the status of the equipment in the whole running time.ensure the pressure and temperature of
oil kept in the predetermined value .coupling is monitored by monitoring equipment
1.3.4.13If the actual condition is different to the assumption,the dimension of inlet baffle or oi1 or
orifice shou1d be changed
1.3.4.14In principle,the machine can be turned off at any scoop tube position If turned off at 0%, the motor
may turn to the speed of empty
1.3.4.15 Long rotation of coupling should be avoided after turn off
38
1.3.5Measures to be taken at standstill periods or at stand by operation

1.3.5.1 If the plant is shutdown for long period,protect the coupling against water ingress and
moisture.preserve bright parts are accordingly
1.3.5.2For protection against corrosion of inner parts run the variable speed couplings for a short
time,at least 1 to 2 months,to wet the inner part with oil.
1.3.6Maintenance intervals and Measures to be taken
1.3.6.1measurea can be taken when unit is running

Check display of all thermometers and pressure gauges during start-up and normal operation in accordance with
the oil circuit and measuring points scheme record values for subsequent comparison.
After 100 operation hours,record and compare the displays of all thermometers and pressure gauges
After 500 operation hours,measure record and compare noise pattern and smooth running(vibration) under same
operating conditions in each case.Irregular r may refer to bearing damage or misalignment.Find out and remove
the cause.
1.3.6.2Measures can only be taken when the unit is at operation
1.3.6.2.1weekly.
Check oil level. The oil level can not be too low. check the operation oil for water content. Find out and remove
the cause of water content.separate or change the oil
1.3.6.2.2 After 100 operating hours
Clean lube oil filter
Clean vent filter
Check smooth running of the actuator,check the end stops grease the articulated joints and exposed parts
Clean oil cooler, if necessary,following manufactures instructions
Check piping and grease oil-lubricated connecting coupling for leaks
Check the operating oil for impurities and condensation water,centrifuge and filter if necessary
Clean the lube oil filter.clean vent filter and wet with oil.check piping and connecting couplings for leaks.
All as after 500 operating hours
Check the quality of working oil,if oil quality is substandard,change the oil6
1.3.6.2.6 check the coupling ,motor and working machine correction and check if the foundation is safe
1.4 Auxiliary equipment

1.4.1 unload car unloader
1.4.1.1 Technical specifications of unload car unloader
Double
Brake motors
Power
39
7.5KW
speed braked
motor drive
Reducer
Speed
1480r/min
Model
LHYM10-4E175-AVY1-B
Speed ratio
151
Total transmission ratio
151
Trolley speed
0.32m
Belt length Increase
10mm
Tread
5210mm
Gauge
1840mm
Height difference between Rail top surface and the theory surface
60mm
The rail type
24kg/m
Maximum wheel load
6000kg
Total weight
18713kg
The belt width of the unloaders is B=1200mmbelt speed V=2.5m/s

1.4..1.2 Handover inspection and check before start-up
1.4..1.2.1 Check the integrity of the walking body ,coupling protection cover complete
1.4..1.2.2 Check the walking mechanism should be straight firm,travel agencies and track surface contact is
good ,there is no obstacles and track derailment wear phenomenon.
1.4..1.2.3 Check coal hoppers should be free from coal adhesion and blockage the position of the baffle is
correct
1.4..1.2.4 Check coal levels in coal bunkers.
1.4..1.3 Operation procedure for start-up and stop
Unload car support three control modes: Local, Programmable control and Interlocking.
1.4..1.3.1 Local operation procedures
a.Switch on the power switch. Preset the unload car based on the operating status of the boiler pulverizing
system and coal levels in bunkers.
b.After belt conveyors run properly, press unload car moves to the correct place and carry out coal blending.
c.After the coal level in the coal bunker reaches a high level,operate the button of unload car to the middle
position to make unload car to the next bunker that needs coal blending.
1.4..1.3.2 Operation procedures of programmable control
a.Preset the unload car based on the operating status of the boiler pulverizing system and coal levels in bunkers.
b.After belt conveyors run properly, press the switch of the baffle on the console to bypassposition ,then the
unload car automatically carry out coal blending.
c.After the coal level in the coal bunker reaches a high level,operate the button of unload car to the middle
position to make unload car to the next bunker that needs coal blending.
1.4..1.3.3 Interlocking control
40
The position of the baffle of the unload car are automatically controlled by coal level signals from the meter of
the coal level in the bunker.
1.4..1.4. Precautions
1.4..1.4.1 During normal operation,the unload car is controlled from the control room. Without the approval of
the shift leader, and programmable control duty person or no emergency circumstances threatening personal safety
and equipment, do not perform local operations arbitrarily.
1.4.1.4.2Pay attention to coal levels in coal bunkers. In case of coal leakage at coal receiving hoppers, operate
the baffle position immediately to prevent coal leakage.
1.4.1.4.3When lowering the unload car, the lower edge should just contact with the coal scuttle. It shall not
compact too tightly or not in the position to prevent damage to the rubber belt or coal leak.
1.4.1.4.4When loading coals, preset the unload car in advance.During operation,make the baffle to the middle
position ,when traveling to the required coal bunker,make the baffle to the position of the bypass
1.4.1.4.5If the linear actuator cannot stretch out and draw back freely during operation and the motor has
abnormal noises, press the stop button immediately to stop operation.
1.4.1.4.6 Prohibit the operation of the handle and tools and debris on the running track
1.4.1.5 Accident handling
1.4.1.5.1During operation, the coal bunker is full and the baffle position cannot operate.
Causes:
a.The fuse in the distributor is damaged.
b.The wiring circuit of the linear actuator is faulty.
c. The button is in poor contact or faulty.
d.The connecting pin between the linear actuator and baffle is damaged so that they are disconnected.
Handling: stop belt conveyors immediately and report the situation to the shift leader for handling.
1.4.1.5.2 Operate the walk button,unload car cannot go
Causes:
a. Motor fuse failure in running mechanism
b. Travel agencies or control loop wiring loose,broken
c. Shaft coupling between motor and speed reducer or speed reducer and ruing gear is broken.
d. There is a foreign body or track deformation on the track,resulting in blocking resistance
Treatment:
Stop the operation. Report it to the shift leader and notify maintenance personnel to recover failures.
1.4.1.5.3 Insitu slip or wheel derailment
Causes:
a. Foreign body blocking
b. There is oil or water on the track
Handling:
a.Stop the car and clean the stuck object
b.Clean oil or water or spread some water to the track
1.4.2
Belt-type electromagnetic iron-separator
1.4..2.1
RCDFJ-1012Belt-type electromagnetic iron-separator
1.4..2.1.1 Technical specification

a. electric control equipment:
41
Model: KGLA-300/30 silicon controlled rectifier control box

Input voltage: 380V Output voltage: 300V (DC) Output current: 30A (DC)
b.
Parameters of iron separator

NO
Item
Parameter
Model
RCDFJ-1012
Applicable conveyor belt width (mm)
1000mm
Applicable conveyor belt speed (m/s)
5.8m/s
Rated suspension height (mm)
Excitation power (KW)
14.8kw
Excitation voltage (V)
540V
Excitation current (A)
27.4A
Maximum magnetic induction intensity of the pole center
300
120mT
corresponding to the rated suspension height (>/= MT)

9
Power of driving motor +power of oil pump
4+1kw
10
Motor voltage (V)
380V
11
Motor current (A)
30A
12
Total weight
13
Overall dimensions
14
Manufacturer
3820kg
317018311540mm
Shandong
huate
magnetoelectricity
technology co., LTD

1.4..2.1.2 Handover inspection and check before start-up
1.4..2.1.2.1 Check whether the steel belt is broken and the roller is complete and gets stuck.
1.4..2.1.2.2 Check whether the bolt of each part is loose or falls off.
1.4..2.1.2.3 Check whether the suspension device is loose, broken or transformed.
1.4..2.1.2.4 Check whether the lubrication oil of speed reducer is good in quality and oil level is normal (the oil
level shall not be 1/3 lower than the oil lens).
1.4.2.1.2.5 Button and change-over switch on the local control box shall be complete and at the right position
with indicating lamp free of damage.
1.4..2.1.3 Operation steps for belt-type electromagnetic iron separator
1.4.2.1.3.1 Local operation procedures
a. Before use, set the voltage regulation button on the control cabinet panel to Zero by turning the button
anticlockwise to the end, and turn the main power switch QF to the OFF position.
b. In case of local control, turn the selection switch SA to the Local position, turn on the main power switch
QF (Power" indicator lights up), and press the Belt Rotation button to allow the belt of iron separator to rotate
normally (Belt Rotation indicator lights up).
c. Press the Excitation button (Excitation indicator lights up), and slowly turn the Voltage Regulation
button on the control cabinet panel clockwise to increase the voltage to 180V. Then, the iron separator can work
normally.
d. To stop the excitation, press Stop Excitation button (the iron separator stops the excitation operation and
the Excitation indicator lights off), and then press Stop Belt Rotation button (the iron separator stops the belt
rotation operation and the Belt Rotation indicator lights off).
1.4.2.1.3.2 Operation procedures of programmable control (separately start the iron separator during starting
42
the procedure)
a. Turn the selection switch to Remote position and switch on the power switch QF.
b. Press the Start button for the iron separator on the control panel. Then, the operation indicator lights
up, iron separator enters the automatic excitation mode, and belt enters the automatic rotation mode.
c. To stop, press the Stop button for the iron separator on the control panel. Then, the operation indicator
lights off, iron separator stops the excitation operation automatically, and belt stops rotating automatically.
1.4.2.1.3.3
Interlock control
Turn the selection switch to Interlock position and turn on the main power switch. Then, the belt carrying
the iron separator is started and the iron separator works. When the belt carrying the iron separator is stopped, the
iron separator stops. (Note: When the iron separator works, the belt conveyor does not work).
1.4.2.1.4
Precautions for operation
1.4..2.1.4.1
In normal circumstances, belt-type electromagnetic iron separator is operated by the operator on
duty in main control room.
1.4.2.1.4.2 Check the oil level to make sure the level in the oil standard calibration position before starting . And
power switch in turn , start the excitation circuit , check the direction and flow indicator of the fan and make sure
thats right. Otherwise , adjust the electrical wiring of the fan and pump.
1.4.2.1.4.3 If start the iron-separator, must make sure its no load .So start the iron-separator belt first , and then
start the materials conveyer. You should make sure the materials conveyer no running before stop the ironseparator belt.
1.4.2.1.4.4 If the big stuff block the lump coal or make the coal overflow.
The operator should stop the equipment and notice the equipment repairman to handle.
1.4.2.1.4.5 Note, the rotation direction of the steel belt and the discard iron direction should be in the opposite
direction.
1.4.2.1.4.6 The iron-separator field winding cooling way is natural cooling way, so we should keep it clean for
heat dissipation. Magnetic system are not allowed to remove, so as not to damage the overall performance of the
magnetic system
1.4.2.1.4.7 If you found the ilicon-controlled fuse is broken, should be identified and troubleshooting, can change
into the same specifications of the molten core, in order to avoid accident
1.4.2.1.4.8 You should check and make sure the oil temperature of the reduction gears lower than 40
1.4.2.1.4.9 It is forbidden to touch the iron-separator with the iron things, in case of accidents. No one shall be
close to the front of the steel belt in the normal operation . in case of accidents.
1.4.2.1.5
Cause and handling of common fault
1.4.2.1.5.1 After the power is switched on and the Start button is pressed, the machine does not work or the
machine works but without excitation.
Causes:
a. The button is in poor contact.
b. Fuse is broken.
c. Control circuit fuse is broken.
Handling:
Carry out overall inspection and report to the group chief for contact and repair.
1.4.2.1.5.2 After the power is switched on, the iron separator can be started and operated, but the automatic
control switch trips after excitation is started.
Causes:
a. Silicon rectifier is broken down and the voltmeter indication is abnormal.
b. DC side is short circuited and current indication is abnormal.
43
Handling:
a. Replace the silicon rectifier.
b. Repair the DC excitation circuit.
1.4.2.1.5.3 Temperature of motor reducer casing increases with abnormal noise.
Causes:
a. Motor is overloaded or bearing is broken.
b. The cycloidal-pin gear in reducer casing is severely worn.
c. No oil is in the reducer.
Handling:
a. Check whether the belt is get stuck with debris, remove the debris if any, and replace the bearing.
b. Replace the cycloidal-pin gear.
c. Fill oil for the reducer to the specified level.
1.4.2.1.5.4 Iron suction capacity less
Reason
a:Suspension height or inclinations changed
Handling
a. Adjust the suspension height or inclinations
1.4.3
Disk-type electromagnetic iron separator
1.4.3.1
Equipment specification
NO
Item
Parameter
Model
RCDEJ-10T4
Applicable belt width (mm)
1000mm
Applicable conveyor belt speed (m/s)
3.15m/s
Manual monorail car models
DX-5
Rated suspension height (mm)
450mm
Magnetic field strength
175mT
Power(KW)
25.3kw
Excitation power (KW)
23.5kw
Power of driving motor +power of oil pump
0.8+1kw
10
Overall dimensions
163013001344mm
11
assembly angle
=9
12
Total weight
3100kg
1.4..3.2 Inspection before start-up

1.4..3.2.1 Each switch, meter and indicating lamp of the control box is complete.
1.4..3.2.2 Each limit switch is complete and accurate.
1.4..3.2.3 Suspension device is firmly fixed and reliable.
1.4..3.2.4 No hanging or dragging occurs to the power supply cable; no blocking or derailment occurs when
dragging the cable bearing.
1.4..3.3 Start-up and stop operation
1.4..3.3.1 Local manual operation
44
A. Switch on the main power supply and push forward button to remove the iron separator to its working
position.
B. After the iron separator is located, push start button to operate the iron separator.
C. After coal filling, push return button to relocate the iron separator at its initial position. Push stop
button and the iron separator will automatically remove the iron.
D. Cut off the main power supply.
1.4..3.3.2 Procedure control
Switch the onsite change-over switch over to "programmable control" position. The iron separator is
automatically started or stopped with the selected coal matching procedure.
1.4..3.4 Notes for operation
1.4..3.4.1 The iron separator is put into operation before starting the belt-type conveyor.
1.4..3.4.2 The current valve shall change within the rated range.
1.4..3.4.3 It is forbidden to arbitrarily clean the accumulated iron or shut down the power supply when the
iron separator is working.
1.4..3.4.4 When removing the accumulated iron below the iron separator, power supply shall be cut off and
special tool shall be used.
1.4..3.4.5 It is forbidden to close to the working iron separator with sharp iron casting or precision instrument
in hand.
1.4..3.4.6 Handle with the sucked large iron casting on time to prevent from coal flow or scratching the belt.
In case of handling failure, emergent suspension works.
1.4..3.4.7 When the travel trolley back and forth to iron absorption, iron limit, in addition to the iron center
should be on the belt and abandon of iron mouth center
1.4..3.5 Cause and handling of common fault
S/N
Fault
Causes
The iron separator does not go

forward or return.
1. Fault occurs to the motor.

2. Fuse is damaged.
Ask for
maintenance.
repair
and
The iron separator fails to return

to the exact position.
1. Limit is damaged.
2. Towing roller derails.
3
Power failure occurs to
the motor.
Ask for
maintenance.
repair
and
Absorption,the ability to weaken

the abandoned iron
The height or the angle

position of the crane is
changed
Ask for
maintenance.
repair
and
Equipment
upgrade
Fastener loosening
Ask for
maintenance.
repair
and
vibration,noise
1.4..4
Three-way pipe of electric plate
1.4.4.1
Equipment specification
Handling
a Specification of three-way pipe:

Item
Parameter
45
Model
DST00
Adaptive bandwidth
1000mm
Flange size
800mm800mm
Three-way pipe inclination
60
angle
5
Electric push rod model
DT1000-500-40
Electric push rod thrust
10000N
Through capacity
775t/h
b.Supporting motor
Model:
YQ-901-6B5
Power:
1.1 KW
Voltage:
400 V
1.4.4.2
a.
Handover inspection and check before start-up

Check whether the electrical baffle plate is in good connection and whether the limit switch is complete
and not loose.

b.
Check whether the bolt fixed at the bottom is loose or falls off.
c.
Check whether the connecting pin is loose or falls off.
d.
Check whether there is any accumulated coal in the coal chute.
e.
Check whether the coal chute or baffle plate is transformed, blocked or not at its exact position.
1.4.4.3
Local operation procedures
a.
Change over the baffle plate according to the requirement of group chief and programmable controller.
b.
Check whether there is any accumulated coal in the coal chute before operation.
c.
Switch the mode change-over switch on the local control box to local position and push A on or B
on on the control box to make the baffle plate A or B to be in "on" position.

d.
Check whether the baffle plate is switched to the exact position in order to prevent from coal blocking
or overflow.
e.
Notify the centralized control room to accomplish the operation according to the requirement.
f.
Under the normal condition, place the mode change-over switch at "programmable control" position.
1.4.4.4
a.
Operation notice
If there is any accumulated coal in the coal chute, remove the accumulated coal in the first place and
then operate the baffle plate.

b.
Pay attention to the working condition of the electric pushrod and the sound of motor during operation.
c.
Pay attention to whether the limit switch works normally and carefully check the position of baffle plate.
1.4.4.5
Fault disposal
1.4.4.5.1 Motor generates insufficient power and buzzes. Pushrod fails to move.
Causes:
a.
Pushrod is over expanded or contracted.
b.
Too much accumulated coal in the coal chute.
c.
The baffle plate is transformed or blocked.

