CUSTOMER

Messrs. Loesche GmbH, Germany

LM46.2+2 Roll MILL

3400 KW GEARBOX (TYPE BPP190S)

INSTRUCTION MANUAL

BATURAJA CLINKER

NOTES TO THE CUSTOMER

Before handling the machine, this instruction manual should be read
through carefully to familiarize yourselves with contents of the manual.
The machine should be handled by skilled operators and staffs.
Consideration should be taken so that this instruction manual should reach
to the persons in charge.
This manual should be kept in file so as to be serviceable at any time.

RO 2012.07.17 M.Nishida H.Kubota

Rev.
Date Designed Checked Approved Approved Reviewed Note
No
Engineering Department QA Dept.
Work No.
11-CAEA02

Doc No. MPA190L-Y230E001

DSS607090 2
General Index

Index Page

I EXECUTIVE SUMMARY...................................................................................................... Z-1

MAIN PARTICULARS OF GEARBOX................................................................................. Z-1
Description ........................................................................................................................... Z-2

Check point at the Time of Commencement of

Z6
Initial Operation Stage with Record Sheet
Periodical Inspection with Record Sheet Z-8

II Installation Manual A
III Operation and Maintenance manual B
Gearbox (Gear reducer)
Annexed Drawings C
V Operation and Maintenance Manual D
Lubrication Oil Unit
Instruction Manual of Each Equipment a-y
 Z-1

I EXECUTIVE SUMMARY

MAIN PARTICULARS OF GEARBOX

Name of Machinery Vertical Type Gearbox (Reduction Gear)

Ordered by Loesche GmbH
Code Word BATURAJA CLINKER
P.O. No.
Mill Size LM46.2+2
Suppliers Name & Work No. SEISA Gear, Ltd. 11CAEA02
Type of Gearbox BPP190S

Nominal Rated Power 3400 kW

Input Speed 990 RPM
Output Speed 24.2RPM
Reduction Ratio 1 / 40.8

Scope of Supply Gearbox (Reduction Gear)

Lubrication Oil Unit, Connecting Piping, SF
Coupling
Power Supply Motor AC380 V
Frequency 50Hz
Control DC DC24V
o o
Ambient Temperature +15 C +35 C

Cooling Water Quality Fresh Water

o
Design Temperature 45 C

Lubrication Oil ISO VG 320

Net Weight of Gearbox 71,000 Kg

Dimension of Gearbox 330 W cm x 410 L cm x 250 H cm

Date Built March 2012

Preservation Period 12 months after completion of seaworthy

packing (Until March 2013)
Warranty Period 36 months after provisional acceptance by
the end user, but not exceeding 48 months
after the gearbox delivery, that is: not
exceeding
Maech 2015
 Z-2

Description

Important Notes
Firstly, please pay your particular attention to this Chapter of the INSTRUCTION

MANUAL for the Gearbox (Gear Reducer)

I Needless to say, it is very important for the User to provide careful check of the
readiness for operation of the gear reducer and the lubrication oil unit before
starting operation and provide proper maintenance, in order to use this gear
reducer (machinery and equipment) for longer period of time with the
expecting output.
There are detailed descriptions as to proper operation and proper maintenance
of the machinery and equipment in the respective chapters and the Supplier
sincerely hopes that the User should operate, monitor and maintain the
machinery and equipment in accordance with the description stated in the
relevant parts of this Manual.

II The following are extract of most important points and things to pay particular
attention, which the Supplier wishes the User to observe during preparation of
operation start, operation monitoring and maintenance services.
Furthermore, please refer to respective chapters in this Manual for further
details and those not written herein.

1. Before and at the time of starting operation

When starting the gear reducer, to make sure the lubrication oil unit in
normal operating condition.
The following steps to be taken.
1) To start up the Heater to heat the oil in the oil tank in case temperature
o
is lower than 10 C..
o
2) To start up oil feed Pump when the oil temperature rises over 10 C and
o
to confirm the oil temperature over 25 C which secures readiness for
operating the mill motor and to ensure stable condition being achieved
and thrust pad chamber being filled up with oil.
3) When such stable condition and readiness is secured it becomes ready
for the Mill Motor to start.
 Z-3

2. Operation restart after shutdown

When the gear reducer being shut down scheduled or even though non-
scheduled, the following to be taken care of.

1) In order to secure sufficient oil volume filled up in the thrust pad chamber
(in case such volume becomes insufficient, there is possibility of being
rusted), Low Pressure Pump shall be operated once a week for minimum
20 minutes.
2) To take exactly same procedure when restart after shutdown.
3) In particular, carefully to confirm that lubrication oil has been filled up in the
gear reducer itself with required volume.

3. Matters to be taken care of during the operation

1) In accordance with Daily Inspection and Periodical Inspection sheets

attached to the Chapter 5 Maintenance and Inspection, status of
operation to be recorded and such recorded data to be kept.
2) If such record is presented to the Supplier periodically, the Supplier will be
able to analyze the data and could furnish the advice which enables the
User to facilitate longer and stable operation.
3) Further, there might be the case where the said operation data could
prevent the gearbox from occurrence of abnormal conditions or trouble in
advance or in case of trouble occurs such data could help precise analysis
of cause, could save recovery lead time and could contribute to longer life
of machines and equipment.

4. Other Important Notes

1) To discharge cooling water completely when operation shuts down.

2) During inching device operation, to ensure lubrication oil is fed properly.
3) When welding for making hardened layer is performed, to ensure earthing
cable being connected properly.

5. Others

1) In addition, it is recommended that appropriate interlock sequence to be

provided so that the high pressure pumps can not be in operation before
achieving stable condition brought by the low pressure pump.
2) For further details, to observe instruction or guidelines for before starting
operation, inspection and maintenance and items to be confirmed, etc.,
as provided in the relevant chapters of this Manuals.
 Z-4

III Attention in case of finding any abnormal situation or trouble

1. To follow the instructions provided in the relevant parts of this manual with
reference to other related description therein.

2. In case any abnormal situation occurs;

1) To stop all the machines and equipment in the facilities/system as a whole.
(because there are cases where it is not clear as to whether such
abnormality is due to gear reducer or other part of facilities.)
2) To inform the real situation as precise and quick as possible through the
communication net work as established.

In this case, preferably, to provide the operation data, simultaneously.

3) Please do not repair, replace and/or restart without the Suppliers

instruction or consent, which might cause the situation where the Supplier
can not take responsibility for proper countermeasures and which also
might cause fundamental damage to the machines and equipment.

IV Finally and repeatedly

1. The supplied machines and equipment is designed and manufactured based

on the condition that the same are properly stored, installed, operated and
maintained in accordance with this Manuals.
2. In particular, special attention to be paid as to stability of oil lubrication system
before starting operation of this gearbox.
3. The Supplier sincerely hopes that the supplied gearbox can be operated for
longer period of time without trouble owing to the Users proper operation and
maintenance.

V Attachments
The following are contained in this Chapter.

"Main Particulars" (in front page)

Check points at various stages together with blank form of data record form, which
should be utilized to keep record, and forward the filled in data to the Supplier
(SEISA) for those initial stage and to store the data made available to the Supplier
upon request for those periodical checks.
 Z-5
Long Term Storage

When the gearbox is inactive for a long period of time, long term storage
preparation is required. The rust proofing method after gearbox delivery is included
in this document.

1. Storage Conditions
Accumulation of rust is greatly influenced according to surrounding
environmental conditions and the state of storage.
Our rust proofing standard is based on the assumption that the gearbox and the
lubrication unit are stored in relatively good conditions.
It is to be stored inside a shop or warehouse, relatively free of humidity, dust,
extreme temperature fluctuation, or corrosive gas like sulfurous acid gas.

2. Re-treatment procedure
1) Storage term is maximum one year. The initial storage term is after
shipment from our factory.
2) After draining lubricant, spray or add the vapor phase inhibitor solvent
(NUCLE OIL 105S, VPI range, JIS K2246 NP-20 equivalent) into the
gearbox and the lubrication unit through inspection cover.
Quantity of the vapor phase inhibitor solvent
Gearbox 5% against the capacity(L/min) of oil pump(L.P)
Lubrication Unit 5% against the capacity(L/min) of oil pump(L.P)

3) Seal up the openings such as air breather, oil outlet, piping connections,
labyrinth seal portion, etc.
4) Apply rust preventive oil (TECTYL 502C, JIS K 2246 NP-19 equivalent) to
outside machined surfaces such as shaft end, installing surface, and
coupling.
5) Cover the gearbox fully with plastic sheet.
6) Repeat this step every one year.

3. Cooling Water Draining from Oil Cooler

Drain cooling water in oil cooler to avoid breakage caused by freeze in the
winter.

4. Note
When operating the gearbox, drain the vapor phase inhibitor solvent and fill with
the recommended lubricant.
 Check point at the time of commencement of initial operation stage

Inspection Item Location Method Reference Criteria Recording Check

Lubricating Oil pressure Pressure gauge Visual Low pressure oil 0.15MPa min. Record required
Condition
o o
Oil temperature Thermometer 15 C min. 55 C max.

Thrust Oil flow Flow switch Visual Within allowable limit No record required for
pad acceptable results

Alignment of input coupling Input couplig Dial gauge, Thickness Within allowable limit Record required
gauge
Gear Tooth contact of Tooth surface of Sketch Even contact over the whole tooth width No record required for
Bevel gear Bevel gear acceptable results
Z-6
 Z7

Operation Record of gear reducer

Input
Time Main Motor Temperature Bearing & Pad Lubrication Equipment
speed
Volt Ampere No.1 No.2 No.3 No.4 No.5 Temperature oC Pressure MPa Oil Flow Oil Press. Note
-1
hh:mm min V A
T1 T2 T3 T4 T5 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 FL1 L/min PG1 MPa

Please fill in the blank and return one copy to the following address within one week after checking to SEISA Gear, Ltd. International Operations
For the attention of (Mr.) T. Kiku and (Mr.) Y. Hamada
email to Tdk_Kiku@Seisa.shi.co.jp; Yko_Hamada@shi.co.jp Fax 81-72-431-0846
Upon receipt of the data the supplier (SEISA)will forward some comments if any.
 Z-8