46
d.
Anchor bolt is loose so that the original angle is changed.
Handling: Report to the group chief and clean the accumulated coal. Repair or maintain if necessary.
1.4.4.5.2 Motor of pushrod is at idle operation.
Cause: Connecting pin inside of pushrod is damaged.
Handling: Report to the group chief for contact and repair.
1.4.4.5.3 Electric pushrod fails to work.
Cause: Motor or circuit is partially fault or at the self-protection status.
1.4.4.5.4 Electric pushrod works, but baffle plate fails to work.
Cause: Axis of the baffle plate may be broken.
1.4.5
DMC bag filter type dust collectors
1.4.5.1
Technical specifications of equipment

Performance and
Unit
parameter
DMC bag filter type dust collectors
model
Filtering area
14.797
8001200
Total pressure of fan
m3
Pa
Treatment air volume

Dust removal efficiency
m /h
200012000
99.9
Maximum dust concentration at the inlet
g/ m
15
Motor power of fan
KW
5.5
Air leakage rate
Power of damper actuator
KW
0.04
Power of rapping motor
KW
0.25
Surface temperature of electric heater
<85
Power of electric heater
KW
Spraying volume of fire water
L/min
100150
Temperature after the belt is dried
1030
Noise
dB(A)
75
Number of installed equipment
set
35
3530
<85
1.4.5.2 Inspection before start-up

1.4.5.2.1
Anchor bolt of each motor and fan shall be complete without any damage or loose condition;
protection shield of each coupling shall be complete and fixed.
1.4.5.2.2
Transmission and rotation of each part is flexible and free of blocking.
1.4..5.2.3 Vibration ash-removal device is complete.
1.4..5.2.4 Dust collector and each air pipe and junction of boxes shall be well sealed without ash or coal
leakage.
1.4..5.2.5 Flat bag shall not be broken or with an air hole.
1.4..5.2.6 Inspection door and access gate shall be firmly closed.
47
1.4..5.2.7 Indicating lamp, switch and button on the local control panel shall be complete; indicating lamp of
power source and change-over switch shall be at the automatic position.
1.4..5.3
Local operation
There is an operation mode selection switch on the control panel of dust collector. Manual or automatic mode
can be chosen according to the requirement. For manual mode, the system operation is controlled by five
switches, namely fan, ash cleaning machine, opening the air valve, closing the air valve and heater. If
switching on the switch, corresponding actuator will work and the indicating lamp will be on. Under this mode,
three switches, fan, closing the air valve and opening the air valve will interlock. During operation, if
switching on several switches at the same time, only the corresponding actuator of the first operated switch works.
In order to guarantee the safety and reliability of the dust collector, working time of ash cleaning actuator and
heater is stipulated. Under the automatic mode, starting and suspension procedure of the system is automatically
accomplished by the computer according to the interlock signal.
1.4..5.3.1 Manual operation procedure
Start-up operation:
a. Place the change-over switch on the control switch plate at manual position.
b. Place opening the air valve switch at the starting position so that the indicating lamp of opening the air
valve will be on. Start-up time is about thirty seconds.
c. Place fan operating switch at the starting position so that the indicating lamp of fan operation will be on
and the fan works.
d. Stop the fan after it operates for 1 to 2 hours (operating time is determined by dust concentration at the
inlet; if the concentration is heavy, operating time is minimum).
e. Place ash cleaning machine switch at the starting position and start to operate the ash cleaning
machine.
f. Stop the ash cleaning machine after it operates for thirty seconds.
g. After stopping the ash cleaning machine, restart the fan. Repeat this process.
Suspension operation: After coal filling and accomplishing the ash cleaning procedure, place closing the air
valve switch at the starting position so as to close the air valve.
1.4.5.3.2 Automatic operation procedure
a. The operation mode selection switch on the control box shall be at automatic position. The system enters
the preliminary status at this time and the air valve is closed.
b. Start: When the interlock signal is connected, the system enters the automatic operation status. After
thirty seconds after the air valve automatically starts, the fan starts to operate. After operating time is set for the
fan (the time is set between 1 and 2 hours before operation), it can automatically implement the ash cleaning
procedure. After the ash cleaning procedure is finished, fan operation procedure is continued.
c. Stop: After the interlock signal turns into off, shut down the machine after 60 seconds. Operate the ash
cleaning machine after the fan stops for ten seconds. After the ash cleaning machine works for 30 seconds, shut it
down. Then the air valve is closed and the electrical heater is opened. When the heating temperature reaches at
65, stop the electrical heater and open the air valve. Operate the ash cleaning machine after 30 seconds. The ash
cleaning machine works for 30 seconds and then shut it down. Close the air valve and the system returns to its
preliminary status.
1.4.5.4 Notes and daily maintenance
1.4.5.4.1
Under the normal condition, the dust collector adopts automatic interlock control.
1.4.5.4.2
All the transmission parts shall stably operate without over-loud noise and with the bearing
temperature of not more than 75.
1.4.5.4.3
Ash cleaning times and operation mode shall be determined according to the quantity of dust.
48
1.4.5.4.4
During the starting and suspension process of the dust collector, stop operating at once for
inspection and handling in case of any abnormal phenomenon.
1.4.5.4.5
During the using process, sealing status of the units shall be frequently inspected. Repair shall be
conducted or the sealing elements shall be replaced in case of air leakage.
1.4.5.4.6
Pay attention to the fan outlet of the dust collector. If there is any smoke out of the outlet, it proves
that the bas is damaged and the bag shall be replaced at once.
1.4.5.4.7
Dust accumulated in the lower hopper of the dust collector shall be regularly cleaned.
1.4.5.4.8
It is forbidden to repair the fan or equipment during its operation.
1.4.5.4.9 If the dust collector is forced to suspend due to fault, main suspension button shall be pressed
after the fault is eliminated to reset the system for restart.
1.4.5.5 Cause and handling of common fault
1.4.5.5.1
Vibration noise of motor or fan is too loud and the temperature exceeds the limit.
Causes:
a. The bearing is damaged.
b. Lubricating oil is deteriorated or insufficient.
c. The coupling center is not aligned.
d. Paddle of rotation part is heavily damaged or blade has too much accumulated dust.
Handling:
a. Inform the maintenance personnel for handling.
b. Replace the oil and add appropriate amount.
1.4.5.5.2
Pressure is too small or smoke occurs to the outlet.
Causes: Filtering bag is damaged.
Handling: Ask for repair and maintenance.
1.4.5.5.3
The dust collector fails to start.
Causes:
a. Fault occurs to the control circuit.
b. Fault occurs to the power source circuit.
c. Fault occurs to the power motor.
Handling: Carry out overall inspection and report to the group chief for contact and repair.
1.4.5.5.4
The dust collector fails to treat with the dust.
Causes: Fault occurs to the element to remove the dust of the dust collector.
Handling: Inform the maintenance personnel for handling.
1.4.6
Pollution discharge devices
1.4.6.1 Cleaning water pump

1.4.6.1.1 Equipment specification
Model: SLW125-315A
Flow rate: 80m3/h
Lift: 104m
Pressure: 0.784MPa
speed2950r/min
motorY2-280S-2
power75KW
49
current128.5A
Quantity: 2 set
Manufacturer: Shanghai liancheng Co.,Led.
1.4.6.1.2 Handover inspection and check before start-up
a. Check that the anchor bolt of the motor and cleaning water pump is fixed and free of loose and falling.
b. Check that power wiring of the motor is in good insulation and wiring box of the motor is complete and
free of damage with good connection.
c. Check that the grounding wire of the motor is well connected.
d. Check that imported flange of cleaning water pump is firmly connected and free of loose and leakage.
e. Check that the bearing packing of the cleaning water pump is free of damage and crack.
1.4.6.1.3 Operation procedure for local start-up and stop operation
1.4.6.1.3.1
Start-up:
a. Turn on the valve of inlet pipe of cleaning water pump.
b. Press start button on the local control box to operate the cleaning water pump.
c. Slowly open the valve of outlet pipe to its maximum degree.
1.4.6.1.3.2
Stop:
a. Press stop button on the cleaning water pump to stop it.
b. Close the inlet and outlet of the cleaning water pump.
1.4.6.1.4 Notes for operation
a. Pay attention to check that water pump and motor shall stably work with normal noise and free of
vibration.
b. Pay attention to check that pressure gauge at the outlet of cleaning water pump is within the normal
range.
c. Pay attention to supervise that current indication on the local operation box is within the normal range.
d. Pay attention to check that no leakage occurs to the valve at the inlet or outlet and pump axis packing.
1.4.6.1.5 Cause and handling of common fault
1.4.6.1.5.1
Water fails to be pumped after starting the pump and there is no indication on the pressure
gauge.
Cause: Industrial water pressure is low.
Handling: Stop the pump and contact with hydraulic worker to increase the industrial water pressure and
then restart.
1.4.6.1.5.2
There is abnormal noise and vibration during the operation of pump.
Causes:
a. Pump axis is damaged or the bearing is lack of oil.
b. There is air in the inlet pipe.
c. Each fixed and interconnecting bolt is loose.
1.4..6.1.5.3
Load of motor increases and the noise is abnormal.
Cause: Paddle and pump are heavily rubbed or the paddle is jammed by foreign matter.
Handling: Observe the pump and motor; replace it with standby pump according to the condition; report to
the group chief and ask for repair and maintenance.
1.4..6.2 Sewage discharge pump
1.4..6.2.1 Equipment specification
Model: 100YZ100-30A
Flow rate: 50-70 m3/h
Lift: 25-30m
50
Quantity: 25 set
Supporting motor:
Model: YKP2-180M-4
Power: 18.5KW
Voltage: 400V
Current: 34.5A
1.4.6.2.2 Handover inspection and check before start-up
a. Check whether the binding bolt of the motor and at the foot of sewage pump is fixed and free of loose
and falling.
b. Check whether the blade and protection shield of the motor are complete.
c. Check that power wiring of the motor is free of damage and wiring is fixed and in good insulation.
d. Check whether the grounding wire of the motor is complete and wiring box and shell of the motor shall
be complete and free of damage and crack.
e. Check that the binding bolt at the outlet of sewage pump shall be fixed and the sewage pump shall be
free of damage and crack.
1.4.6.2.3 Start-up and stop mode
After closing the main switch of power source of the sewage pump, switch the change-over switch to the
automatic position which can automatically control to start or stop according to the level in the sewage pool.
1.4.6.2.4 Notes for operation of sewage pump
a. Pay attention to the operation condition of sewage pump and stop the pump for inspection in case of any
abnormal condition.
b. Pay attention to that whether there is too much coal slime and sundries in the sewage tank. If so, clean it
up in time to prevent paddle from being buried by coal slime or jammed by sundries.
c. Pay attention to the vibration condition of the sewage pump and stop the pump in case of any
abnormality.
d. Local on-duty personnel in charge of belt shall be responsible checking the sewage pump of this belt.
e. After discharging sewage, clean with cleaning water to prevent from blocking the pipeline.
1.4.6.2.5 Cause and handling of common fault
1.4.6.2.5.1
Motor fails to rotate.
Causes:
a. Voltage of power source is too low.
b. Missing phase, power failure or circuit fault occurs to the power source.
c. Suction inlet is blocked.
d. Stator winding is burnt out.
Handling: Stop the pump and report to the group chief for contact the inspection personnel for treatment.
1.4.6.2.5.2
Water pump flow rate lift decreases or water fails to spill out.
Causes:
a. The rotation direction of paddle is incorrect.
b. The rotation speed reduces.
c. Cover plate of the paddle is heavily worn.
d. The motor has poor operation condition; temperature is too high or overloaded; thermal protector
actuates.
e. The sealing material fails to be tightly pressed so that the air enters.
Treatment:
a. Change the position of any two of three phase power source.
51
b. Check the voltage and frequency of the power source.

c. Replace the paddle and cover plate.
d. After the temperature reduces, protection device automatically relocate and then operates. In case that
such condition continuously occurs, figure out the reason after cutting off the power source.
e. Adjust the progress to prevent from air in.
1.4..6.2.5.3
Stator winding of the motor is burnt out.
Causes:
a. The pump is out of the service range and operates in the large flow rate zone for a long time so that the
protector is out of work.
b. Stator and rotor of the motor fail to share the same center or axis bending causes collision between
stator and rotor or paddle and pump body.
c. The motor suffers two-phase operation.
Treatment:
a. Adjust the service range of the pump and replace the thermal protector.
b. Adjust the concentricity and calibrate the axis or adjust the clearance of the paddles.
c. Figure out the route and eliminate the fault.
Replace the motor.
1.4.7
Sampling device for coal as fired
1.4..7.1 Technical specification of sampling device for coal as fired

1.4..7.1.1 Main performance parameter
Applicable belt speed: 3.15m/s
Sampling speed: 4m/s
Sampling quantity: 5-10kg/time
Adaptable water: %
Sampling time control: min-10h
Sampling weight control: 1t-2t
Sampling scheme: comply with GB475-96
Sample preparation scheme: comply with GB474-96
1.4..7.1.2 Scraper sampling machine
a. Model: S70-1000 Sampling quantity: kg/time
Sampling speed: m/s
b. Model of supporting motor:R87DV112M4 Power: 4 KW
Voltage: 380V
1.4..7.1.3 Crusher
a. Model: MM3 Particle size of feeding material: 50mm
Discharging size: 3mm
Output: 4t/h,Speed:927rpm
b. Supporting motor:
Model: Y132M2-6B3 Power: 15KW
Voltage: 380V
Rotation speed: 927 r/min
1.4..7.1.4 Splitter
a. Model: S73B-00 Splitting ratio: 1/1000-1/3 adjustable
52
Output speed:22rpm
Adaptation granularity:13mm
Opening width:60mm
b. Supporting motor
Power: 0.12KWKW
Voltage: 380V
c. Model of supporting speed reducer: SAF37DR63S4
1.4..7.1.5 belt feeder
a. Model: SF1-350B-00 belt width: B=350mm
belt speed: 0.054m/s
output:0.55t/h
b. Supporting motor
Power:0.37KW
Voltage: 380V
c. Model of supporting speed reducer: SA57DT71D4
1.4..7.1.6 Bucket elevator
a. Model: TD100
Output: 2t/h
belt speed: m/s
b. Model of supporting speed reducer: SA77DV100M4 Power: 2.2KW
Voltage: 380V
1.4..7.1.7 Sample catcher
a.typeS58-6/20-00
Capacity of sample bucket25L
speed2.1r/min
b.Supporting motor
ModelSAF57R17DR63L4 power0.25KW
voltage:380V
1.4..7.2
Inspection before start
1.4..7.2.1 Scraper sampling machine
a. Each fixed connecting bolt is not loose or falling and limit switch and electric pushrod are free of
abnormality.
b. Sampling head shall be free of block coal and sundries. If there is any, clean it up in time.
c. Connecting axis and fixed axis of the electric pushrod and transmission swinging arm at the force end shall
be free of falling and abnormality.
d. Check whether the discharge port of chute-type material vessel can be opened or closed flexibly.
e. Check whether the limit switch is tight and whether the swinging arm can flexibly rotate and accurately
relocate.
f. Skidway and coal grate shall be free of accumulated coal. In case of blocking, clean up in time. Friction
resistance rubber of the buffer shall be free of damage and coal pipe shall be free of coal.
1.4..7.2.2 Feeding belt machine
a. Check that upper and lower rollers are complete and flexibly rotate.
b. Cover plate and material chute of the belt machine shall be complete, the frame is fixed and reliable and the
belt is free of tearing, scratching and heavy deviation.
c. There are no sundries near the motor and speed reducer and the oil level of speed reducer is normal.
d. Scraper on the belt removal machine of feeding machine shall fully contact with the transmission adhesive
tape.
1.4.7.2.3 Ring-type crusher
a. There are no sundries around the motor and crusher. Each binding bolt is not loose or falling. Machine door
53
is firmly closed.
b. Check that each worn part is not heavily worn.
c. Draw-in box of the motor is complete and the grounding wire is well connected.
1.4.7.2.4 Splitter
a. Check whether the limit switch is tight and whether the swinging arm can flexibly rotate and accurately
relocate.
b. Road wheel on the material head of splitter works normally. In case of deviation, adjust it in time.
c. Clearance between the cleaning surface on the cleaning machine and material mouth of splitter shall be
adjusted appropriately by taking non-contact as the standard.
d. Check whether the rotary hopper works normally and each coal pipe is free of sundries and blocking.
1.4.7.2.5 Electrical cabinet
a. Each switch contactor shall be complete and in good contact.
b. Thermal controller, each button and indicating lamp are easy to be used.
c. Surface of each electrical element is clean and free of accumulated dust.
1.4.7.3 Start-up and stop
1.4.7.3.1 Turn off the main power switch of sampling machine and switches of each branch circuit.
1.4.7.3.2
Place the manual and automatic change-over switch at "automatic" position..
Control system of the sample preparation machine is realized by advance PLC. With complete automation mode
and under the normal condition, on-duty personnel are not required to do any operation. When C7 belt-type
transmission normally operates and after some time, the belt machine interlocks the control system PLC of this
machine and the system will automatically start. Starting sequence: hoppersplitterelectric pushrodringtype crusherfeeding belt machinesampling head After C7 belt-type transmission stops, the system
automatically stops after a while. Stop sequence is opposite to the starting sequence.
Manual mode is mainly used for separate start of the equipment as well as maintenance and commissioning.
This system has unique fault detection procedure and fault testing element, which can timely and effectively
detect the fault of equipment and alarm for reminding to close the system, and show the fault part on the mimic
panel.
1.4.7.4.
Inspection for operation
1.4.7.4.1
Check that there shall be no collision or jam during operation of sampling head.
1.4.7.4.2
Motor and speed reducer of the belt feeder normally work and are free of noise and vibration.
There is no obvious rise in temperature.
1.4.7.4.3
During the operation of electric pushrod, the motor is free of abnormal noise and the temperature is
free of obvious rise.
1.4.7.4.4
Belt feeder normally actuates and well operates. Coal pipe is free of heavy blocking.
1.4.7.4.5
Ring-type crusher stably and reliably operates and output is normal. There is no abnormal noise
and vibration in the motor and machine.
1.4.7.4.6
Lubricating oil level is normal and the oil quality is good. Oil circulation is normal and no leakage
occurs after observing the oil level meter.
4.7.4.7 Check that the motor of splitter is free of abnormal noise; temperature and vibration do not obviously
increase.
1.4.7.4.8
Check whether the sample and sample preparation in the sampling box are good.
1.4.7.4.9
Open the machine door; observe whether the rotary hopper normally operates and each fixed coal
pipe is free of blocking.
1.4.7.4.10 Regularly clean the ferromagnetic foreign matter in the coal crusher.
1.4.7.4.11 Carry out a tour inspection for this device every 30 minutes.
54
1.4.7.5.
Notes for operation
1.4.7.5.1
When opening the sampling head to check the inspection door, it is forbidden to put in any part of
human body.
1.4.7.5.2
When cleaning the accumulated coal in the sampling head, power failure is implemented with
person to monitor to prevent from wrong power supply. Tightly hold the tapping pin and do not drop it in the coal
cylinder.
1.4.7.5.3
Sampling system and the whole system are not interlocked. This system only has one operation
mode, local control.(conflict with Article 4.8.3.2)
1.4.7.6 Accident disposal
1.4.7.6.1
Sampling head is stuck forward or backward.
Phenomena:
a. Pay attention to the signal lamp of each actuation. If the stop lamp is not on after forward or backward lamp
is on, or backward lamp is not on after the stop lamp is on, check the sampling head on site at once.
b. Sampling head fails to stop at the normal position (normal position is above the sampling coal cylinder).
Handling: Report to the group chief for inspection and power failure and make a record.
1.4.7.6.2 Sampling head has an abnormal frequency and continuous actuation.
Phenomenon: Pay attention to the actuation signal lamp of the sampling head. The forward, stop and
backward indicating lamps are alternatively on (actuation occurs about every 6 minutes in normal condition).
Pay attention to the actuation noise.
Handling: Report to the group chief for repair and maintenance. Record the fault condition and inspection record
on the book.
1.4.7.6.3 Each coal cylinder is blocked.
Handling: Report to the group chief. Figure out the reason and dredge.
1.4.7.6.4 Belt suffers severe deviation or breaking.
Handling: Stop the equipment at once if above mentioned condition occurs.
1.4.7.6.5 Sampling head fails to actuate.
Handling: If the system coal filling is normal but the sampling head fails to actuate, other equipments shall be
stopped.
1.4.7.6.6 The equipment automatically trips.
Handling: If the equipment trips, it cannot be forcedly started. Figure out the reason and start after the fault is
eliminated.
1.4.8
Electronic belt scale
1.4.8.1 Technical specifications for electric belt scale