Periodical Inspection Inspection during mill shutdown

Inspection Item Location Method Reference Criteria Recording Check

Gear Tooth contact of Tooth surface of Bevel Sketch Even contact over the whole No record required for
Bevel gear gear tooth width acceptable results

Appearance Visual No abnormalities such as

pitting
Roller bearing Return oil filter, Oil Overhaul and cleaning No iron dust
strainer
Sliding bearing No metal dust

Thrust pad Lubricaring oil for Return oil filter Overhaul and cleaning No metal dust
thrust pad

Amount of wear Clearance gauge (Allow No abrupt change (0.2 mm) Record required
match marks to mate) X-X
XX-XX
XXX-XXX
XXXX-XXXX

Upper casing
Output flange
Oil flow Flow switch visual Within allowable limit No record required for
acceptable results
Properties of lubricating oil Sampling oil Ask oil maker for Oil maker's instruction Record of date of
checking replacement required

Oil level in oil tank Oil level gauge Visual Within allowable limit No record required for
acceptable results
 Z-9

Inspection Item Location Method Reference Criteria Recording Check

Aligment of input coupling Input coupling Dial gauge, Thickness Within allowable limit Record required
gauge

Input coupling T-gridmember Refer to chapter 8 Refer to chapter 8 No record required if

satisfactory

Loose bolt Each bolt Hammering No looseness No record required for

acceptable results

Periodical inspection:

Conduct inspection once every 3 months and keep the record.

Even if no abnormality is detected under daily inspection and even when operation is not allowed to stop due to the necessity of continuation of production run,
be sure to conduct inspection at least once every 6 month.

Please keep the record of checking result as per this sheet and store such record within at least the warranty period of the gearbox, and please forward it to the
supplier (SEISA) upon request so necessitated.
 Z 10

Operation Record of gear reducer

Input
Time Main Motor Temperature Bearing & Pad Lubrication Equipment
speed
o
Volt Ampere No.1 No.2 No.3 No.4 No.5 Temperature C Pressure MPa Oil Flow Oil Press. Note
-1
hh:mm min V A
T1 T2 T3 T4 T5 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 FL1 L/min PG1 MPa

Please keep the record of checking result as per this sheet and store such record within at least the warranty period of the gearbox, and please forward it to the supplier (SEISA) upon request so necessitated.
 A- 0

INSTALLATION MANUAL

NOTES TO THE CUSTOMER

Before handling the machine, this instruction manual should be read through carefully

to familiarize yourselves with contents of the manual. The machine should be handled

by skilled persons. Consideration should be taken so that this instruction manual should

reach to persons in charge. This manual should be kept in file so as to be serviceable

at any time

SAFETY PRECAUTIONS..............................................................................................................1

Installation.......................................................................................................................2

1.1 Hauling and Unpacking...................................................................................................3

1.2 Piping ..............................................................................................................................4

1.3 Wiring..............................................................................................................................4

INSTALLATION .............................................................................................................................5

Receipt and Storage ......................................................................................................................5

Installation of Gear Reducer (Gearbox body) ................................................................................5

Long Term Storage ........................................................................................................................8

INPUT SHAFT COUPLING .........................................................................................................10

SF Coupling 1180T10 Type .........................................................................................................11

TOOL LIST...................................................................................................................................12
 A- 1

SAFETY PRECAUTIONS

Before handling this machine, be sure to read this manual and other appendices

carefully to familiarize yourselves with contents of the manual for proper operation.

Start on using this machine after having been well acquainted with all the equipment

knowledge, safety information, and cautionary instructions.

The rank of safety precautions is classified into "WARNING" and "CAUTION" in this

instruction manual.

Warning!
Where occurrence of dangerous situations such as death or serious injury is
presumable in the case of mishandling

Caution!
Where occurrence of dangerous situations such as light injury or only physical
damage is presumable in the case of mishandling.
Even such matters which fall under Caution! may possibly lead to serious results
depending upon the circumstances. Be sure to observe the instructions gives by
Caution! where every description covers important notes.
 A- 2

Installation

Caution!
Do not touch the key groove of shaft end and the acute part of corner of the
machine direct by unarmed hand. There is a possible danger of suffering
injuries.

When coupling with the companion machine, keep the centering accuracy
within the control value as shown in the instruction manual, drawing, etc. There
is a possible danger of failure caused when the machine is used beyond the
control value.

Before coupling with the companion machine, check for the direction of rotation.
There is a possible danger of failure and injury caused depending upon the
difference in the rotating direction.

Protect the exposed rotating part with safety cover or the like. There is a
possible danger of injury caused by entanglement.
 A- 3

1.1 Hauling and Unpacking

Warning!
When the machine is lifted for hauling, never gain access to the underside of
the machine. There is a possible danger of the accident of human body caused
by falling-off.

Caution!
Before lifting the machine, check the machine weight and lifting procedure, and
use such hauling tools as are possessed of rated capacity of lifting not less
than the machine weight. There is a possible danger of failure and injury
caused by falling-off and turnover.

Unpack the machine after making sure of ist top and bottom. There is apossible
danger of failure and injury caused by turnover.
 A- 4

1.2 Piping

Caution!
Connecting work of pipelines should be executed by the use of piping
appliances and materials adaptable to the rated pressure. There is a possible
danger of injury and fire caused by gushing hydraulic oi.

1.3 Wiring

Caution!
Connecting work with power cable should be executed on the basis of the wire
connection diagram provided inside the terminal box or instruction manual for
motor. There are such possibilities as electrification and fire.
Ground the earth terminal securely. There is a possible danger of electrification.
 A- 5

INSTALLATION

Receipt and Storage

Upon arrival of the vertical gear reducer (Gearbox) at the designated point, take proper

precautions against damage, loss, pilferage, etc. during the storage period at the Users

premise and until the machine and equipment have been installed in the site.

Storage is to be under roof and solid ground or in the closed dry room.

While the machine is in storage, cover it with sheeting or the like for protection against

rain water. At the same time, use extreme care to prevent the inclusion of dust and

moisture.

Handle heavy objects carefully under the skilled engineer's guidance when lifting and

handling the machine.

Installation of Gear Reducer (Gearbox body)

(1) Heavy duty lifting equipment and tools and instruments necessary for installing the
gear reducer should be prepared by the party who undertakes installation

(For tools, description is given on tool list)

Select each of them designed to metric unit.

(2) Before installing the gear reducer, first measure the level of foundation structure
and make sure that the horizontality in both axial direction and transverse direction
of the gear reducer input shaft is not more than 0.1 mm/m in the area of one meter
square and not more than 0.4 mm in the whole area. At the same time, put the
check results on record. If necessary, insert shims.
 A- 6

If burrs and the like are discovered on the foundation structure, remove them to
keep the foundation well conditioned. Lift up the gear reducer and make sure that
the bottom surface (installation level) of the gear reducer is free from burrs, dirt, etc.

Thereafter, place the gear reducer temporarily in the predetermined position.

After determining the gear reducer position, tighten anchor bolts (for tying the lower
case and foundation structure).

Foundation bolts to be tightened as per required torque. Subsequently weld

stoppers to the foundation structure by field adjustment.

Install scaffoldings along with the above practices.

Prepare such scaffoldings as will permit the safest work.

(3) Mount the mill table on the output flange. At this time, do not allow the output flange
to rotate. In addition, use extreme care not to exert an impact on the output flange.

(4) Install and connect lubrication pipings (connecting pipings) into the Gear reducer
and lubrication oil unit.

(5) Install external pipings.

If the gearbox is to be left out as it is for a long period of time, confirm the seal at the
oil inlet with vinyl sheet and provide sealing for reinforcement as necessary.

(6) Install the components of lubrication unit as indicated on the flow diagram.

(7) Lay down the piping between the gearbox and lubrication oil unit by field
adjustment.
 A- 7

(8) Flushing

The gear reducer proper and lubrication unit have need of no flushing as they are
cleaned up before shipment.

Apply flushing only to the piping between the gear reducer and lubrication oil unit.

If the actual lubrication unit is put to use for this flushing, the unit is subject to
recontamination. To prevent this, use the unit prepared for flushing purpose.

Immediately after the completion of flushing, charge the machine with

recommended oil (VG320) and carry out flushing work by the use of recommended
oil(VG320). Until operation has been started, allow the oil to run through the
machine at intervals of once every 10 days.

NOTICE

To avoid breakage of water pipes in oil cooler caused by freeze in winter, cooling
water in oil cooler should be drained daily.

(9) Preservation Procedure after Installation

In case the gearbox (reduction gear) has been unpacked and mechanically installed
but is not put into operation for rather long period, please follow the procedure for
Long Term Storage attached hereto.
 A- 8

Long Term Storage

When the gearbox is inactive for a long period of time, long term storage preparation is

required. The rust proofing method after gearbox delivery is included in this document.

1. Storage Conditions

Accumulation of rust is greatly influenced according to surrounding environmental

conditions and the state of storage.

Our rust proofing standard is based on the assumption that the gearbox and the
lubrication unit are stored in relatively good conditions.

It is to be stored inside a shop or warehouse, relatively free of humidity, dust,

extreme temperature fluctuation, or corrosive gas like sulfurous acid gas.

2. Re-treatment procedure

1) Storage term is maximum one year. The initial storage term is after shipment
from our factory.

2) After draining lubricant, spray or add the vapor phase inhibitor solvent (NUCLE
OIL 105S, VPI range, JIS K2246 NP-20 equivalent) into the gearbox and the
lubrication unit through inspection cover.
Quantity of the vapor phase inhibitor solvent
- Gearbox: 5% against the volume of case
- Lubrication Unit: 5% against the volume of oil tank

3) Seal up the openings such as air breather, oil outlet, piping connections,
labyrinth seal portion, etc.

4) Apply rust preventive oil (TECTYL 502C, JIS K 2246 NP-19 equivalent) to
outside machined surfaces such as shaft end, installing surface, and coupling.

5) Cover the gearbox fully with plastic sheet.

6) Repeat this step every one year.