Model
Item Parameter
PLR-4-X1000
PLR-4-X1200
PLR-4-X650
Applicable belt width
1000mm
1200mm
650mm
Applicable belt speed
3.15m/s
2.0m/s
1.8m/s
Accuracy
0.25%
0.25%
0.25%
Inclination angle of belt
13
14
Installation location
C7ABC3A belt
C1AB belt
C1011 belt
Application temperature:
-30+60
55
-30+60
-30+60
Power voltage
400V
400V
400V
1.4.8.2 Inspection before input

1.4.8.2.1
Weighing platform is firmly installed and any loose is forbidden.
1.4.8.2.2
Sundries cannot be accumulated among the scale frames.
1.4.8.2.3
Roller on the scale frame and three groups of rollers on the adjacent scale frame shall flexibly
rotate; any jam or stuck is forbidden.
1.4.8.2.4
Rotary drum in the scale section shall be complete and free of suspension.
1.4.8.2.5
Roller of the scale shall be free of accumulated coal.
1.4.8.3 Notes for operation
1.4.8.3.1
Belt shall not deviate and the coal point shall be at the center of belt.
1.4.8.3.2
Keep the coal layer even and appropriate flow rate. Load indicator shall be within the stipulated
range.
1.4.8.3.3
Counter of the weighing segment cannot display the figures properly during the operation. Report
to the group chief and notify relevant personnel.
1.4.8.3.4
If roller of the frame and several front and back rollers fail to rotate, ask for the inspection
personnel for treatment.
1.4.8.3.5
Do not collide the scale frame and hock one-time element.
1.4.8.4 Calibration commissioning and daily maintenance
1.4.8.4.1
Coal scale which is put into use shall not be calibrated by the inspection and operation personnel.
1.4.8.4.2
The secondary instrument is set zero (automatic zero setting) only can be conducted by the hot
work personnel with belt measurement certificate issued by superior level.
1.4.8.4.3
Zero setting shall be conducted before coal filling and the hot work personnel shall tell the zero
setting result to the group chief.
1.4.8.4.4
Object calibration shall be carried out regularly.
1.4.8.4.5
Object calibration shall be conducted by hot work personnel, operation personnel and inspection
personnel.
1.4.8.4.6
It is forbidden to wash the scale frame with water. Regularly clean the scale frame, scale sensor and
speed sensor.
1.4.8.4.7
It is forbidden to put coal and rubbish on the scale belt.
1.4.8.5. Object calibration method and notes
1.4.8.5.1 Object calibration method: First use self-calibration weight for calibration. If qualified, place the
electric three-way plate on the #4 belt-type transmission at the hopper of object calibration device. The coal enters
the hopper of object calibration device. When the object calibration controlling instrument reaches the rated
weight, C4A belt-type transmission stops coal filling. Place the electric three-way plate below the object
calibration hopper at any side of C5 belt-type transmission where the electric belt scale is. Open the slide valve
under the object calibration hopper and repeat this process till the second calibration.
1.4.8.5.2 Notes: After the hopper of the object calibration device is filled with coal, it is forbidden to lift the
weight of the object calibration device. After the hopper of the object calibration device is filled with coal, the
weight shall not be at the object calibration device. Or the sensor on the object calibration device will be damaged.
Even civil structure in the coal crushing room may be damaged.
56
1.4.9cranes & hoists
1.4.9.1Distribution of cranes & hoists

Raw coal hopper underground Electric hoistQ=5tH=7m
number1set
Electric hoistQ=5tH=14m
number1set
number1set
Chain blockmanualQ=1TH=10m number2set
emergency coal hopper underground Electric hoistQ=2tH=14m
number1set
fine coal hopper underground Electric hoistQ=1tH=12m
number1set
crude coal hopper underground Electric hoistQ=1tH=12m
number1set
Coal crusher house Electric hoistQ=5tH=6m
number2set
number1set
number3set
Fine crusher house Electric single-beam cranes Q=10Tspan20.5mH=36mnumber1set
number8set
number5set
Screening house
number4set
number1set
number2set
#1 transfer towerElectric single-girder suspension cranes Q=2Tspan10mH=15m number1set
Electric single-girder suspension cranes Q=2Tspan2.5m H=7m number1set
number1set
#2 transfer tower Electric hoistQ=5tH=7m
number1set
number1set
number1set
#3 transfer tower Electric hoistQ=2tH=5m
number4set
number1set
Bunker house transfer tower Electric hoistQ=2tH=60m
number1set
number1set
57
number1set
Chain blockmanualQ=0.5TH=6m number2set
bunker house
number2set
number2set
coal field
number2set
#7 belt trestle bridgeElectric single-girder suspension cranes Q=2Tspan5.25mH=12m number2set
number1set
Limestone coal hopper underground Electric hoistQ=2tH=14m
number1set
Limestone coal crush houseElectric hoistQ=12tH=12m
number2set
number2set
number1set
Mill house
number4set
number5set
1.4.9.2Technical specifications of cranes & hoists
NO
name
model
unit
num
ber
Prod
ucin
g
area
Manufactur
er
1.
Electric hoist
CD15t-7m
set
Hena
n
Henan
Weihua
2.
Electric hoist
CD15t-14m
set
Hena
n
Henan
Weihua
3.
Electric hoist
CD12t-10m
set
Hena
n
Henan
Weihua
4.
Chain blockmanual
HS1t-10mWA1t-10m
set
Zheji
ang
Zhejiang
Shuangniao
5.
Electric hoist
CD12t-14m
set
Hena
n
Henan
Weihua
6.
Chain blockmanual
HS2t-8mWA2t-8m
set
Zheji
ang
Zhejiang
Shuangniao
7.
Electric hoist
CD11t-12m
set
Hena
n
Henan
Weihua
8.
Chain blockmanual
HS1t-9mWA1t-9m
set
Hena
n
Zhejiang
Shuangniao
9.
Electric hoist
CD11t-12m
set
Hena
n
Henan
Weihua
10.
Chain blockmanual
HS1t-9mWA1t-9m
set
Zheji
ang
Zhejiang
Shuangniao
58
note
11.
Electric hoist
CD15t-6m
set
Hena
n
Henan
Weihua
12.
Electric hoist
CD15t-18m
set
Hena
n
Henan
Weihua
13.
Electric hoist
CD15t-12m
set
Hena
n
Henan
Weihua
14.
Chain blockmanual
HS2t-6mWA2t-6m
set
Zheji
ang
Zhejiang
Shuangniao
15.
Chain blockmanual
HS2t-7mWA2t-7m
set
Zheji
ang
Zhejiang
Shuangniao
16.
Chain blockmanual
HS1t-7mWA1t-7m
set
Zheji
ang
Zhejiang
Shuangniao
17.
Electric single-beam
cranes
LD10t-20.5m
set
Hena
n
Henan
Weihua
18.
Electric hoist
CD13t-6m
set
Hena
n
Henan
Weihua
19.
Chain blockmanual
HS1t-6mWA1t-6m
set
Zheji
ang
Zhejiang
Shuangniao
20.
Electric hoist
CD110t-6m
set
Hena
n
Henan
Weihua
21.
Chain blockmanual
HS2t-6mWA2t-6m
set
Hena
n
Zhejiang
Shuangniao
22.
Electric hoist
CD12t-6m
set
Hena
n
Henan
Weihua
23.
Electric hoist
CD13t-35m
set
Hena
n
Henan
Weihua
24.
Electric hoist
CD13t-9m
set
Hena
n
Henan
Weihua
25.
Chain blockmanual
HS1t-10mWA1t-10m
set
Zheji
ang
Zhejiang
Shuangniao
26.
Electric single-girder
suspension cranes
LX2t-10m
set
Hena
n
Henan
Weihua
27.
suspension cranes
LX2t-2.5m
set
Hena
n
Henan
Weihua
28.
Electric hoist
CD12t-15m
set
Hena
n
Henan
Weihua
29.
Chain blockmanual
HS1t-7mWA1t-7m
set
Zheji
ang
Zhejiang
Shuangniao
30.
Electric hoist
CD15t-7m
set
Hena
n
Henan
Weihua
31.
Electric hoist
CD12t-7m
set
Hena
n
Henan
Weihua
32.
Electric hoist
CD15t-18m
set
Hena
n
Henan
Weihua
59
33.
Chain blockmanual
HS1t-7mWA1t-7m
set
Zheji
ang
Zhejiang
Shuangniao
34.
Chain blockmanual
HS1t-5mWA1t-5m
set
Zheji
ang
Zhejiang
Shuangniao
35.
Electric hoist
CD12t-5m
set
Hena
n
Henan
Weihua
36.
Electric hoist
CD12t-12m
set
Hena
n
Henan
Weihua
37.
Chain blockmanual
HS1t-7mWA1t-7m
set
Zheji
ang
Zhejiang
Shuangniao
38.
Electric hoist
CD12t-60m
set
Hena
n
Henan
Weihua
39.
Electric hoist
CD12t-8m
set
Hena
n
Henan
Weihua
40.
Chain blockmanual
HS2t-8mWA2t-8m
set
Zheji
ang
Zhejiang
Shuangniao
41.
Chain blockmanual
HS1t-7mWA1t-7m
set
Zheji
ang
Zhejiang
Shuangniao
42.
Electric hoist
CD11t-6m
set
Hena
n
Henan
Weihua
43.
Chain blockmanual
HS5t-6mWA5t-6m
set
Zheji
ang
Zhejiang
Shuangniao
44.
Electric hoist
CD13t-50m
set
Hena
n
Henan
Weihua
45.
Electric hoist
CD13t-9m
set
Hena
n
Henan
Weihua
46.
Electric hoist
CD12t-6m
set
Hena
n
Henan
Weihua
47.
suspension cranes
LX2t-12m
set
Hena
n
Henan
Weihua
48.
Electric hoist
CD12t-14m
set
Hena
n
Henan
Weihua
49.
Chain blockmanual
HS2t-6mWA2t-6m
set
Zheji
ang
Zhejiang
Shuangniao
50.
Chain blockmanual
HS2t-8mWA2t-8m
set
Zheji
ang
Zhejiang
Shuangniao
51.
Electric hoist
CD12t-14m
set
Hena
n
Henan
Weihua
52.
Chain blockmanual
HS2t-8mWA2t-8m
set
Zheji
ang
Zhejiang
Shuangniao
53.
Electric hoist
CD112t-12m
set
Hena
n
Henan
Weihua
54.
Electric hoist
CD13t-6m
set
Hena
n
Henan
Weihua
60
55.
Electric hoist
CD13t-18m
set
Hena
n
Henan
Weihua
56.
Chain blockmanual
HS1t-8mWA1t-8m
set
Zheji
ang
Zhejiang
Shuangniao
57.
Electric hoist
CD110t-15m
set
Hena
n
Henan
Weihua
58.
Electric hoist
CD12t-40m
set
Hena
n
Henan
Weihua
59.
Chain blockmanual
HS2t-6mWA2t-6m
set
Zheji
ang
Zhejiang
Shuangniao
1.4.9.3Routine maintenance of cranes & hoists motor

1.4.9.3.1All the AC motor are squirrel-cage motor can be started directly. Design of the motor must fit the
require of run continuity. That means the motor will not be too hot when environment temperature reach 50 .If
system voltage low,in the heaviest load conditions driven equipment work at 103% of rated speed.When the
frequency is rated, and the deviation of voltage and rating less than (10%,the motor should be able to output
power rating.When the voltage is rated, and the deviation of frequency and rating less than 5%,the motor should
be able to output power rating.When the voltage and frequency variation was 10%the motor should be able to
output power rating.
1.4.9.3.2 all DC motor is shunt type,rated voltage is 220 v able to continuous work in the actual conditions in
any voltage 220v DC system allows.Dc motor equipped with a starterDc motor starting current is no more than
2.5 times the full load current. Motor start at 70% rated voltage insulation level is F,limited to The temperature
rise B insulation.
1.4.9.3.3the motor is designed to be started online directly.Starting current should not exceed 6 times full load
current of all the auxiliary equipment.
1.4.9.3.4 motor can start at a constant speed 3 times per hour ,continuous start 2 times
1.4.10wiper
1.4.10.1Technical specifications of wiper

Belt width
1000/1200mm
Belt height
1200mm
Plough plate height
600mm
Plough head height
450mm
Model of electric drive pusher
DTIIA70500
idler number
Parallel idler
Trough idler
Idler diameter
133mm
Idler bearing model
305
61
Hopper mass
180kg/set
Equipment total mass (kg)
1000kg/set
1.4.10.2 Preparation and inspection before start-up of wiper

1) There is No NO OPERATION on on-site control box, tripping indicator lights up, and changeover switch is
set to PC position.
2) There is no serious wear or fracture or coal deposit and sundries on the wiper rubber.
3) No slackness or displacement of bearing pedestal.
4) Upper and lower limit switches should be installed in right position.
5) There should be no unsoldering or slackness in the electric drive pusher and no bending or deformation in
pusher.
6) The corresponding belt of the wiper ready to start should be free of big coal pieces or other sundries.
1.4.10.3 Start-up and stop operations of wiper
1) When water, ice, snow and frost, etc. are needed to be discharged from the strap, or in case that water flows
along the belt down into the coal chute on snowy days, there is a need to use wipers.
2) On permitted by the shift engineer on duty, press button Down and the wiper will drop down while the staff
on duty should be in close supervision. When most of the water on the belt is wiped off, press UP button, and
the wiper will rise up. If there is a need to stop IN the process of lifting or dropping, press stop button and the
wiper will stop running.
1.4.10.4Routine maintenance
1.4.10.4.1Plough plate is single plateheight not low than 600mmAs plough dropping, it is appropriate that the
plate just touches the glue covered on the rubber belt, too tight or insufficient touching is not appropriate, so as to
prevent damage to the rubber belt or coal leak.
1.4.10.4.2The plate automatically rise up and drop down under the action of electric drive pusher
1.4.10.4.3The wiper must run safely,drop and rise smoothly.wiper must ensure the glue is trough when stop.when
wiper is working,plate and glue must be Parallel.
1.4.10.4.4The support hinge of wiper use Sliding bearing.Make sure lube system no leak,Temperature rise not
more than 40bearing Temperature not more than 80
1.4.11Bridge type grab crane
1.4.11.1Distribution of bridge type grab crane

name
Hoisting
capacity
t
lifting
height
m
set
Distribution
Motor
protecti
on level
Control
model
Bridge type grab

crane
2t
12
coal water settling

pond rain water
settling
pondoutside
IP55
local
1.4.11.2Technical Specifications of bridge type grab crane

62
NO
name
unit
Bridge type grab crane
Hoisting capacity
span
Maximum lifting height
Working level
Running
gear
Lifting
gear
A3
Run speed
motor
12
m/min
model
20
ZDY112-4
power
Kw
0.4
speed
r/m
1380
Electric hoist type
CD
lifting speed
m/min
8m/min
lifting height
12
Run speed
m/min
20
motor
kw
ZD131-4/3KW
1.4.11.3 Usage and maintenance

1.4.11.3.1Running gear should run good performance , running smooth , easy installation and maintenance ; main
and auxiliary hook can lifting any object within the region
1.4.11.3.2lifting gear motor reducer , hook should be safe and reliable.
1.4.11.3.3wheel set of wheels should be strictly controlled within the specified range,
1.4.11.3.4test :in the unload situation,connect the electric power source,start and test whether the running gear
,control system and safety device are sensitive and accurate or not.Not use them before adjusting to safety and
precise.
1.4.11.3.5Do not exceed the rated elevating capacity.
1.4.11.3.6Do not hang articles aslant alone the direction of main beam
1.4.11.3.7please check every parts of the crane regularly,especially the joint of the main beam and the cross beam.
1.4.11.3.8Check the wheel at any time.crack,pressure mark and egregious abrasion are not allowed .If the defect
mentioned above exceeds 3mm,the wheel should be discard and a new one should be changed.
63
Chapter II Bucket Wheel Stacker and Reclaimer