3. Cooling Water Draining from Oil Cooler

Drain cooling water in oil cooler to avoid breakage caused by freeze in the winter.

4. Note

When operating the gearbox, drain the vapor phase inhibitor solvent and fill with the
recommended lubricant.
 A- 9

INSTRUCTION MANUAL

OF

SF COUPLING

1180T10 TYPE
 A - 10

SEISA Gear, Ltd.

INPUT SHAFT COUPLING

For centering coupling, attach a dial gauge to a coupling on side of a motor and

measure the OFFSET on the outer circumference of the centering datum surface for a

coupling on side of a reducer.

Measure the OFFSET on the surface by a thickness gauge.

Make certain the OFFSETS of the outer circumference and the surface are within the

allowable values. After centering, pack fully grease into clearance and tooth spaces.

Insert gradually grid members between both couplings so as to cover the outer

circumferences by knocking the grid members with a wooden or plastic hammer and

spreading little by little the grid members from their ends. Apply the spaces around the

grid members with as possible.

Remove an excess of grease flush with top of the grid members. At the time apply a

little grease to the outer circumference of a boss on hub so that a cover enters

smoothly. Put a gasket between both covers and tighten bolts. Then grease sticks out,

consequently wipe off it after tightening.

See the attached Fig.15 for grease to be applied.

Check the revolution direction before connecting the main motor

and the reducer by the SF coupling.

 A - 11

SF Coupling 1180T10 Type

Fig 1: Dimension between surface

Fig. 2: Maximum error for angle

Fig. 3: Maximum error for parallelis

Note

o
Errors for angle of Fig. 2 shall be measured on the positions at a distance of 180
 A - 12

TOOL LIST

NOTES TO THE CUSTOMER

Before handling the machine, this instruction manual should be read through
carefully to familiarize yourselves with contents of the manual.

The machine should be handled by skilled operators and staffs. Consideration

should be taken so that this instruction manual should reach to the persons in
charge.

This manual should be kept in file so as to be serviceable at any time

Tools in the TOOL LIST shall be for the Customers supply.

 A - 13

No. Name Sketch Qty Remarks

1 Double open end wrench 1 JIS B 4630 Nominal size
8X10 (M5, M6)

2 Double open end wrench 1 JIS B 4630 Nominal

size 13X7 (M8, M10)

3 Double open end wrench 1 JIS B 4630 Nominal

size 19X22 (M12,
M14)

4 Double open end wrench 1 JIS B 4630 Nominal

size 24X27 (M16,
M18)

5 Double open end wrench 1 JIS B 4630 Nominal

size 30X32 (M20,
M22)

6 Double open end wrench 1 JIS B 4630 Nominal

size 36X41 (M24,
M27)

7 Double box end wrench 1 JIS B 4630 Nominal

size 17X19 (M5, M6)

8 Double box end 1 JIS B 4630 Nominal

wrench size 22X24 (M14,
M16)

9 Double box end 1 JIS B 4630 Nominal

wrench size 27X30 (M18,
M20)
 A - 14

No. Name Sketch Qty Remarks

10 Double box end 1 JIS B 4630 Nominal
wrench sise 32X36 (M22,
M24)

11 Double box end 1 Marketing product

wrench M48

12 Double box end 1 Marketing product

wrench M80

13 Monkey wrench 1 JIS B 4604 Nominal

size 250

14 Pliers 1 JIS B 4604 Nominal

size 200

15 Torque wrench For tightening M80 1 Allowable preload for

gear reducer mounting
bolt 1968KN
16 Thightening box Tightening box for M64, M56, M48, Each
M42, M6, M30 1
17 Macjicists hammer 1 Nominal size #3

18 Screw driver 1 JIS B 4609 Nominal size

5.5x75
 A - 15

No. Name Sketch Qty Remarks

19 Screw driver 1 JIS B 4609 Nominal size
9x200

20 Philips head screw driver 1 JIS B 4633 Nominal size

#1

21 Philips head screw driver 1 JIS B 4633 Nominal size

#4

Tab. 1: Tool list

 A - 16

Tools Q'ty Remarks

Dial gauge 3 Accuarcy 0,01 mm
Magnet base 3
Spirit level 1 Accuracy0.02 mm/m
Straight edge Length 1500 mm
Block for above 2
Working platform (scaffolding)
Wire 1 set
Air source
Pover Source
Tab. 2: Other tools ols and instruments, if the installer considers that they are necessary
 B-0

OPERATION AND MAINTENANCE

Manual

NOTES TO THE CUSTOMER

Before handling the machine, this instruction manual should be read through
carefully to familiarize yourselves with contents of the manual.

The machine should be handled by skilled persons.

Consideration should be taken so that this instruction manual should reach to

persons in charge.

This manual should be kept in file so as to be serviceable at any time

 B-1

SAFETY PRECAUTIONS

Before handling this machine, be sure to read this manual and other appendices

carefully to familiarize yourselves with contents of the manual for proper operation.

Start on using this machine after having been well acquainted with all the equipment

knowledge, safety information, and cautionary instructions.

The rank of safety precautions is classified into "WARNING" and "CAUTION" in this

instruction manual.

Warning!
Where occurrence of dangerous situations such as death or serious injury is
presumable in the case of mishandling

Caution!
Where occurrence of dangerous situations such as light injury or only physical
damage is presumable in the case of mishandling.
Even such matters which fall under Caution! may possibly lead to serious results
depending upon the circumstances. Be sure to observe the instructions gives by
Caution! where every description covers important notes.
 B-2

Contents Page

SAFETY PRECAUTIONS.............................................................................................................B-1

Chapter General ..................................................................................................................B-4

Chapter 2 Specifications .......................................................................................................B-8

Chapter 3 Lubrication ..........................................................................................................B-11

Chapter 4 Operation.............................................................................................................B-13

Capter 5 Maintenance and Inspection .............................................................................B-19

Chapter 6 Disassembly and Reassembly ..........................................................................B-28

Chapter 7 Alarm and Interlock ............................................................................................B-29

Chapter 8 Instruction manual SF Coupling .......................................................................B-34

Chapter9 Instruction manual Flow Monitor B-38

Chapter10 Instruction manual Resistance Blub B-73

Chaptor11 Inching Device B-89

Appendix Instruction Manual of Lubrication Unit(Saparate Chapter)

 B-3

Contents of Annexed Drawings

No. Title Page

Dwg. No.1 GEAR REDUCER OUTLINE DRAWING C-1

Dwg. No.2 GEAR REDUCER ASSEMBLY DRAWING C-2

Dwg. No.3 INCHUNG DEVICE ASSEMBLY DRAWING C-3

Dwg. No.4 GEAR REDUCER FLOW DIAGRAM (1/2) C-4-1

Dwg. No.5 GEAR REDUCER FLOW DIAGRAM (2/2) C-4-2

Dwg. No.6 GEAR REDUCER PIPING DRAWING (1/3) C-5-1

Dwg. No.7 GEAR REDUCER PIPING DRAWING (2/3) C-5-2

Dwg. No.8 GEAR REDUCER PIPING DRAWING (3/3) C-5-3

Dwg. No.9 GEAR REDUCER PIPING DRAWING (1/2) C-6-1

Dwg. No.10 GEAR REDUCER PIPING DRAWING (2/2) C-6-2

Dwg. No.11 PIPING BETWEEN GEAR REDUCER AND OIL UNIT (1/2) C-7-1

Dwg. No.12 PIPING BETWEEN GEAR REDUCER AND OIL UNIT (2/2) C-7-2

Dwg. No.13 PIPING BETWEEN GEAR REDUCER AND OIL COOLER (1/2) C-8-1

Dwg. No.14 PIPING BETWEEN GEAR REDUCER AND OIL COOLER (2/2) C-8-2

Dwg. No.15 INPUT SHAFT COUPLING ASSEMBLY C-9

Dwg. No.16 THRUST PAD ASSEMBLY DRAWING C-10

Dwg. No.17 GEAR REDUCER TERMINL BOX WIRING C-11

Dwg. No.18 OPERATION RECORD OF GEAR REDUCER C-12

Dwg. No.19 LUBRICATION OIL LIST C-13

Dwg. No.20 AMOUNT OF OUTPUT FLOAT BY HIGH PRESSURE OIL C-14

Dwg. No.21 RESISTANCE BLUB C-15

 B-4

Chapter General

Warning!
Such practices as hauling, unpacking, installation, piping, wiring, running,
operation, maintenance and inspection should be carried out by persons
possessed of expert ism and workmanship. There are such possibilities as
electrification, fire, failure, and injury.

Caution!
Do not insert your finger or any substances into the openings of the machine.
There are such possibilities as electrification, fire, failure, and injury.
 B-5

1.1 Gear Reducer

This reducer is a totally enclosed three.stage vertical reducer with one-stage bevel gear

and one-stage planetary gear one-stage planetary gear for roller mill drive where input

shaft and output shaft are arranged horizontally and vertically respectively as shown in

sectional assembly drawing.

It is so designed and manufactured that the motor power will be reduced to the

specified revolutions and transmitted to the roller mill and, at the same time, that the

crushing load of roller mill and, at the same time, that the crushing load of roller mill can

be supported.

The crushing load of roller mill is supported by the solidly-built reducer casing through

the twelve thrust plain bearings incorporated into the casing.

The sliding part of the thrust plain bearing is filled up with oil, so that a sufficient oil film

will be formed by rotation.

Since planetary gears are adopted in the final stage, the casing can be designed to a

cylindrical shape to equalize the bearing rigidity of each thrust plain bearing arranged

on the casing, thus improving the share of loading on each plain bearing significantly.
 B-6

The planetary gear unit is constructed of a sun gear in the center of reducer, four

planetary gears meshing with the sun gear, a planetary frame supporting the said

planetary gears, and internal gear on the outside of the planetary gears meshing

therewith.

The sun gear provided with no bearings is supported by the meshing force of gears and

it is constructed for free movement so as to come to the position where the load of four

planetary gears is automatically equalized and to maintain a satisfactory tooth contact.