2.1 DQ750/750-35 bucket wheel stacker
2.1.1
2.1.2
t/m3
2.1.3
2.1.4
2.1.5
2.1.5.1
2.1.5.2
2.1.5.3
2.1.5.4
2.1.5.5
2.1.5.6
Production capacity: Material piling: 750 t/h Material reclaiming: 750 t/h
Materials: Coal; Material unit weight: 0.8-1.5t/m3
Piling height: Height of the piled material-912m Above the track: 10.5m Below the track: 1.5m
Rotation radius: 35m
Bucket wheel mechanism
Type: Non-grid bucket wheel
Diameter of bucket wheel: D=5500mm
Capacity of bucket wheel: V=0.35m3
Number of bucket wheel:
Z=9
Rotation number of bucket wheel: n=2.66.5r/min
Supporting motor
Model: Power: 75 KW
Voltage: Current:
2.1.5.7 Speed reducer: P2HF062+MC2RLSF04
2.1.6
Pitching mechanism
2.1.6.1 Model:
Hydraulic amplitude
2.1.6.2 Pitching speed: nose-up pitch 5 m/min back-up pitch 5m/min
2.1.6.3 Pitching angle: Nose-up pitch+10.090 0 back-up pitch -12.1400
2.1.6.4 Common operation oil pressure: about Mpa Regulated oil pressure: Mpa
2.1.6.5 Oil supply for operation: C Low temperature hydraulic oil
2.1.6.6 Supporting motor
Model: YL-4 Power: 15 KW
Voltage: V
2.1.7
Rotation mechanism
2.1.7.1 Rotation radius: 35 m
2.1.7.2 Rotation speed: 0.020.12 r/min (m/min)
2.1.7.3 Speed adjustment mode: Frequency adjustment speed
2.1.7.4 Rotation angle: +110
2.1.7.5 Supporting motor Model: Y200L-8 Power: 15 KW
Voltage: V
2.1.7.6 Speed reducer type: PHF062+KF107AD6
Speed reducer transmission ratioi=774.4
2.1.8
Traveling mechanism:
2.1.8.1 Traveling speed: 6/m/min (note: traveling speed includes fast and slow)
2.1.8.2 Wheel diameter: 27mm
2.1.8.3 Motor model: YM4 Power: 4x11kW
2.1.8.4 Rail clamping device: Manual-electrical rail clamping device
64
2.1.8.5
2.1.9
2.1.9.1
2.1.9.2
2.1.9.3
2.1.9.4
Speed reducer: Horizontal side-placed suspension type i=

Cantilever belt conveyor:
belt width: m
belt speed: m/s
belt specification: B=10005(4.5+1.5)
Motor Model: Y250M-4 Power: 55kw
Voltage: V
2.1.9.5 Type of Speed reducer : MC3RLHF04+1FAN
Horizontal side-placed suspension type i=20
2.1.9.6 Tight tensioning mode: Hammer type
2.1.10
Tail car:
2.1.10.1 Type of tail car: half lying tail car
2.1.10.2 belt width of tail car: B=1000mm , belt speed: V=3.15m/s
2.2 Handover Inspection and Check Before Start-up for Bucket Wheel Stack
Reclaimer
2.2.1
Check the coal storage condition on the coal yard and choose the operation mode and piling place.
2.2.2
Check whether derail occurs to the track and traveling wheel. Track and its both sides shall be free of
accumulated coal and large object which may effect traveling.
2.2.3
Check whether there is obstacle within the operation range before operation. Pull out the anchor and
loosen the rail clamping device. Start operation after confirmation.
2.2.4
Inspection of driving part:
2.2.4.1 Motor:
a. Motor has a complete appearance and wiring box is complete. Lead-out wire and cable are free of damage
and grounding wire is good.
b. Foot screw of motor is not loose.
c. Rain prevention shell is complete and the foot is fixed. Coupling shall be complete and connecting bolt shall
be complete and not loose.
2.2.4.2 Speed reducer:
a. The oil level of speed reducer is normal and the oil quality is good.
b. Foot screw of speed reducer is not loose and the air hole shall be unblocked free of oil leakage.
2.2.4.3 Belt conveyor:
a. Belt shall be free of scratching, adhesive falling or tearing and its edge shall be free of heavy damage.
b. Upper and lower rollers as well as aligning roller shall flexibly rotate and be complete.
c. Front and tail rollers as well as driving and direction-changing rollers shall be free of coal. Adhesive of roller
shall be free of damage and falling.
d. Coal chute shall be complete and protection skin shall be good free of coal leakage. Coal plate shall not be
severely worn and be free of accumulated coal and sundries.
e. Tight tensioning device shall be complete and free of transformation.
f. Cleaning machine at the head part of each belt conveyor and empty section shall be fixed and not be severely
worn.
2.2.5
Check whether the oil level of speed reducer of each traveling mechanism, cantilever belt conveyor,
65
rotation mechanism, bucket wheel transmission mechanism is normal, or add oil to the normal level according to
the regulations.
2.2.6
Check whether driving wheel, driven wheel and rail wheel are complete; bucket wheel does not get
loose; each structure is free of crack and weld; bolt shall be fixed.
2.2.7
Cable shall be in the roller and the appearance shall be free of damage, broken and loosing.
2.2.8
For rotation bearing, gear anastomosis, lubricating and braking condition are all in a good condition.
2.2.9
Check that hydraulic system and other pipelines shall be free of breaking or oil leakage. Oil level of the
oil tank shall be normal and oil quality is good. Regulate relevant working pressure according to the hydraulic
principle. Jigger of oil pump is flexible and easy to use. Foot screw shall be fixed and oil tank shall be free of
accumulated water and snow.
2.2.10
Check that each operation button and switch are complete and each signal lamp, bell, instrument and
lighting lamp at the stop position shall be complete and free of damage.
2.2.11
Platform of door column and tail car shall be piled with tools or any sundries. Safety measures must be
taken in case of placement.
2.2.12
Check whether the spraying system is free of leakage and well works.
2.3 Operation mode of bucket wheel stacker

2.3.1
Mode for material piling at the pointed place
During material piling, cantilever shall be adjusted to the appropriate height. During this process, material is
piled while height of the cantilever rises to the required height. Then the traveling mechanism is moved for one
position or the cantilever rotates one angle. Continue to pile the material from bottom to top. This method is
herringbone stacking method (recommended).
Herringbone stacking method

2.3.2
Mode for material rotary piling:
Fix the main machine at some position, which means the car suspends temporarily. Material is piled according to
the rotation radius of cantilever. Rotary angle is generally 15-75. Then, move forward a certain distance and
repeat above mentioned content. After a certain length, pile from bottom to top.(less used)
b
f
d e
Rail Center
66
Mode for material rotary piling

2.3.3
Long piling method:
Adjust the cantilever to a certain height during material piling. Pile the material while the car goes forward till the
stipulated length. Cantilever rotates to the second layer and piled material reaches a certain height. Repeat this
process.(recommended)
Long piling method

2.3.4
Slope reclaiming method
Slope multiple layer cutting method: For this method, moving time of bucket wheel equals to the cutting layer.
Cutting material is piled along the self-piling slope of the piling material. Dig the material from top to bottom.
Height of each digging is no more than 2 meters. Meantime, the car suspends and cantilever rotates at interval.
After the cantilever rotates more than 60 in total, the car goes backward for a distance of S, [S=(0.4-0.6)h,
h=500mm]At this time, lower the bucket wheel to dig a height and then continue to dig. Cantilever rotates at
interval in an opposite direction for second slope reclaiming. After reaching the stipulated depth, the traveling
mechanism travels one cutting-in.
2.3.5
Horizontal full layer reclaiming method
Reclaim from top to bottom on one side of track according to the height of material pile. When the car goes
forward for a certain distance after rotating for 60, which means the depth of hopper is S, height between layers
is hopper cutting height H which is generally 1/2D (D is hopper diameter), about no more than 2m. Cantilever
rotate in an opposite direction to the edge of material pile and the car moves forward one cut-in distance. Lower the
hopper to the next layer and rotate the cantilever in an opposite direction. In this way, reclaim the first layer, the
second layer, the third layer, etc.
Above mentioned operation mode is realized by multiple actuation. This machine mainly has the following
actuation methods:
a. Set a final limit switch for the car when forward and backward in order to prevent from derailing.
b. Cantilever pitching adopts hydraulic transmission according to the horizontal direction with nose-up pitch of
13.2, back-up pitch of 13.4 and rotary angle of 110.
c. Tail car includes piling and reclaiming positions and position changing mechanism accomplishes. When
piling, swinging rod is 90 against the horizontal surface; when reclaiming, swinging rod is horizontally placed.
2.4
2.4.1
Stacking Operation Procedure of Bucket Wheel Machine

Switch on the knife-switch of the main power and all air switches of branch circuits.
67
2.4.2
After checking and confirming all the handles are at zero position, place the "power control" switch at
the "working" position and make sure the "power control" indicator is on.
2.4.3
Press the "on" button and make sure the "on" indicator is on.
2.4.4
Measure whether the three-phase voltage is balanced.
2.4.5
Shift the handle of "rail clamp" to the "loosening" position and make sure the "loosening" indicator is
on; check whether the "rail clamp" is loosened. (When the rail clamp is not loosened manually before the start-up
of the bucket wheel machine)
2.4.6
Press the "electric hooter" button and make preparations for the start-up of the bucket wheel machine.
2.4.7
Shift the handle of "tripper car shift" to the "stacking" position and check whether the tripper car is in
stacking mode. (At this point, the front cantilever support shall be in the position within 0 - 15 to ensure the safe
shift position of tripper car.)
2.4.8
Place the handle of "cart traveling" at the "fast forward (fast backward)" position and drive the cart to
move forward (backward); after the bucket wheel machine is adjusted at the appropriate stacking position, place
the handle of "cart traveling" at the "zero" position. (When driving the cart, pay attention to the height of front
cantilever to prevent it from touching the coal pile.)
2.4.9
Shift the "cantilever belt" handle to the "stacking" position; start the cantilever belt conveyor; pay
attention to the changes of current indication of "cantilever belt conveyor"; after checking and confirming all parts
are in normal operation, contact the master control personnel to start the belt conveyor #3.
2.4.10
Select an appropriate operation mode of coal stacking according to the conditions of the coal yard and
the coal pile.
2.5 Parking Procedure of Bucket Wheel Machine During the Stacking

Operation
2.5.1
After receiving the notice of stopping the stacking from the master control room, the driver should make
preparations for parking.
2.5.2
After all the coal on belt #3 is unloaded, contact the master control personnel on duty to stop its
operation.
2.5.3
After all the coal on the cantilever belt is unloaded, place the "cantilever belt" handle at the "zero"
position and make sure the current indication of "cantilever belt conveyor" is at zero and that the cantilever belt
stops its operation.
2.5.4
Shift the handle of "tripper car shift" to the "reclaiming" position; after the tripper car is in the lowest
position, place the handle of "tripper car shift" at "zero" position. (At this point, the front cantilever support shall
be in the position within 0 - 15 to ensure the safe shift of tripper car.)
2.5.5
Operate the "cart traveling" handle and drive the cart to the specified location; place the front cantilever
along the direction of coal pile.
2.5.6
Place the rail clamp operation handle at the "clamping" position and make sure the "clamping" indicator
is on.
2.5.7
Press the "off" button and make sure the "off" indicator is on; shift the "power control" switch to "zero"
position and make sure the "power control" indicator is off.
2.5.8
Switch off the main power switch and all air switches of branch circuits. Then the whole operation
procedure is completed.
68
2.6. Operation Procedure of Reclaiming

2.6.1
Switch on the knife-switch of the main power and all air switches of branch circuits.
2.6.2
Place the "power control" switch at the "working" position and make sure the "power control" indicator
is on.
2.6.3
Press the "on" button and make sure the "on" indicator is on; measure whether the three-phase voltage is
balanced.
2.6.4
Shift the handle of "rail clamp" to the "loosening" position and make sure the "loosening" indicator is
on; check whether the rail clamp is loosened.
2.6.5
Press the "electric hooter" button and make preparations for the start-up.
2.6.6
Shift the handle of "tripper car shift" to the "reclaiming" position and check whether the tripper car is in
the "lowest" position.
2.6.7
Contact the master control personnel to start the belt conveyor #3.
2.6.8
Shift the "cantilever belt" handle to the "reclaiming" position and start the cantilever belt conveyor.
2.6.9
Drive the cart to the "reclaiming" location (pay attention to the height of front cantilever to prevent it
from touching the coal pile).
2.6.10
Place the operating handle of "bucket wheel" at the "on" position and start the bucket wheel with no
load; pay attention to the current changes of "bucket wheel motor".
2.6.11
After thorough inspection, contact the main control personnel about the completion of preparations for
reclaiming.
2.6.12
Operate the "elevating" handle to the "rise" or "descend" position; adjust the height of cantilever support
to an appropriate position; select an appropriate operation mode of coal reclaiming according to the conditions of
the coal yard and the coal pile.
2.7 Parking Procedure of Bucket Wheel Machine During the Reclaiming

Operation
2.7.1
After receiving the command of stopping the reclaiming, the driver should stop the rotation of cantilever
support first and raise the front cantilever support.
2.7.2
After all the coal in the bucket wheel is unloaded, shift the "bucket wheel" handle to "zero" position and
make sure the current indication of "bucket wheel motor" is at zero and that the bucket wheel stops rotating.
2.7.3
After all the coal on the cantilever belt is unloaded, shift the "cantilever belt" handle to the "zero"
position and make sure the current indication of "cantilever belt conveyor" is at zero and that the cantilever belt
stops its operation.
2.7.4
After all the coal on belt #3 is unloaded, contact the master control personnel on duty to stop its
operation.
2.7.5
Shift the handle of "tripper car shift" to the "zero" position
2.7.6
Drive the cart to the specified location and place the front cantilever support along the direction of coal
pile.
2.7.7
Press the "off" button and make sure the "off" indicator is on
2.7.8
Shift the "power control" switch to "zero" position and make sure the "power control" indicator is off.
2.7.9
The driver should switch off the main power switch and place the anchoring device if leaving the bucket
wheel machine.
69
2.8 Notes to the Use of Bucket Wheel Machine

2.8.1
The driver shall check the conditions of the coal yard and the coal pile before the operation to make sure
the coal is stacked in a certain shape and reclaimed in layers. Before the traveling of the cart, the front cantilever
of the bucket wheel machine must be raised, so as not to touch the coal pile. It is strictly forbidden to drive the
bucket wheel machine with cantilever touching the coal to avoid tipping.
2.8.2
Before starting the bucket wheel machine, the driver must honk the alarm bell to remind the personnel
around of leaving. During the rotary operation of the cantilever belt conveyor, no one is allowed to stay on both
sides of the cantilever belt.
2.8.3
Reclaiming is forbidden when the cart is traveling. When the cart operates in rotation mode, it must only
travel slowly at a step of 200-300mm. When the cart operates for reclaiming at a fixed point, it shall not travel.
2.8.4
Before the operation of stacking and reclaiming, the driver must make sure the tripper car is at the
appropriate location.
2.8.5
When the cutting height of reclaiming is more than 1/2 of the diameter of bucket wheel machine,
rotation of cantilever support is forbidden.
2.8.6
When the bucket wheel machine is operated with the coal bulldozer, a safe distance of more than 3m
must be maintained.
2.8.7
For stacking at a fixed site, the cantilever height shall be appropriate, and attention shall be paid to the
shift of rotation. It is required that the coal pile shall not touch the cantilever belt and that the cantilever shall not
be located too high to cause coal dust.
2.8.8
Whenever the cable drum goes through the middle position of the coal yard, the retracting and laying
directions of the cable shall be shifted, and the driver must check the rotation state of the drum to make sure
whether the shift switch is correct and whether the voltage is matched.(Note: During cable retracting, the voltage
shall be less than or equal to 250V; during cable laying, the voltage shall be less than 100V.)
2.8.9
During the use of axial plunger-type variable pump of elevating mechanism, attention shall always be
paid to the oil's cleanliness and the prevention of leakage and suction failure accidents.
2.8.10
Maintenance operation is forbidden when the bucket wheel machine is working.
2.8.11
During the rotary operation, attention shall be paid to the shift of rotation, so as not to damage the
devices. The rotary system shall be stable during the operation and free of impact during the shift of direction.
2.8.12
During the stacking of coal, the driver shall keep in touch with the program control personnel and
strictly control the coal quantity. Overloaded operation is forbidden. A distance of more than 3m shall be kept
from the bottom of the coal pile to the rails.
2.8.13
During the parking, the cantilever belt shall be laid flat along the inside of the coal pile.
2.8.14
Lifting heavy objects with the cantilever is forbidden.
2.8.15
When leaving, the personnel on duty shall disconnect the main power switch, turn off the air
conditioning and heating devices and place the anchoring device and rail clamp.
2.8.16
For operation at night, adequate lighting must be provided.
2.8.17
It is forbidden to use the heater in the cab to warm water or food, so as to avoid electric shock.
2.8.18
It is forbidden to use the sprinkler system when the temperature is below zero.
2.8.19
When the wind scale is larger than 6, the devices shall be stopped and appropriate measures shall be
taken.
2.8.20
If any abnormity is identified, the driver shall check it thoroughly and report it to the team chief timely.
2.8.21
If an accident happens and endangers the safe operation of the devices, the driver shall stop the machine
immediately, report it to the team chief and notify the maintenance team for treatment.
70
2.9 Causes and Treatment of Common Faults of Hydraulic System

2.9.1
Sudden stop of the bucket wheel during the operation:
Causes: The bucket wheel gets too deep into the coal pile.
Treatment: Stop the bucket wheel; drive back the cart; raise the cantilever support; restart the machine after the
warning light disappears.
2.9.2
Vibration of oil pipe:
Causes:
a. Air is sucked into the pipe.
b. Oil spills at the overflow valve.
Treatment:
a. Open the air valve of the oil pipe and remove the air.
b. Inform the maintenance personnel for treatment.
2.9.3
Failure to operate of the elevating mechanism:
Causes:
a. The amplitude-variable pump has a low pressure.
b. The solenoid valve does not operate.
Treatment: Inform the maintenance personnel for treatment.
2.9.4
The oil generates foam:
Causes:
a. Oil level is low inside the tank.
b. There is air in the oil pipe.
Treatment:
a. Fill oil to the standard oil level.
b. Open the air valve and remove the air.
2.9.5
Vibration during the elevating:
Causes:
a. There is air in the pipe.
b. The amplitude-variable pump has a low flow or pressure.
Treatment:
a. Remove the air.
b. Inform the maintenance personnel for treatment.
2.9.6
Pressure of the system exceeding that of the overflow valve:
Causes:
a. The overflow valve is stuck.
b. The oil hole is blocked.
Treatment: Stop the machine and inform the maintenance personnel for treatment.
2.9.7
Pumping failure of the oil pump:
Causes:
a. The auxiliary pump has a low pressure.
b. The tank is airtight.
c. The oil has high viscosity.
d. The oil temperature is too low.
Treatment:
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a. Inform the maintenance personnel for treatment.

b. Open the tank cover.
c. Replace the high-viscosity oil with low-viscosity oil.
d. Start the pump in advance to raise the oil temperature.
2.9.8
Low or no pressure of the oil pump:
Causes:
a. Oil spills at the overflow valve.
b. Rotation direction of the pump is not right.
Treatment: Inform the maintenance personnel for treatment.
2.9.9
Excessive heat of the oil pump:
Causes:
a. Pump is worn or damaged.
b. The oil has too low viscosity.
c. The pump exceeds the rated pressure.
2.9.10
Occurrence of significant noise during the operation of the oil pump:
Causes:
a. The piston is too tight or stuck.
b. The oil-suction filter is blocked.
c. The oil level is too low and air is sucked into the suction inlet.
d. The operating oil has too high viscosity.
Treatment:
a. Inform the maintenance personnel for treatment.
b. Inform the maintenance personnel to clean the filter.
c. Check the oil level and add oil.
d. Replace the high-viscosity oil with low-viscosity oil.
2.10 Maintenance of the Bucket Wheel Machine

2.10.1
General Provisions of Lubrication Points and Lubrication
2.10.1.1 The bearings and bushings of the traveling wheel of tripper car, the turnabout drum of tripper car belt,
cable drum, driving and driven wheels of traveling mechanism, and the drum roll and turnabout drum of
cantilever belt conveyor etc. shall be injected once a week with calcium-based lubricating grease.
2.10.1.2 The slewing bearing and bucket wheel bearing shall be injected with lubricating oil and grease (onethird of oil mixed with two-thirds of lubricating grease) with manual pump for each shift.
2.10.1.3 The roller bearings shall be filled with lubricating grease once. Attention shall always be paid to the
operation conditions.
2.10.1.4 The hydraulic coupler shall use #20 turbine oil and the oil level shall be checked once a week.
2.10.1.5 The reduction gearboxes of travelling mechanism, rotary mechanism, cantilever belt conveyor, bucket
wheel drive and cable drum shall use N220 medium extreme pressure gear oil, and the oil shall be filtered or
replaced every six months.
2.10.1.6 The brake push rod shall use #20 turbine oil.
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2.10.2 Refueling and Maintenance System for Bucket Wheel Machine

2.10.2.1 Management of the oil shall be strengthened, and different types of oil shall be kept separately and may
not be used indiscriminately.
2.10.2.2 Oil drums must be dedicated, clean and kept properly with no oil spills, damages or lost.
2.10.2.3 Operating personnel must be acquainted with the characteristics commonly-used grease, so as to avoid
the use of wrong grease and causing damages to the devices.
2.10.2.4 All oil inlets and nozzles of the bucket wheel machine must be complete and intact. Otherwise, the
operator shall promptly notify the maintenance personnel for treatment.
2.10.2.5 The operating personnel shall monitor the oil level of the hydraulic system and all reduction gearboxes,
and add oil timely when the oil level falls below the specified level.
2.10.2.6 Refueling must be carried out conscientiously. Careless and fraudulent behaviors are forbidden.
2.10.3
Maintenance and Inspection Items of Bucket Wheel Machine
2.10.3.1 The oil dirt and dust on all motors, pumps and tanks, and the materials at the head and tail drums, in the
upper roller room and on the turnabout drum shall be cleaned during the day shift on every Monday.
2.10.3.2 All parts of the machinery, the hydraulic system and lubrication points shall be inspected during the day
shift on each day.
2.10.3.3 Ground wire of the rails shall be inspected during the day shift on each day to ensure good electrical
conductivity, as well as the ground wire of all electrical devices.
2.10.3.4 The oil level of all reduction gearboxes shall be checked during the day shift on every Monday, and oil
shall be added if it is insufficient.
2.10.3.5 The bearings and bushings of the traveling wheel of tripper car, the turnabout drum of tripper car belt,
cable drum, driving and driven wheels of traveling mechanism, and the drum roll and turnabout drum of
cantilever belt conveyor etc. shall be injected with calcium-based lubricating grease once a week during the day
shift on every Tuesday.
2.10.3.6 The slewing bearing and bucket wheel bearing shall be injected with lubricating oil and grease with
manual pump for each shift.
2.10.3.7 The limit switches of traveling, slewing and elevating mechanisms shall be inspected by the means of
starting the machine during the day shift on every Wednesday with the cooperation of maintenance personnel; the
rails shall also be checked (the rails shall not sink; the wheels shall not get stuck between the rails, or rub the
edges or have axial displacement); the roadbed and rail shall be calibrated.
2.10.3.8 The clearance and operating conditions of the traveling brake shall be inspected and tested with the
cooperation of maintenance personnel during the day shift on the fourth of each month (normal clearance shall be
0.5-0.7mm).
2.10.3.9 The working conditions of distribution box and all other electrical components shall be inspected and
tested with the cooperation of electrical maintenance personnel during the day shift on the fifth of each month.
2.10.4
Requirements of Hydraulic System
2.10.4.1 The hydraulic oil filled in the tank of the machine must be filtered with the oil filter before its use.
2.10.4.2 Oil pipe system shall be kept clean; the parts with oil leakage shall be cleaned up promptly.
2.10.4.3 Air shall be prevented from entering the oil pipe system. Oil in the tank shall be maintained above the
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specified oil level. After the maintenance, the pump must be filled with oil before the trial run, to prevent pumping
failure and damage to the pump. It is strictly prohibited to start the pump under the operating conditions of
simultaneous maximum working pressure and maximum flow. The pump flow shall be reduced at the rated
working pressure.
2.10.4.4 After the maintenance in winter, the pump shall be started and stopped several times during the trial run
to warm the oil. Operation can be started after the hydraulic parts operate flexibly.
2.10.4.5 During the cleaning of the tank, the pulverized coal as well as the cotton cloth etc. used for wiping the
tank shall be prevented from falling into the tank.
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Chapter III Program Control System

3.1 Control Object
S/N
Content of Monitoring and

Control
Qty
Code
belt conveyor
24
Oscillating coal feeder
11
YG
Bucket wheel stacker and

reclaimer
DL
Coal crusher
SM
High screen
GS
Fine crusher
XS
Raw coal bunker
Unloading car unloader
belt-type iron separator
CT
10
Plate-type iron separator
CT
12
Electric three-way
13
ST
13
Vibrator
16
16
14
Precipitator
35
CC
15
Sampling device for coal as

fired
QY
16
Object calibration device
SJ
17
Electronic belt scale
2 sets
DZC
18
Bridge-type coal grab
Set
QZ
Remarks
Only interlock and output and input of

"stacking and reclaiming" signals are
involved.
Response signal only
3.2 Control Functions

Coal handling control system has strong control and monitoring functions. PLC control program can realize
the automatic sequence control of coal handling system (including coal loading and coal blending), and provide a
variety of auxiliary operational control modes (interlocking manual control and unlocking manual control, etc.).
The program control system also provides powerful monitoring and management functions, including: process
monitoring, analog monitoring, alarm management, report management, voice alarm, operation help etc.
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3.3 Functions of the Main Screen Buttons

3.3.1
Program-Controlled Start After selecting and confirming the process is right, click the button for
automatically starting the selected process devices in accordance with the program in opposite direction of coal
flow;
3.3.2Program-Controlled Stop After the completion of coal loading, click the button for automatically
stopping the process devices in accordance with the program in the direction of coal flow;
3.3.3
Interlocking Automatic Mode one operation mode of coal loading. Click the button and its color
will change from green to red, indicating that the automatic operation mode has been selected in the coal loading
system;
3.3.4
Interlocking Manual Mode one manual operation mode of coal loading. Click the button and its
color will change from green to red, indicating that the interlocking manual operation mode has been selected in
the coal loading system;
3.3.5
Unlocking Manual Mode one manual operation mode of coal loading. Click the button and its
color will change from green to red, indicating that the unlocking manual operation mode has been selected in the
coal loading system. The operation mode is used by the upper workstation to operate the field devices when the
whole system has no interlocking relationships.
3.3.6
Programmed Coal Blending one mode of bunker allocation. Click the button and its color will
change from green to red, indicating that the mode of programmed bunker allocation has been selected. During the
bunker allocation, the coal plow will automatically lift and drop in accordance with the program to feed coal into
the bunker.
3.3.7
Manual Coal Blending one mode of bunker allocation. Click the button and its color will change
from green to red, indicating that the mode of manual bunker allocation has been selected. During the bunker
allocation, the operator can lift and drop the coal plow by using the mouse on the upper screen to feed coal into
the bunker.
3.3.8
Menu Selection Click the button and the sub-buttons of real-time trend, historical trend, alarm
record, report management and exit will pop up.
3.3.8.1 Real-Time Trend Click the button to bring up a screen showing the status of the devices in a chart
form. The data will not be saved, but only used for real-time analysis.
3.3.8.2 Historical Trend Click the button to bring up the screen with historical trend chart.
3.3.8.3 Alarm Record Click the button to bring up the screen with alarm records. Alarm events and
associated attributes shall be recorded in a tabular form, which is easy for query.
3.3.8.4 Report Management Click the button to bring up the screen with report operation. The operator
can fill in, query or print the reports.
3.3.8.5 Exit close the menu selection.
3.3.9
Process Selection Click the button to bring up the screen with process selection. All devices for
different processes are included in the screen. Click the responsive device box, and its color will change,
indicating that the device has been selected. When the process is selected correctly, a message box will pop up to
prompt the next step of operation.
3.3.10
Coal Blending Selection Click the button to bring up the screen with coal blending selection. It is
used to set the tail bunker and manually select the bunkers.
3.3.11
Equipment Maintenance Click the button to bring up the equipment maintenance screen. It can be
used to set the maintenance status of the equipment under repair and maintenance. The equipment set with
maintenance status cannot be operated from the upper screen.
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3.3.12
Fault Removed Faults affecting the operation of the equipment shall be removed immediately.
After the troubleshooting, click the button to confirm it before continuing to operate the equipment.
3.3.13
Current Display Click the button to bring up the screen with the current state of the belt. The
screen can reflect the real-time current value of the belt in operation visually in the form of instrument.
3.3.14
Zero Clearance of Electronic Scale The program control system can accumulate the coal amount
according to the measuring pulse of the electronic scale. Click the button to bring up the screen with zero
clearance of electronic scale, and to further confirm whether to clear the figure. If yes, click the button of zero
clearance in the screen.
3.3.15
Help Click the button to bring up the help screen. A detailed description of the selected devices for
each process is included in the screen to facilitate the operator to understand.
3.3.16
System Control Functions and Operation Flow
Coal handling control system mainly has the following operation control modes: automatic mode, interlocking
manual mode and unlocking manual mode and local manual mode. Automatic mode is the normal operation
mode.
3.4 Automatic Mode

3.4.1
Process of Automatic Mode
The automatic mode is used to achieve the sequential automatic control of coal handling technological process
(startup of the devices in the opposite direction of coal flow, shutdown in the direction of coal flow, interlocking
protection etc. are performed automatically by the program control). In automatic mode, the workstation function
keys or mouse are used to operate.
3.4.1.1 Combination of Operation Modes of Coal Handling Control System
3.4.1.1.1Raw coal field Coal yard
3.4.1.1.1.1Underground coal scuttleOscillating feederC1A beltCoarse crusher AC2A beltC3A
beltCantilever Buchet Wheel stacker RechlaimerCoal yard
3.4.1.1.1.2Underground coal scuttleOscillating feederC1B beltCoarse crusher BC2B beltCA3
beltBucket wheel machineCoal yard
3.4.1.1.2 Coal yard raw coal bunker
3.4.1.1.2.1
Bucket wheel machine C3A belt C4AB belt high screen AB C5AB belt C7AB
belt C8AB belt C9AB belt raw coal bunkers (1A1B1C1D)2A2B2C2D
3.4.1.1.2.2Bucket wheel machine C3A belt C4AB belt high screen AB Fine coal crusher AB
C5CD belt high screen C5AB belt C7AB belt C8AB belt C9AB belt raw coal bunkers
(1A1B1C1D)2A2B2C2D
3.4.1.1.2.3Bucket wheel machine C3A belt C4A belt high screen A Fine coal crusher A C5C belt
high screen C6B belt fine crusher C5C belt high screen C5A beltC7A belt C8AB belt
C9AB belt raw coal bunkers (1A1B1C1D)2A2B2C2D
3.4.1.1.2.4Bucket wheel machine C3A belt C4B belt high screen B Fine coal crusher B C5D belt
high screen C6A belt fine crusher C5D belt high screen C5B beltC7B belt C8AB belt
C9AB belt raw coal bunkers (1A1B1C1D)2A2B2C2D
3.4.1.1.3Raw coal field Raw coal bunker
3.4.1.1.3.1Underground coal scuttleOscillating feederC1AB beltCoarse crusher ABC2AB beltC3CD
beltC4AB beltHigh screen ABC5AB beltC7AB beltC8AB beltC9AB beltRaw coal
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bunker(1A1B1C1D)2A2B2C2D
beltC4AB beltHigh screen ABFine coal crusher ABC5CD beltHigh screen C5AB beltC7AB
beltC8AB beltC9AB beltRaw coal bunker (1A1B1C1D)2A2B2C2D
beltC4A belt High screen AFine coal crusher AC5C beltHigh screen C6B beltFine crushC5C
beltHigh screen C5A beltC7A beltC8AB beltC9AB belt Raw coal bunker(1A 1B 1C 1D)
2A2B2C2D
beltC4B beltHigh screen BFine coal crusher BC5D beltHigh screen C6A beltFine crushC5D
beltHigh screen C5B beltC7B beltC8AB beltC9AB belt Raw coal bunker(1A 1B 1C 1D)
2A2B2C2D
3.4.1.1.4Emergency underground coal bunker Raw coal bunker
3.4.1.1.4.1Emergency underground coal bunkerOscillating feederC3B beltC4AB beltHigh screen
ABC5AB beltC7AB beltC8AB beltC9AB beltRaw coal bunker(1A 1B 1C 1D)
2A2B2C2D
3.4.1.1.4.2Emergency underground coal bunkerOscillating feederC3B beltC4AB beltHigh screen
ABFine coal crusher ABC5CD beltHigh screen C5AB beltC7AB beltC8AB beltC9AB
beltRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.4.3Emergency underground coal bunkerOscillating feederC3B beltC4A belt High screen
AFine coal crusher AC5C beltHigh screen C6B beltFine crushC5C beltC5A beltC7A
beltC8AB beltC9AB belt Raw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.4.4Emergency underground coal bunkerOscillating feederC3B beltC4B belt High screen
BFine coal crusher BC5D beltHigh screen C6A beltFine crushC5D beltC5B beltC7B
beltC8AB beltC9AB beltRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.5Coarse coal underground coal bunker Raw coal bunker
3.4.1.1.5.1Coarse coal underground coal bunkerOscillating feederC10C3CDC4ABHigh screen
ABC5AB beltC7AB beltC8AB beltC9AB beltRaw coal bunker(1A 1B 1C 1D)
2A2B2C2D
3.4.1.1.5.2Coarse coal underground coal bunkerOscillating feederC10C3CDC4AB beltHigh screen
ABFine coal crusher ABC5CD beltHigh screen C5AB beltC7AB beltC8AB beltC9AB
beltRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.5.3Coarse coal underground coal bunkerOscillating feederC10C3CDC4A belt High screen
AFine coal crusher AC5C beltHigh screen C6B beltFine crushC5C beltC5A beltC7A
beltC8AB beltC9AB beltRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.5.4Coarse coal underground coal bunkerOscillating feederC10C3CDC4B beltHigh screen
BFine coal crusher BC5D beltHigh screen C6A beltFine crushC5D beltC5B beltC7B
beltC8AB beltC9AB belt Raw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.6Fine coal underground coal bunker Raw coal bunker
3.4.1.1.6.1Fine coal underground coal bunkerOscillating feederC11C5CD beltHigh screen C5AB
beltC7AB beltC8AB beltC9AB beltRaw coal bunker((1A1B1C1D)2A2B2C2D
3.4.1.1.6.2Fine coal underground coal bunkerOscillating feederC11C5C beltHigh screen C6B
beltFine crushC5C beltC5A beltC7A beltC8AB beltC9AB belt Raw coal
3.4.1.1.6.3Fine coal underground coal bunkerOscillating feederC11C5D beltHigh screen C6A
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beltFine crushC5D beltC5B beltC7B beltC8AB beltC9AB belt Raw coal