Resistance bulbs for the measurement of lubricating oil temperature and bearing

temperature at the necessary points are incorporated to make sure that the gear

reducer is maintained in normal condition, and they are designed to be capable of

giving an alarm and stopping the mill motor in case of emergency.

An alarm circuit should be incorporated by the customer.

 B-7

1.2 Lubrication System

This gear reducer is equipped with a forced lubrication system, so that the gears and

bearings are lubricated and cooled by forced lubrication oil.

The lubrication oil units is composed of oil tank, gear pump direct-coupled with motor,

oil strainer, oil cooler, temperature control valve, oil heater, valve and various kinds of

instruments and meters. (Refer to flow diagram.)

Lubricating oil is pressurized by gear pump, filtered by oil strainer, cooled by oil cooler

and introduced to the reducer-side oil header from which the lubricating oil is distributed

to lubricated parts such as gears and bearings.

Arrangement is made so that constant-temperature lubrication can be performed

automatically during the continuous operation by the automatic temperature control

valve installed in the outlet of oil cooler.

Arrangement is made so that constant- temperature lubrication can be performed

automatically during the continuous operation by the automatic temperature control

valve installed in the outlet of oil cooler.

Flow monitor with contact and pressure switch are provided on The necessary points of

oil flow line to permit detection of abnormalities in oil flow and oil pressure.
 B-8

Chapter 2 Specifications

Warning!

Never remodel the machine. Any remodeling practices may load to a danger
of failure and injury.

Do not use the machine in the explosive atmosphere. Such uses much lead
to danger of explosion, fire and accident of human body.

Caution!

Do not use the machine outside the scope of specifications. Such uses
may lead to a danger of failure and injury.

Do not remove the nameplate of the machine.

 B-9

2.1 Specifications for Gear Reducer

Totally-enclosed vertical 3-stage gear

Type
reducer
Transmitting capacity 3400 kW
-1
Input shaft revolutions 990 min
-1
Output shaft revolutions 24.2 min
Reduction ratio 1/40.8

Shaft end connection method:

Direct coupled with motor by SF
Input shaft
coupling
Output shaft Direct coupled with mill table
Prime mover Three-phase induction motor
Forced lubrication for both gears and
Lubrication method
bearings

Rotating direction:
Input shaft Clockwise viewing from mill motor
Clockwise viewing from top side (No
Output shaft
reverse rotation)
 B - 10

2.2 Particulars of Gear

1st 2nd 3rd

Sun Planetary International Sun Planetary International
Pinion Gear
gear gear gear gear gear gear
Kind Bevel gear Spur gear Spur gear
Normal Modus 26.2 20 20
Number of teeth 22 40 25 33 92 25x 35 95
o o o
Spiral Angel 25 0 0
Material SNCM420H SNCM420H SCM 440H SNCM420H SCM 440H
Carburizing,
hardening & hardening &
Heat Treatment Carburizing, hardening and tempering hardening and
tempering tempering
tempering
Tooth surface Gear cutting with
Grinding Machining Grinding Machining
finish carbide tool

2.3 Input Shaft Coupling

SF Coupling Model 1180T10
 B - 11

Chapter 3 Lubrication

Caution!

The machine is supplied without filled up with lubricating oil.
Before starting on operation, fill the machine with the lubricating oil of the
type as recommended by instruction manual, drawing, etc. up to the
specified level.
The machine will result in failure if it is put in running without lubricating oil
or in the state of short of oil.
 B - 12

Lubrication of each part is most important for the operation of the gear reducer. If oil

properties are improper or where lubricating condition is poor, it is unable to allow the

gear reducer to exhibit its performance sufficiently irrespective of the gear reducer

being manufactured to the highest precision. Since this gear reducer is so designed as

to use the oil with properties as shown in the annexed drawing 14, it is recommended to

control the properties of oil, flow rate of oil, oil temperature, oil pressure, etc.

sufficiently.

The parts to be lubricated inside the casing are all lubricated by forced lubrication.

Annexed drawings 3 and 4 show the flow diagram and the flow rate of oil to each

lubricated part respectively.

During the operation, the return oil screen and filter screen should be cleaned up so

that lubrication will be effected by clean oil.

For the lubrication system, refer to separate instruction manual for lubrication unit.
 B - 13

Chapter 4 Operation

Warning!

During operation, never gain access to or come in contact with rotators
(shaft etc.).
There is a possibility of the accident of human body caused by
entanglement.

Caution!

Do not use the machine under the load exceeding the rated value. There is a
possibility of failure and injury.

During operation, the machine partially becomes relatively hot. Do not allow
your hand and body to come in contact with the machine.

In case of abnormality, stop the machine forthwith to investigate into the
cause of abnormality and never operate the machine until remedial actions
have been taken. There is a possibility of failure and injury.
 B - 14

As long as installation of the gear reducer is completed properly, a success or failure of

operation mainly depends upon the control of lubrication.

It is absolutely necessary to keep proper properties of lubricating oil and sufficient

supply of oil.

4.1 Preparation before Operation

1) Before operating the lubrication unit, make sure that the oil tank is sufficiently
charged with oil. For the operation of the lubrication system, refer to separate
instruction manual of lubrication system.