3.4.1.1.7Coal yard Raw coal bunkerCombined upper coal method
3.4.1.1.7.1 Coal yardBucket wheel machineC3A+C10C4ABHigh screen ABC5ABC7AB
C8ABC9ABRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.7.2 Coal yardBucket wheel machineC3A+C10C4ABHigh screen ABC5CD+C11High
screen C5ABC7AB C8ABC9ABRaw coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.7.3 Coal yardBucket wheel machineC3A+C10C4AHigh screen AFine coal crusher AC5C
beltHigh screen C6B beltFine crushC5C beltC5A beltC7A beltC8AB beltC9AB belt Raw
coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.7.4Coal yardBucket wheel machineC3A+C10C4BHigh screen BFine coal crusher BC5D
beltHigh screen C6A beltFine crushC5D beltC5B beltC7B beltC8AB beltC9AB belt Raw
coal bunker(1A1B1C1D)2A2B2C2D
3.4.1.1.7.5Coal yardBucket wheel machineC3A+C10C4AHigh screen AC5C+C11High screen
C6B beltFine crushC5C beltC5AC7A C8ABC9ABRaw coal bunker(1A 1B 1C 1D)
2A2B2C2D
3.4.1.1.7.6Coal yardBucket wheel machineC3A+C10C4BHigh screen BC5D belt+C11High screen
C6A beltFine crushC5D beltB5BC7B C8ABC9ABRaw coal bunker(1A 1B 1C 1D)
2A2B2C2D
3.4.1.2 Selection of Operation Mode
Click the "Automatic" button with a mouse in the bottom of the screen, and the automatic button will change from
green to red, indicating that the automatic operation mode has been selected in the coal handling system.
3.4.1.3 Setting of Bunker Allocation Mode
Before the process is started, if the process is from the coal source to the coal bunker, the bunker allocation mode
must be selected at this time. Point the mouse to the "Bunker Setting" button in the bottom of the operation screen,
and click the left mouse button to pop up the "Bunker Setting Operation Box". If "Automatic Bunker Allocation"
is desired, point the mouse to the button "Automatic Bunker Allocation", and click the left mouse button. When
the color of the indicator of "Automatic Bunker Allocation" button changes, it indicates that automatic bunker
allocation mode has been selected. Selection steps of manual bunker allocation mode are the same as those of
automatic bunker allocation mode.
3.4.1.4 Selection of Process
Process shall be selected with the upper computer. A total 26 processes are included in the three combinations.
In the flow chart, use the mouse to click the box with the name of the process-related devices to be started, and the
color of the device name will change, indicating that the device has been selected. When all the devices for the
selected process have been selected, a prompt box will pop up to prompt the operator to click the button of the
selected process. If wanting to re-select, the operator can click the "re-select" button, and then the process can be
re-selected. Then follow the prompts and click the process button below the flow chart. When the left mouse
button is released, and corresponding prompts will pop up if any device for the process has occupied by another
process, or if there is any device not in the programmed position, or if any device has a fault. If the selected
process meets the conditions of start, a operation box of correct process will pop up.
3.4.1.5 Start of Process
After it is confirmed that the process can be started, give a first bell at the field. When the first bell is given, the
electric retractable devices and electric three-way baffles within the scope of the process start to operate, and the
process can be started after the bell. Point the mouse to the Start button and click the left mouse button, and then
the process is started.
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If a baffle is not in place, an accident prompt will pop up in the CRT station monitoring screen, and the operation
of the process will be interrupted. If all the electric retractable devices and electric three-way baffles within the
scope of the process are in place, all the selected devices along the line will be started in a delay mode from the
end of the belt conveyor to the coal source in accordance with the selected process in the opposite direction of the
coal flow.
3.4.1.6 Stop of Process
When the coal handling is completed, "process stop" operation shall be carried out immediately. For "process
stop" operation, all the selected devices will be stopped one by one in a preset delay time mode from the coal
source device to the last device according to the selected process along the coal flow direction. The delay time is
set to ensure that the device in operation will not be stopped before all the coal on it is unloaded.
During automatic operation, if any device is identified with a fault or accident, such as stay cord failure, severe
off-tracking and skidding or coal-blocking for10 seconds, stop the belt immediately and trip all the devices in an
interlinked way in the opposite direction of coal flows. While the devices downstream the fault point shall be
maintained in the original working state. After the fault is removed, click the "Fault Removed" button at the
bottom of the operation screen to re-start the devices from the upstream of the fault point in a delay mode. The
operator can also perform the "process stop" operation when the fault is not removed, i.e., stopping the devices
one by one in a preset delay time mode from the downstream of the fault point to the last device along the coal
flow direction. Coal crusher shall not be tripped if it itself is free of faults. When the "Emergency Stop" button
(available on the operating console and the upper computer) is pressed, all other operating devices along the line
will be stopped immediately.
The status of the devices can be checked any time on the upper computer CRT, such as running, coal-blocking,
off-tracking, skidding, and stay cord failure.
The system also has the function of overhaul setting for the device. When the on-site device needs an overhaul,
the operator can set "Overhaul" for the device on the upper computer, and then the PLC control program will stop
the operation of the device.
3.4.2 Manual Operation
Manual operation includes interlocking manual mode and unlocking manual mode.
Point your mouse to the Manual button and click your mouse. The "manual checkbox" is displayed. To
choose the interlocking manual mode, point your mouse to the Interlocking Manual and click your mouse. When
the indicator turns from gray to red, the system has switched to the interlocking manual mode. The steps for
choosing unlocking manual mode are the same as those for the interlocking manual mode.
3.4.2.1 Interlocking manual mode: after you choose and start the running process, start devices one-to-one
on the upper workstation against the coal flow; you can operate any device in the process during shutdown, and all
devices are in interlocking shutdown status before you operate them. The interlocking relation is the same as the
automation mode in the running process. You need to notice one point here: interlocking manual operation upon
any device in the stop-running process only be applied in an emergency. To use the interlocking manual mode to
stop a device, you send a fault signal to the program equivalently. If you want to restart this device, you must
follow the "fault removal" procedure.
3.4.2.2 Unlocking manual mode
The unlocking manual mode refers to operating onsite devices from an upper workstation without any
interlocking relations. In this mode, you can start or stop any onsite devices.
Note: if a system has any device running in the automated or interlocking manual mode, you are not
80
allowed to switch the system to the unlocking manual mode. Otherwise, the interlocking relations of original
running devices are removed, and they cannot be interlockingly stopped at an accident.
3.4.3 Coal Blending Mode
Coal blending includes "auto blending", "manual blending", and "local blending". "Auto blending" further
includes sequential blending, residual blending, and prioritized blending (low coal level).
3.4.3.1 Control mode of auto blending
First select the tail bunker, overhaul plow, and overhaul bunker. The upper display shows the symbol of tail
bunker beside the coal bunker, and the corresponding plow will turn gray after being set as "overhaul" state. On
the "blending checkbox", choose "auto blending", the conveyor system sends the "program starting" signal and the
conveyor belt runs first, carrying out a sequential coal blending for target coal bunkers by their sequence. Each
bunker consumes several minutes (dependent on the actual condition of the site), and the system goes to the next
bunker, with overhaul plows automatically skipped. When bunkers are full, a high coal level alarm is sent. In the
process of sequential blending, coal plows of high coal level are automatically skipped.
In the process of auto blending, if any bunker has a low coal level or extra-low coal level, the programmed control
system automatically switches to this bunker until the low-coal-level signal is removed. If any bunker behind the
tail bunker has a low coal level or extra-low coal level, the system sends an "empty bunker" alarm.
After all bunkers involved in the coal blending have a high coal level, the program automatically performs a
delayed stop from the coal source, and at the same time starts residual blending via the belt from the first coal
plow. In this process, the system allocates a certain time for each plow following the coal flow direction before
switching to the next plow for coal blending. After all plows are completed, the sequential residual blending
program switches back to the first plow for a circulation until the conveyor belt stops.
In the sequential blending and residual blending processes, if any plow is lowered and stuck, the "lowering stuck"
signal is sent, and the system automatically sets this plow as an "overhaul plow" without affecting the following
coal plows. During auto blending, if any plow is lifted and stuck, the "lifting stuck" signal is sent, and the system
automatically sets the plow as tail plow, and the bunker where the plow resides as the tail bunker, without
affecting the auto blending process.
The upper computer in this system has the overhaul function for coal plows and coal bunkers. Any coal plow or
overhaul bunker set as "overhaul state" do not participate in the coal blending, and overhaul plows are
automatically skipped in coal blending.
3.4.3.2 Manual blending mode
The "manual blending" mode is to realize one-to-one soft operation of "lifting and lowering" for onsite plows via
the PLC of an upper computer.
3.4.3.3 Bunker metering
The coal blending system is also provided with complete bunker metering and furnace metering function, which
creates conditions for balance calculation of the power plant.
The programmed control system can added up feed amount of each coal bunker based on the measuring impulse
of electronic belt scale for metering of each bunker and furnace, to form the coal consumption reports.
3.4.4 Monitoring and Alarm
3.4.4.1 The upper software not only sends control commands, but also monitors working status and parameters of
each device. The control system of the upper computer has abundant operation interface functions, which
81
visualize the production and management processes of the coal handling system, making the programmed control
more precise. System interfaces include the flow chart interface, trend interface, report interface, and composite
window interface.
3.4.4.2 Device accident alarm
The programmed system is provided with complete alarm functions for the protection of belt conveyor:
stretching, deviation, slipping, tearing, and blocking, etc.
The PLC has the self-diagnosis function.
a) Voice alarm: the upper computer automatically starts the multimedia voice based on the fault information when
a fault occurs and sends the voice alarm though the audio device.
b) The PLC can display the fault time and fault nature in Chinese characters, and make recordings.
c) Some parts of the flow chart on computer screen can change colors or flickers, to indicate the fault areas.
d) After a device sends an accident alarm, the monitoring screen of the upper computer can automatically display
the flow chart of the fault area, the figure of the major accident device changes its color, and the real-time alarm
little window shows the accident nature and occurrence time. At the same time, the voice alarm system sends a
voice to report the accident situation.
e) Alarm records can be outputted from a CRT screen or printer, and saved on the hard disk as ASCII files for 30
days.
f) Over the screen, you can click "interlocking auto" or "interlocking manual" to interlockingly-manually choose a
coal loading mode. When the alarm window under the button turns from green to red, the running mode has been
selected.
3.4.5 Inspection and Preparation Before System Shift-Over and Start
3.4.5.1 Preparation before shift-over
3.4.5.1.1 The chief attendant shall first check running logs, shift records, equipment defects, and work sheets, and
master equipment operation and maintenance, equipment defects, and other abnormalities.
3.4.5.1.2 Voltage indications displayed on the CRT shall be in normal scope.
3.4.5.1.3 All buttons, mouse, indicators, switches, and signals are intact, and all monitors and onsite cameras work
properly. Otherwise, query the chief attendant of the shift and report to the shift leader if necessary.
3.4.5.1.4 If the system is running during a shift change, carefully observe indications of the ampere meter and
working conditions of each monitor, and do not change the shift until everything is secured. The one take the shift
will be liable for any problem rising from the shift change.
3.4.5.1.5 The communication system works normally, and air conditioners and other equipment/tools are intact.
3.4.5.1.6 Utilities, doors and windows are intact.
3.4.5.1.7 Disk faces, table boards, floors, glass, toilets, and stairs shall be clean and reach the standards for
civilized production.
3.4.6. Pre-start Check
3.4.6.2.1 The chief attendant shall call the local attendant 10 minutes before the start to explain the running
mode of the equipment and arrange for pre-check, especially to check the change-over switch, pull switch, verify
the position of baffles, and confirm that there is no condition endangering personal or equipment security and no
maintainer is working. Only upon the reception of a confirmative callback, can the equipment be started. If the
local attendant does not reply to the call, the equipment can by no means be started. The chief attendant shall
82
always concern about safety production.

3.4.6.2.2 Carefully check and test faulty audios, CRT screen indicators, and alarm windows, and contact
maintainers immediately if any exception is found.
3.4.6.2.3 Select the correct process based on the running mode that the shift leader sets.
3.4.6.2.4 If there is any problem or you want to use other running mode, report to the shift leader and notify
the local attendant to recheck the system.
3.4.6.2.5 Set tail bunkers based on the running condition of the boiler pulverizing system.
3.4.7 Precautions for Programmable Operation and Monitoring
3.4.7.1 Precautions
3.4.7.1.1 Before the system is started, notify the local attendant for overall inspection and verification of
baffle position. Do not start the equipment until the local attendant calls back.
3.4.7.1.2 When the equipment is started, the normal current shall be restored in 5 seconds, and no-load
current for each device shall be in the normal range. Otherwise, stop and check the equipment.
3.4.7.1.3 When the system is started, do not start the next belt until the upper belt is started normally.
3.4.7.1.4 Do not start the equipment frequently. You can start the equipment twice continuously only at cold
state.
3.4.7.1.5 If the current of the running equipment rise abruptly or drop to zero, stop the equipment
immediately.
3.4.7.1.6 Closely watch the current of equipment, coal level in bunkers, system alarms, and display of alarm
windows, control feed amount of coal, and control the system output to 400t/h.
3.4.7.1.7 For monitoring, notice whether indicators of equipment on the CRT are normal, and whether preset
drop positions of coal plows meet the requirements of prioritized coal blending and sequential coal blending.
Concentrate and be smart. In case of any exceptions found, operate precisely. Do not chat or do anything
irrelevant to the work.
3.4.7.1.8 Do not test indicators or do other test during the running, and do not touch any buttons related to the
running.
3.4.7.2 Monitoring for running
When the system is running, closely monitor the ampere meters and signals of each power device, and handle
any exception immediately with correct judgment and method:
3.4.7.2.1 If the current or load of the system increases, notify the coal source attendant to adjust the feed
amount. The chief attendant shall be liable for the abnormal sound generated due to overload.
3.4.7.2.2 If a belt conveyor has a large current fluctuation while other belt conveyors work properly, the
possible cause is that the belt of the conveyor is stuck, deviated, or broken, the end support roller falls off, or the
tension device and driving device fail. In these cases, immediately stop the equipment and all other devices to the
coal source, and notify the local attendant to check for the problem.
3.4.7.2.3 If a crusher sees abnormally changing or abruptly fluctuating current, the possible cause is
overload, coal jam, getting stuck by foreign articles, hammer ring damage to lose weight balance, motor failure,
bearing or bearing pedestal fault, or crushing malfunction caused by foreign articles. In these cases, immediately
open the bypass door of the roller screen and disable the interlocking mechanism. Stop the equipment and report
to the shift leader.
3.4.7.2.4 If the upper conveyor sees a gradually decreasing current while the next conveyor sees a gradually
increasing current, the possible cause is coal jam. In this case, stop the equipment and all devices to the coal
83
source immediately.
3.4.7.2.5 If the current suddenly drops below the normal no-load value, the belt may be broken or the coupler
is damaged. In this case, immediately stop the equipment and all devices to the coal source.
3.4.7.2.6 If the current suddenly drops to zero, there may be a local shutdown or appliance failure. In this
case, stop the equipment and all devices to the coal source.
3.4.7.2.7 When the "sequential blending" mode is used, notice the coal levels and avoid coal overflow.
3.4.7.2.8 When the signal of baffle position changes, the interlocking mechanism shall not actuate.
3.4.7.2.9 If the belt iron separator loses power, notify the local attendant to check the problem.
3.4.8 Failure Causes in Programmable Operation and Treatment
In case of any fault occurring to primary and secondary equipment of the coal handling system, immediately
report to the shift leader, notify local attendants to handle the problem, and report to related leaders if necessary.
Contact maintainers for proper treatment.
3.4.8.1 Failure of belt conveyor
3.4.8.1.1 Belt conveyor shuts down, and the ampere meter points to zero.
Causes:
a) Thermocouple actuating of motor;
b) Fault of operation loop;
c) Shutdown by the attendant;
d) Blown fuse.
Treatment:
Quickly check whether the failed belt conveyor is connected in shunt tripping to the next belt conveyor. If no,
immediately stop the failed machine and all belt conveyors to the coal source.
3.4.8.1.2 The current of belt conveyor increases during running and fluctuates abnormally.
Causes:
a) The belt deviates, to increase the resistance;
b) The belt is overloaded;
c) The belt slips, causing the current to fluctuate greatly;
d) The belt deviates due to insufficient tension, causing great fluctuation of ampere meter, because the
tension device fails, and the friction changes accordingly;
e) The belt is torn longitudinally, and is therefore hindered suddenly, causing the current to rise instantly;
f) The return belt carries coal, making the tension device turn over from the rail, and the current increases.
g) Driving, rotating, and transmission parts fail, raising the current.
Treatment:
a) Notify the local attendant to check the equipment. If the problem persists, stop all belt conveyors from the
failed equipment to the coal source as well as the coal source equipment for adjustment.
b) Notify the attendant of the coal source equipment to decrease feed amount, and stop the coal source
equipment if necessary.
c) Stop all belt conveyors from the failed equipment to the coal source as well as the coal source equipment,
and stop the failed equipment if necessary.
d) Immediately stop all belt conveyors from the failed equipment to the coal source as well as the coal source
equipment.
3.4.8.1.3 The current of belt conveyor drops suddenly below the no-load current during operation.
84
Causes:
The belt is horizontally broken, and the driving, rotating, and transmission parts are idle.
Treatment: immediately stop all belt conveyors from the equipment to the coal source, as well as the coal
source equipment.
3.4.8.2 Unexpected shutdown of vibration coal feeder
Treatment: query the local attendant of the vibration coal feeder and report to the shift leader. Report to
related leaders if necessary. Contact maintainers.
3.4.8.3 A High amplitude vibration screen fails, and the running indicator is off.
Treatment: quickly check whether all devices between the High amplitude vibration screen and coal source
are tripped. If there is no shunt tripping, stop the roller screen, notify the attendant to stop the coal source
equipment, and report to the shift leader.
3.4.8.4 Failure of belt iron separator
3.4.8.4.1 The iron separator is tripped during operation, the running indicator is off, the accident horn rings,
and the "iron separator is tripped" alarm window is on.
Causes:
a) Local abnormal shutdown;
b) The belt iron separator fails, but the thermocouple replay actuates.
Treatment:
Report to the shift leader, and notify the local attendant or maintainers to check the fault. Do not start the
equipment until the fault is removed.
3.4.8.4.2 The belt iron separator loses power, and running indicator is off, and the "control power off" alarm
window is on.
Causes:
a) The local attendant cuts off the power;
b) Blown fuse;
c) Fault of operation loop.
Treatment:
a) Report to the shift leader;
b) Notify the local attendant to check the problem;
c) If the local attendant does not cut off the power, contact maintainers.
3.4.8.5 Failure of coal crusher
3.4.8.5.1 The coal crusher is overloaded, and the current increases.
Causes:
a) The system output is large;
b) Pores of High amplitude vibration screen are blocked;
c) The hammer ring is damaged or stuck by foreign articles.
Treatment:
Stop the coal crusher, and open the bypass baffle of the High amplitude vibration screen (until the bypass is
through).
3.4.8.5.2 The coal crusher has a coal jam, and the current increases.
Causes:
a) The system output is large;
b) Pores of High amplitude vibration screen are blocked;
c) Belt C5 stops and is not interlocked, and belt C4 is tripped.
85
Treatment:
Stop the coal crusher, and open the bypass baffle of the High amplitude vibration screen (until the bypass is
through).
3.4.8.5.2 The coal crusher vibrates, and the current increases.
Causes:
a) The hammer ring is damaged, and the rotor loses balance;
b) It gets stuck by foreign articles that enter the machine;
c) The rotating parts, or motor, bearing, and bearing pedestal work abnormally.
Treatment:
Immediately stop all running equipment from the coal crusher to the coal source.
3.4.8.6 The coal feeder fails, and the running indicator is off.
Causes:
a) The local attendant shuts down the equipment by spotting an exception;
b) Blown fuse
Treatment:
Report to the shift leader and query the local attendant. Do not start the equipment until the fault is removed.
3.4.8.7 Failure of electrical baffle
3.4.8.7.1 Both "A on" and "B on" indicators are on.
Causes:
a) The baffle is not in the correct position;
b) The limit switch is damaged.
Treatment:
Notify the local attendant to verify the condition. If the fault cannot be removed, be prepared for noninterlocking during shutdown, and report to the shift leader.
3.4.8.7.2 Both "A on" and "B on" indicators are off.
Causes:
Blown fuse or damaged position signal indicator.
Treatment:
Notify the local attendant to verify the condition. If the fault cannot be removed, be prepared for noninterlocking during shutdown, and report to the shift leader.
Attached table: Checklist for regular test and switchover of coal handling system
Date
Monday
Tuesday
Content
System interlocking test
Requirements and Standards
Executor
After the running equipment is loaded with
Shift
leader,
coal, the baffle is put to position via
and
programmed control, and the indicator is on.
attendant
Inspection and test of unloading
The baffle position is normal,
Chief
car unloader
flexible walking, no jam
deputy
chief
and
attendants
Wednesday
Thursday
Oil level and quality inspection
Inspection and test of vibration
Oil levels in each oil cup and inspection holes
Chief
are normal, free of leakage and quality
deputy
degradation..
attendants
Coal amount is adjusted and subject to
Chief
86
and
and
coal feeder
overall inspection.
deputy
attendants
Friday
belt deviation signal test
Actuating properly
Chief
and
deputy
attendants
Saturday
Inspection
and
test
of
high
amplitude crusher
Iron separating room is thoroughly cleaned
Chief
and all checked.
deputy
and
attendants
Sunday
Inspection and test of audio,
Pull
accident button, and ancillary
collector, iron separator, and accident audio
devices
are in normal conditions.
10 , 20 ,
Cleanup of zero-meter ash trench
West and east trenches are cleaned, and the
and 30
of boiler
floor is flushed clean.
Coal grab in the coal-water
Grad interior of the settling pond is clean.
th
th
th
switches,
start/stop
signals,
dust
Chief
attendant
Shift leader
every
month
1st every
month
settling pond
Driver of the
bridge-type
coal grab
rd
3 every
Cleanup of coal grabbed from the
Drive of the
month
coal-water
coal bulldozer
settling
pond
and
transfer to the coal yard

Every
Test of emergency lamp
Chief
Monday
attendant, and
attendants
of
each belt
Every
Air filter inspection of vehicles
Drive of the
Monday
Every
Tuesday
coal bulldozer
Oil level and quality check for
Drive of the
vehicles, and refuel
coal bulldozer
Remarks: 1. Regular work shall be performed between 8: 00 to 14: 00 everyday with the results properly
recorded, and the defect list shall be filled in case of any problem.
2. Each shift shall implement related inspections and tests based on the above requirements, which are listed
into examination.
87
Chapter IV Loader
4.1 Structure and Performance
4.1.1 Structure
The loader is mainly composed of eight parts: diesel engine, hydraulic torque converter, gearbox, drive shaft and
drive axle, steering system, brake system, hydraulic system, and electrical system.
4.1.2 Technical Performance
Table 1
Item
Unit
Performance specifications of loader

Specificatio
ns
Item
ZL50
Physical dimension
Model
Unit
Specificati
ons
Hopper capacity
2.5
Length of loader
mm
7250
Extension time of swing

arm
8.5
Width of loader
mm
2940
Inclination time of
bucket
Height of loader
mm
3273
Rated load
Wheel base
mm
2760
Gear 1
Km/min
010
Wheel span
mm
2250
Gear 2
Km/min
030
Minimum terrain
clearance
mm
505
Reverse gear
Km/min
014
Maximum unloading
height
mm
3055
Maximum traction
15
Maximum unloading
distance
mm
2224
30
Bucket outward
mm
6558
16.8
Rear wheel outward
mm
5628
Maximum climb
Self weight
Minimum turning radius

4.1.3 Technical Performance of Diesel Engine
Table 2 Technical performance of diesel engine

Item
Unit
Specifications
Model
61359a
Type
Single-cylinder vertical four-stroke W combustion

chamber
Number of cylindersbore x
6135*140
88
stroke
Item
Unit
Specifications
Displacement
12
Compression ratio
16.5
Rated speed
R/min
2200
Rated power
KW
154.35
Maximum torque
R/min
76.6
Fuel
#0 or #-10 light diesel oil
Minimum fuel consumption
Kw/h
135.975
Fan diameter
mm
675
Adjuster
TQ250/1100B49E
Maximum working pressure
Mpa
0.8
Displacement
135 (1000r/min)
4.1.4 Technical Performance of Hydraulic Torque Converter

Table 3
Technical performance of hydraulic torque converter
Item
Unit
Specifications
Type
Single-stage four-element twin turbo
Torque ratio
Cold oil pressure circulation
Inlet oil pressure of torque

converter
Mpa
0.56
Outlet oil pressure of torque

converter
Mpa
0.280.35
4.1.5 Gearbox
Table 4
Item
Technical specifications of gearbox

Unit
Specifications
Type
Stroke-type hydraulic shift
Gear position
Forward 2, backward 1
Forward gear-I
Km/h
2.155
Forward gear-II
Km/h
0.578
Backward gear
Km/h
1.577
Variable oil pump
Gear pump
Model
CB130
Item
Unit
Specifications
Rotational speed
R/min
2200
Flow
L/min
140
Annual working pressure
Mpa
1.11.5
89
4.1.6 Drive Shaft and Drive Axle

Table 5
Technical specifications of drive shaft and drive axle
Item
Unit
Specifications
Main drive
Type
First reduction of spiral bevel gear
Reducing ratio
6.167
Hub reduction
Type
Spur gear drive itinerary
Reducing ratio
4.4
Drive axle and wheel

Type
Four-wheel drive or dual-wheel drive
Tire
23.525
Tire pressure
Mpa
Front wheel: 0.340.36
Tire pressure
Mpa
Rear wheel: 0.280.30
4.1.7 Brake System

Table 6 Technical specifications of brake system
Item
Unit
Foot brake
Specifications
Hydraulic air four-wheel brake
Air pressure
Mpa
0.65
Pressure ratio
15: 5: 1
Diameter of brake cylinder
mm
75 (32)
Effective diameter of friction plate
mm
381.4
Hand brake
Type
Mechanically operated internal dual

shoe brake
Inner diameter of brake hub
mm
305
Size of brake band (length x width x

thickness)
mm
352*76*6.5
4.1.8 Steering System

Table 7 Technical specifications of steering system
Item
Unit
Type
Specifications
Hydraulic power steering
Number of steering oil cylinders

Inner diameter x stroke
Piece, mm
Steering pump (gear pump)
290*340
CB2080
Working pressure of system
Mpa
14
Flow
L/min
122
Steering angle to main pin
35 for left and right each
90
Distribution valve
Dual slidertriple slider
Working pump
CBG160
Rotation speed of oil pump
R/min
2200
Flow of oil pump
L/min
320
Operating pressure:
Mpa
16
4.1.9 Electrical System

Table 8 Technical specifications of electrical system
Item
Unit
Specifications
System voltage
24
Storage battery
Set
26Q195
Bulb voltage
24
Start of diesel engine
24electric start
No storage battery
Drawing start
4.1.10 Refuel Capacity

Table 9
Refuel capacity
Item
Unit
Specifications
Fuel
300
Hydraulic oil
200
Oil pan of engine oil
22
Bridge (differential and planetary)
16
Gearbox
45
4.2 Maintenance Interval and Period

4.2.1 Maintenance Interval
4.2.1.1 Overhaul
Engines are overhauled every two years (2400 cumulative working hours); and chassis is overhauled once a year
(1200 cumulative working hours).
4.2.1.2 Minor repair
A minor repair is arranged between two overhauls of chassis (600 cumulative working hours).
4.2.1.3 General maintenance
4.2.1.3.1 Grade-I maintenance (daily maintenance): every 8 hours.
4.2.1.3.2 Grade-II maintenance: every 50 hours (a week).
4.2.1.3.3 Grade-III maintenance: every 200 hours (a month).
91
4.3 Common Troubles and Troubleshooting Methods

4.3.1 Drive System
Table 10 Fault diagnosis and troubleshooting of drive system
Symptom
Causes
The shift pressure

of gear is low, and
gears cannot be
engaged.
The oil level of the gearbox is

too low.
The main oil way leaks.
The variable-speed pump fails.
The speed change valve is
improperly adjusted.
The speed change valve fails to
be adjusted.
The adjusting valve of the speed
change valve is jammed.
The stop valve of the speed
change valve cannot be
reset.
Oil suction pipes of the variablespeed pump are blocked.
Troubleshooting Method
Add oil.
Repair the oil way.
Replace the oil pump.
Readjust the variable-speed pump.
Replace a new pipe.
Replace the spring.
Disassemble the valve and find out the cause.
Clean up the pipes.
The shift pressure The piston seal of the gear is

of gear-I is low,
damaged.
and the gear cannot The seal ring of the oil way is
be engaged.
damaged.
The oil way of the gear leaks.
Replace the seal ring.

Repair the oil way.
The pressure is
normal when the
clutch is started,
but the vehicle
does not move or
the gear cannot be
shifted.
Re-engage the gear.

Release the brake.
Disassemble and check the clutch.
The
gear is not properly

engaged.
The brake is not released.
The clutch is dead.
Symptom
Causes
The
oil
temperature
is
high,
and
the
torque
converter
and speed control
system
are
overheated.
The oil level in the gearbox and

oil pan is too low.
The oil level in the gearbox is
too high.
The shift pressure is low, and the
clutch slips.
Add oil.
Discharge the oil until the oil level drops to the specified
position.
Check the oil pressure and piston ring.
92
The drive force is

insufficient.
The shift pressure is extra low.

The oil level of the torque
converter is too high.
The impeller of torque converter
breaks.
The large-overrun clutch is
damaged.
The oil surface is too low.
The clutch is not clearly
released.
The clutch is not completely
released.
The output power of the diesel
engine is insufficient.
Check and adjust the oil level.

Discharge the oil until the oil level drops to the specified
position.
Replace the impeller.
Repair the clutch and replace it if necessary.
Add new oil.
Disassemble and repair.
Check and adjust the clutch, and release the air.
Adjust the engine as required.
The brake cannot

be
released
normally.
The piston of the air brake valve

is blocked or damaged.
Air exists in the brake oil way.
The piston of the brake cylinder
cannot be reset.
The assistor does not actuate
properly.
Clean or replace the piston.

Release the air.
Repair the piston.
Check the assistor.
4.3.2 Brake System

Table 11 Fault diagnosis and troubleshooting of brake system
Symptom
Causes
The foot brake force

is insufficient.
The brake cylinder leaks.

Air exists in the brake hydraulic
pipe.
The accelerator has oil leakage.
The oil inlet of the brake cylinder
is blocked, or the brake oil is
insufficient.
The air pressure is too low, or air
leakage occurs.
The brake plate is worn and
infiltrated by oil.
Replace the packing leather.

Release the air.
Replace the packing leather.
Clean the oil inlet, and fill up the brake oil.
Find the cause the remove the fault.
Replace it.
4.3.3 Steering System

Table 12 Fault diagnosis and troubleshooting of steering system
Symptom
Causes
The idle stroke

of steering wheel
The gap between the nut and flat gear

is too large.
Adjust as required.
Adjust as required.
93
is extra large.
The tappet and universal joint have

big gaps or are not properly
adjusted.
The
universal
moment
is
insufficient.
The steering pump is worn, and the

flow is insufficient.
The overflow pressure of the steering
permanent
flow
valve
is
insufficient.
The steering valve has oil leakage.
Repair or replace the steering pump.

Adjust the overflow pressure to 7.5 Mpa.
Adjust the steering valve.
The
steering
wheel
rotates
heavily.
The nut is over engaged with the

sector gear.
The air pressure of the tire is
insufficient.
The up-thrust bearing of the steering
valve rod is too tight.
The valve rod of the steering valve is
stuck.
Readjust it.
Charge the tire.
Readjust it.
Repair it.
4.3.4 Working Hydraulic System

Table 13 Fault diagnosis and troubleshooting of working hydraulic system
Symptom
Causes
The swing arm hoisting

and steering force is
insufficient.
The oil seal of the oil

cylinder is damaged.
The distribution valve is
overrun, and the gap
between valve rods is
too big.
The pipe system has oil
leakage.
The working oil pump leaks.
The safety valve is not
properly adjusted.
The oil suction pipe and
filter screen are blocked.
The hydraulic oil level is too
low.
The speed change valve is
not in the correct
position or the valve rod
is stuck.
Replace the oil seal.

Replace the valve.
Repair it.
Replace the oil pump.
Adjust as required.
Clean it and replace the oil.
Add new oil.
Repair it.
The oil pump gives out a

big noise.
The oil inlet pipe or oil filter

is blocked.
There
are
too
many
Clean it and replace the oil.

Replace the oil.
94
hydraulic oil foams.
4.4 Maintenance Items

4.4.1 Grade-1 maintenance (daily maintenance): every 8 hours.
4.4.2 Grade-II maintenance: every 50 hours (a week).
4.4.3 Grade-III maintenance: every 200 hours (a month).
4.4.4 Daily maintenance before operation
4.4.4.1 Check the water level of the radiator.
4.4.4.2 Check the oil amount in the oil pan of the engine.
4.4.4.3 Check oil amount in the fuel tank.
4.4.4.4 Check tightness of oil pipes, water pipes, air pipes, and accessories of each part.
4.4.4.5 Check connections of storage batteries.
4.4.4.6 Check the amount of hydraulic working oil.
4.4.4.7 Verify the foot brake and hand brake work properly.
4.4.4.8 Verify operating levers are flexible and set at the neutral gear.
95
Chapter V ZD220 Coal Bulldozer

5.1 Main Specification and Technical Parameters
5.1.1 Engine
Model
Type
ZD220-3
In-line, water-cooled, four-stroke, overhead valve direct injection, turbocharged diesel engine
Rated speed
1800rPm
Rated power
162KW/1800rpm/220HP
5.1.2 Driving Speed (km/h)
Forward
0-3.6
0-6.5
0-11.2
Backward
0-4.3
0-7.7
0-13.2
5.1.3 Coal Bulldozer

Width of relieving tool (mm)
3725
Height of relieving tool (mm)
1315
Maximum lifting height (mm)
1210
Maximum depth of cut (mm)
538
5.1.4 Hydraulic System (Working Device)

Maximum working oil voltage
14Mpa(140kg/cm2)
Model of oil pump
Gear oil pump
Flow
262L/min(1800rpm)
5.2 Operation Rules

5.2.1 Engnie Operation
5.2.1.1 Before you start the engine, verify the following:
a) Conduct routine inspection.
b) The brake pedal is locked.
c) The variable-speed joystick is at the neutral gear or locked.
d) After the relieving tool is lowered to the ground, its joystick is locked.
e) The fuel joystick is pushed to the minimum position.
f) Open the manual fuel stop valve if it's closed (check the oil level?).
5.2.1.2 Start
a) Turn the switch key to the "START" position to start the engine. Observe whether the oil pressure pointer
of the engine is normal, and whether the lubricant pressure is correct.
b) Keep the key at the "START" position for less than 15 seconds.
c) If you fail to start the engine, start it again 2 minutes later.
5.2.1.3 Post-start check
a) Run the engine at low speed and with empty load, and check whether the oil level indicator of the engine
96
points the green range.

b) Pull back the fuel joystick to make the engine run at medium speed and with empty load for 5 minutes.
c) When the water temperature indicator points to the green range, run the engine with empty load.
d) After preheat running, check whether indicators are normal.
e) Check whether the exhaust color is normal, and whether there any abnormal noise or vibration.
f) Verify there is no leakage of diesel, engine oil, and water.
5.2.1.4 Engine shutdown
a) Turn the key of the start switch to the "OFF" position.
b) After operation is over, turn off the manual fuel valve.
2.2 Operation procedure of coal bulldozer
5.2.1.5 Start
a) After the engine is started, pull back the fuel joystick to accelerate the engine.
b) Release the handle of the relieving tool from the locking position, to raise the relieving tool 500mm above
the ground.
c) Step down onto the middle part between the left and right brake pedals, push the locking handle of the
brake to the "release" position, and release the brake pedal.
d) Push the locking handle of the gear lever to the release position.
f) Push the gear lever to the target position to start the bulldozer.
5.2.1.6 Changing speed
a) Push the gear lever to the target gear to change the speed.
b) You can change the speed of the bulldozer when it moves.
5.2.1.7 Shifting between forward and backward gears
To switch from the forward gear to the backward gear, step down the brake pedal and shift the gear after the
bulldozer slows down.
5.2.1.8 Turning
a) When the bulldozer moves, pull the steering lever (at the side that you want to turn to) back to half of the
stoke. The steering clutch is released, and the bulldozer turns slowly.
b) Pull the steering lever to the end. The steering brake of the same side works, and the bulldozer has a spot
turn.
5.2.1.9 Turning on downhill path
a) Do not turn on soft or clay downhill roads.
b) On the abrupt slope that the bulldozer can move down by its own weight or a carry-scraper is drawn to
turn on a downhill, pull the steering handle to half of the stoke to control the bulldozer turn to the contrary
direction. That is, pull the left (right) joystick to a half, the bulldozer turn to left (right) slowly.
5.2.1.10 Halt
a) Push the fuel control lever to reduce the rotation speed of the engine.
b) Push the gear lever to the neutral gear position.
c) Step down the middle part of the brake pedal. After the bulldozer stops, lock the brake with the locking
handle.
d) Lock the gear lever with the locking handle.
e) Put the relieving tool flatly on the ground.
f) Lock the joystick of the relieving tool with the locking handle.
g) Stop the engine by following the engine operation specifications.
2.2.7 Operation of relieving tool of the coal bulldozer
a) The joystick has four positions: lifting, maintaining, lowering, and inclining.
97
b) For an inclination operation, if the inclination piston reaches the stroke end, reset the joystick to the
maintain position as soon as possible.
d) When the relieving tool of the coal bulldozer is at the highest or lowest position, do not perform the
inclination operation.
5.2.1.11 Engine start at the winter
a) Preparation
1) Replace lubricants of each device with specified low-viscosity types.
2) Use #10 light diesel as the fuel.
3) Add anti-freezing agent to the coolant.
b) Start procedure
1) Before starting the engine, pull the booster for 2 to 3 seconds.
2) Turn the key of the start switch to the "START" position, to rotate the crankshaft.
3) While the crankshaft rotates, push into the booster.
4) If the start fails, try 2 to 3 minutes later following the same procedure.
5) If the rotation of the engine slows down, apply ether spray. Notice that the rotation speed of the engine
should not exceed 1000 r/min.
5.2.2 Notices for Operation
5.2.2.1 During the operation, when the oil temperature is too high, reduce operation load and stop the operation.
Resume until the oil temperature drops.
5.2.2.2 On an inclined floor, if the oil tank has less fuel, the engine may suck in air to shut down due to inclination
and vibration of the vehicle, and the brake efficiency is low. Therefore, you should always notice the fuel amount
in the oil tank.
5.2.2.3 To go down a downhill road, push the gear lever to the low gear and the accelerator lever to the low speed
position, to utilize the speed difference between the engine and vehicle, so that the hydraulic torque converter can
function as the brake to some extent.
5.2.2.4 When you drive on a slope, do not turn or shift the gear. Do not go down a downhill road using the self
weight or inertia of the vehicle.
5.2.2.5 When the vehicle drives, do not sit or stand in any other parts than the cab.
5.2.3 Troubleshooting
5.2.3.1 The diesel engine cannot be started.
S/N
1
Fault diagnosis
The fuel system fails. The

diesel engine does not ignite,
and the air enters the oil
return pipe.
b.The air enters the fuel
system.
c.The fuel pipe is blocked.
d.The fuel filter is blocked.
e.The fuel delivery pump
b.Check whether oil pipe connectors are loose, and release the air;
unscrew release screws of filter on the fuel injection pump, and release
the air with hand pump oil.
c.Check whether pipes are unblocked.
d.Clean or replace the filter element.
e.Check whether oil pipes have air leakage and whether the filter screen
is blocked.
98
does not supply oil.

2
The electronic system fails,

and the starting dynamo does
not work.
Wires
are
incorrectly
connected, or not properly
contacted.
The storage battery has a low
power.
Carbon brush of motor does
not properly contact the
communtator.
Check whether wire connections are correct and secured.

Connect storage batteries of full power in parallel.
Repair the carbon brush, and clean up the communtator with wood flask
paper.
The cylinder pressure is

insufficient. Oil injection is
normal, but the engine does
not ignite. Engine oil enters
the exhaust pipe.
The piston ring is worn.
The air valve leaks.
Check the piston ring, and replace the cylinder gasket if necessary.
Check the air valve, adjust the gap, and replace it if necessary.
Oil injection is too early or

too late. The diesel engine
does not ignite at oil
injection, or ignite once and
shut down.
Check whether the scale on the connecting disk of the fuel injection
pump is correct, and adjust the scale if it does not meet the requirements.
5.2.3.2 The diesel engine has noise.

S/N
Fault diagnosis
The oil injection is too early, and the cylinder

gives out rhythmed metallic noise.
Adjust angle of advance for oil injection to meet the

standard requirement.
The oil injection time is too late, and the

cylinder gives out low knocks.
Adjust angle of advance for oil injection to meet the

standard requirement.
The fit clearance between steel jackets of

piston pins is extra large, and clashes are
heard at the outer wall of the cylinder.
Replace the piston ring or replace the piston or cylinder

liner dependent on the abrasion condition.
The piston pin fits the steel jacket loosely,

and slight sharp noise is heard during
running.
Replace the liner of the connecting rod small end, to

achieve the required clearance.
The pitman box is worn to increase the fit

clearance, and clashes are heard in the crank
case.
Check the bearing bush, and replace it if necessary.
The radial clearance of the crankshaft roll is

too small, harsh sound is heard during
running, and the noise rises when stepping on
the accelerator.
The radial clearance of the crankshaft roll is
Check the bearing that gives out noise, and replace it if

necessary.
99
too large, and rattling sound is heard during

running.
7
Front and rear thrust bearings of the

crankshaft are worn, and the radial clearance
is extra large, causing the crankshaft to swing
front and back; when the diesel engine is in
idle running, clashes of crankshaft swing are
heard.
Check the axial clearance and abrasion of thrust bearing,

and replace it if necessary.
The cylinder collides with the piston, and

heavy knocks are heard at the cylinder cover
during running.
Remove the cylinder shield, find out the cause, and adjust
the clearance.
The drive gear is worn, the backlash is extra

large, and the front cover plate gives out
abnormal sound.
Adjust the backlash, and replace the gear if necessary.
10
The swing arm adjusting screw and push rod

ring seat run out of engine oil, and dry
friction noise is heard during running.
Remove the cylinder shield and add lubricating oil.
5.2.3.3 The color of exhaust gas is abnormal.

S/N
Fault diagnosis
The exhaust gas is black.

The diesel engine is overloaded.
Oil supplies for each cylinder are uneven.
The valve clearance is incorrect.
The angle of advance for oil injection is too
small, and oil injection is too late, making
some engine oil burning in the exhaust
pipe.
The air inflow is insufficient, and the air filter
or exhaust pipe is blocked.
Reduce the load to the regulated scope.

Adjust oil supply of each pump for oil injection, to
achieve even supply of oil.
Adjust the valve clearance, check the sealing cone, and
remove any defect.
Adjust the angle of advance for oil injection to the
specified value.
Clean up the air filter, and replace the filter element if
necessary.
The exhaust gas is blue.

The air filter is blocked, and the air inflow is
not smooth, or there is too much engine oil
in the oil disk.
The piston ring gets stuck or overworn, less
elastic; or the piston ring is inversely
installed along the fillet direction, letting
engine oil into the combustion chamber.
The equipment runs with low load for long
time. At the rated power of less than 40%,
the clearance between the piston ring and
cylinder plunger is too large, and the engine
oil enters the combustion chamber.
The oil pan is filled with excessive engine oil.
Disassemble or clean up the air filter, and reduce the

amount of engine oil to the specified value.
Disassemble and check the piston ring, and replace it if
necessary.
Increase the load properly, and select a correct power for
the equipment.
Fill engine oil to the scale label.
100
5.2.3.4 Common faults of electrical start system

S/N
Fault diagnosis
The starter does not rotate.

The electric brush does not properly contact.
The connecting lead is not properly contacted.
The starting motor is short-circuited.
The storage battery has insufficient power and
small capacity.
Clean up the surface of the commutator or replace

the electric brush.
Sort out the lead, and tighten the connector.
Find out the short-circuited part, and troubleshoot it.
Charge the battery or replace it.
The starting motor runs slowly with empty load.

The brush connector does not contact properly or
falls off.
The bearing bush is damaged.
The field winding or armature winding is locally
short-circuited.
Spring breaks.
The storage battery has insufficient power or small
capacity.
Clean up the surface or replace the brush.

Replace it.
Find out the short-circuited part, and troubleshoot it.
Replace a new one.
Charge or replace the battery.
The generator gives out noise.

The bearing is loose or cracked.
The rotator collides with the stator.
Replace it.
File the collision surface with a file.
The gear of the starting motor gets stuck with the

flywheel ring gear, or the motor gear cannot quit.
Disassemble gears and check the engagement. Make

gears run flexible.
After the start button is released, the motor

continues to run:
a. The contact of electromagnetic switch is welded
to the coupling screw.
b. The adjusting screw does not work properly.
Disassemble and repair the switch.

Readjust it.
The storage battery cannot be charged or output

large current, and the voltage drop is quick. White
crystals appear on the polar plate.
Handle by following the precautions for charging a

storage battery.
The charging dynamo does not work or generates

small current.
The silicon diode, field coil, or rotor coil is opencircuited or short-circuited.
The regulating voltage of the regulator is lower
than the voltage of the storage battery.
The exciting circuit is open-circuited or shortcircuited.
The triangle belt is worn or has insufficient
tension.
The charging current meter is damaged.
Replace or repair it.

Adjust the voltage to the specified value.
Disassemble and check the lead.
Replace the triangle belt or adjust the tension angle.
Replace a new one.
The charging current is unstable.
Clean up the surface, and weld the spring or replace

101
The carbon brush is contaminated, worn, or

improperly contacted, or the brush spring
provides insufficient pressure.
The press fitting of silicon diode is loose.
Internal elements of the regulator fall off or does
not contact properly.
The triangle belt is loose.
Wire connector is loose.
it.
Replace it together with the radiator unit.
Re-weld it or grind it with #0 rubber.
Readjust the tension force.
Check and tighten it.
The charging current is extra large, the voltage is

too high, and the generator radiates heat.
wiring of magnetic field or cathode of armature is
short-circuited, and turn-to-turn short circuit
occurs to field coils.
The rotator coil is short-circuited, and clashes with
the stator.
The regulating voltage is too high.
The emitter and collector of end power tube of
transistor regulator are short-circuited.
The magnetized coil in the Vibrating voltage
regulator is open-circuited or short-circuited,
and the additional resistance burns out.
Repair it.
File the collision surface with a file.
Readjust it to the specified value.
Change the power tube.
Repair or replace it.
5.2.3.5 Common faults and troubleshooting of main clutch and its control system
S/N
Fault diagnosis
The main clutch slips.

The friction plate is worn.
The adjusting ring is loose.
Reduce the clearance or replace the friction plate.

Readjust and fix it.
The main clutch cannot bind.

The joystick malfunctions.
Pin bearings of joystick lack oil.
The drifting valve lacks oil or leaks.
The safety valve of the hydraulic system
malfunctions.
Adjust it.
Add grease.
Add oil and repair it.
Repair it.
Impact sound is heard for gear shift of the

gearbox, and the small brake malfunctions.
Adjust it.
The oil level of the main clutch drops abruptly.

The seal ring on the driving gear in the transfer
case leaks oil.
The main clutch pump gives out abnormal sound.

There is internal grinding loss.
Air is sucked in.
Repair it.
Cleanup the filter screen at the oil suction.
5.2.3.6 Common faults and troubleshooting of gearbox and its operating system
S/N
1
Fault diagnosis
The gearbox gives out abnormal sound.

Lubricant is insufficient or its viscosity is low.
102
Add lubricant or replace lubricant of high

viscosity.
Gear bearing is worn or damaged.

Bimetal liner and spline housing have a grinding loss.
Replace it.
Replace worn parts and check the oil way.
Gear shift does not work.

Gear chamfering for bind wheel and bind set is damaged.
Fork slider bends and deforms.
The fork copper bush falls off.
The interlocking shaft is not in the correct position.
The fork is damaged.
a. Replace the bind wheel and bind set.

b. Repair the fork slider and align it.
c. Replace the copper bush and rivet the end
face tightly.
Adjust it.
Gear detachment and disorder

Components of the operating mechanism are not in
correct positions.
Some bolts of the operating system are loose.
Reassemble or adjust them.

Check and tighten the loose bolts.
5.2.3.7 Common faults and troubleshooting of steering system and brake system
S/N
1
S/N
Fault diagnosis
The steering clutch slips or is not completely separated.

The steering hydraulic system lacks oil.
The steering hydraulic system has severe internal
leakage, and the system pressure is extra low.
The sealing ring is damaged and oil leaks.
The steering hydraulic system has damaged components.
The reduction valve of the steering hydraulic system
malfunctions.
The friction plate is badly damaged, and the clutch slips.
Add oil and check the oil way.

Check system pressure and eliminate
internal leakage.
Replace hydraulic components.
Repair it.
Replace the friction plate.
Fault diagnosis
The steering clutch gives out abnormal sound during running,

and the friction plate is damaged.
Replace the friction plate.
The brake does not work.

The adjusting clearance is extra large.
The brake band is seriously worn, and even the rivet head
exposes.
The brake band is damaged.
The joystick is not in the correct position.
Reduce the clearance.

Replace the brake plate.
Replace the brake band.
Adjust it.
The steering handle or brake pedal cannot be reset:

The continuous pin roll does not rotate flexibly.
The reset spring malfunctions.
Add grease to the pin roll.

The steering pump gives out abnormal sound:

There is internal grinding loss.
Air is sucked in.

Clean up the filter screen at the oil
suction.
5.2.3.8 Common faults and troubleshooting of final drive

S/N
1
Fault diagnosis
The floating seal leaks.

The floating seal ring is worn or damaged.
The rubber ring of the floating seal ages and deforms.
103
Replace the seal ring or re-grind it.

Replace it.
Reassemble it.
The assembly is abnormal.

2
Bearing is overheated.
a. Radial backlash is too small.
b. Lubricant is insufficient.
Adjust it.
Add lubricant.
Abnormal noise is heard during running.

a. Lubricant is insufficient.
b. Gear or bearing is damaged.
Add lubricant.
Replace it.
5.2.3.9 Common faults and troubleshooting of traveling mechanism

S/N
Fault diagnosis
Track falls off:

a. The track tension is insufficient.
b. The thrust wheel, guide wheel, and carrier roller (tri-wheel) have
flange abrasion.
c. The radial symmetric line of tri-wheel deviates.
Increase the tension.

Adjust and repair it.
The tri-wheel sees a extra-fast flange abrasion:

a. The radial symmetric lines of tri-wheel mutually deviate.
b. Traveling stand deforms.
c. The tri-wheel is not in the correct radial relative position against
the drive wheel.

Repair and calibrate it.
Repair it.
The tri-wheel has oil leakage.

The floating seal ring is worn or damaged.
The rubber ring of the floating seal ages and deforms.
The O-ring at the shaft end is damaged.
The oil plug at the shaft head is loose.
Replace the seal ring or re-grind

it.
Replace it.
Replace it.
Tighten it.
The tension device of the track fails.

The oil nozzle fails.
The seal ring is worn or damaged.
The guide wheel conflicts with the traveling stand.

Replace it.
The track plate is loose.

The tightening torque of the track bolt is insufficient.
Tighten it by the regulated

torque.
104
Chapter VI Fire alarm system

6.1 Medium speed water spray fire alarm system of coal conveying system
This system is used to protect cable interlayer, cable room, oil tank area and coal pier and other areas. It
including control valves, pipe parts, spray nozzle, alarm control part and so on.The system can start in local and
remote,and can display the running state.spray water supply intensity is not less than10.2L/minm2feed water
pressure not less than 0.35Mpastart up mode for manual, automatic or remote control.The area is divided into
several protected areas.Each region have independent deluge valve group and supporting pipe. Fire of cable
interlayer, tunnels, coal pier should be monitored by the fire detection system,when the fire broke out, open deluge
valve through an electrical signal. When fire broke out in a protection area,deluge valve of adjacent area will open
at the same time, water come from the main pipe of water spray system. Open valve need start the pump at the
same time, the rapid response butterfly valve shall be installed in the downstream of the deluge valve group, and
in this way, if the deluge valve failure occurs, butterfly valve can be manual closed and open (when the fire broke
out).
6.2 Composition of medium speed water spray system

6.2.1deluge valve components include deluge valve and auxiliary piping systems
6.2.2Drive pipe system: including water pressure gauge, 24V dc electromagnetic valve, manual control valves and
accessories;
6.2.3Alarm piping system: including pressure switch, hydraulic alarm, alarm control valve, filter and accessories;
6.2.4test pipe system: including pressure gauge, valves and pipe fittings
6.2.5drainage pipeline system, including water collector, Angle valves and accessories
6.2.6sprayer (mesh)
6.2.7Y type filter (before the deluge valve)
6.2.8control panel ark
6.2.9water spray extinguishing system of water supply pipe;
6.3 Technical Specifications of the deluge valve

6.3.1Model: DN80, DN100, DN150DN200
6.3.2Work pressure: 0.14 ~ 1.6Mpa
6.3.3Connecting flange: 1.6Mpa
6.4 Technical Specifications of the nozzle

Nozzle/design: open,15/20mm
6.5 Water curtain system

Nozzle of Water curtain system arranged in 1~3rowspraying water into the water curtaincan prevent the
105
flame through the open place, to prevent the fire spreading, cooling fire insulator, enhance its fireproof
performance, and can put out fire locally.when fire broke outthe fire detector or engineer discovered fire, open
the valve electrically or by handthen the system spray water through the water curtain nozzle,
At coal pier,transfer station, coal belt conveyor openings between bunker house all set the water curtain
insulator
106

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Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

ZAMBIA MAAMBA 2150MW POWER PLANT PROJECT

Fuel Operation and

Operation and Maintenance Manual

Prepared by: Wang Feng

Reviewed by: Li Qingtang 22 / 07 /2016

Approved by: Li Mingda 22/ 07 /2016

Name of Variation Order

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

2.3.3 Long piling method:..........................................................................................................................68

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

5.1 Main Specification and Technical Parameters.............................................................................................97

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

de-ironing separator have iron falling pipe lead to the ground.

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Motor Motor Motor

power voltage current

mm output ion both ends

Quant Braking Hydraulic

speed ity of device

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Name of the roller

NO of the bearing pedestal

Number of the roller

1.1.1.2 Technical Specifications of the roller and bearing pedestal

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

1.1.2 Handover inspection and check before start-up

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

1.2 Vibration coal feeder

Picture of vibrating coal grates

Grates surface sizemm

Grates hole sizemm

Zambia Maamba 2150MW Fuel Operation and Maintenance Manual

1.2.1.1Use and Maintenance

Raw coal emergency coal hopper underground vibration Coal Feeders

0500raw coal hopper

Single maximum Dynamic load

Single static load

crude coal fine coal hopper underground vibration Coal Feeders