2) Since the gear reducer is prevented from starting unless the temperature of
o
lubricating oil to the gear reducer is maintained at 10 C and above, check the oil
temperature.
o
3) To start up oil feed pump when the oil temperature is maintained at 10 C and to
o
confirm the oil temperature over 25 C which secures readiness for operating the
mill motor and to ensure stable condition being achieved and thrust pad chamber
being filled up with oil.

4) When such stable condition and readiness is secured it becomes ready for the mill
motor to start.
o
5) As oil temperature is automatically controlled at approximately 35 to 45 C by
temperature control valve during normal operation, allow the cooling water valve of
cooler to be left open.

6) After making sure that all interlocks given in Chapter 7 will operate even during the
test run, start the oil flow pump. Thereafter, start up the gear reducer.

7) Carry out the operation of only the lubrication system until no more foreign matter
has been detected in the oil strainer. Clean up the oil strainer as necessary.
 B - 15

While the lubrication system only is in operation, check pipings to make sure that they

are free from oil leaks. Thereafter, make sure that oil pressure, oil temperature and oil

flow are normal and, at the same time, check through the flow monitor and flow sight

that bearings and gears are lubricated.

In addition, check if individual equipment of low-pressure and high-pressure units is in

operation normally.
 B - 16

4.2 Operation of Gear Reducer

For the forced circulation and lubrication system, refer to instruction manual for

lubrication system.

o o
1) Oil temperature can be controlled automatically at 15 C to 55 C by conducting a
continuous run. Make sure that automatic control of oil temperature can be effected.

2) Start up the oil feed pump and make sure through the flow monitor that thrust pad is
supplied with oil.

o
3) Confirm the oil temperature over 25 C which secures readiness for operatin the
mill motor and to ensure stable condition being achieved and thrust pad chamber
being filled up with oil.

4) When such stable condition and readiness is secured it becomes ready fort he mill
motor to start.

5) Though the main gear reducer can be started under this condition, put it into
operation by the method whereby an abrupt overload being avoidable on the
occasion of test run.

6) After making sure that the lubrication system is in operation normally, conduct the
test run of the gear reducer.

To start with, be sure to check if the rotating direction of input shaft is as indicated
on drawing. After conducting the run-in of the machine for 8 hours under a 70%
load until the bearing temperature has become constant under no load, start on a
100% load run gradually.
 B - 17

During this run-in operation, give careful attention to abnormal vibration from shaft
and casings, parts from which an abnormal sound is emitted, and abnormality in
bearing temperature.

7) After the run-in operation, check the tooth surface. Tooth contact is acceptable if it
ranges evenly over the whole face width except for both ends of face width.

8) After checking the tooth surface, start on a test run under normal load.

9) At the initial stage of operation, clean up the return oil screen and filter screen
frequently. During the production run, check them at least every 200 hours and
clean them up as necessary.

10) Even after starting on a normal load test run, give careful attention to abnormal
vibration, abnormal noise and bearing temperature in the same way as in the case
of run-in operation.

Check again if there are any abnormalities in the lubrication system and whether
the oil flow to each lubricated part is proper.

If it is likely that bearing temperature rises abruptly during the test run, then it is
necessary to conduct a careful inspection.

11) Upon completion of a 200-hour operation, conduct the inspection of tooth surface.
Unless any abnormalities are detected on the tooth surface, carry on the production
run of the mill under the rated load.
 B - 18

12) During the production run, give careful attention to vibration and sound, and
conduct daily inspection (See page 21) and periodical inspection (See page 22, 23).

4.3 Notice when you bring main motor to stop

To avoid breakage of water pipes in oil cooler caused by freeze in winter, cooling water

in oil cooler should be drained daily.

 B - 19

Capter 5 Maintenance and Inspection

Warning!

Do not take off the internal inspection cover during operation (including the
operation of lubricating oil pump only). Hot lubrication oil will scatter, leading
to the danger of a scald.

Whenn checking the condition of tooth surface, apply lockint to the drivint
and driven machines securely.
There is a possibility of the accident of human body caused by entanglement
into the gear meshing section etc.

Do not operate the machine while the safety cover etc. that were removed
for inspection are being left uncovered.
There is a possibility of the accident of human body caused by
entanglement.
 B - 20

This chapter describes the servicing procedure for the case where repairs, adjustments,

etc. are needed as a result of periodical inspection and daily inspection.

It is recommended that adjustments and repairs of main components should be make

under the guidance of our technical staff.

In cases any abnormalities are discovered under inspection, make repairs each time

and put the results on record. When placing an order with us for spare parts and

replacement parts, be sure to inform us of particulars given on the nameplate and Part

No. which is identifiable by reference to annexed drawings.

Periodical Inspection

Due to difficulty in disassembling this gear reducer from the viewpoint of mill

construction, conduct inspection through the inspection manhole.

Conduct inspection periodically as per attached sheets and more frequently while the

gear reducer is new. Check for the following items on the occasion of inspection.
 B - 21

5.1 Daily Inspection: Inspection during operation

Inspection Item Location Method Reference Criteria Recording Check

Lubrication 0,15 MPa min. No record required for
oil pressure pressure gauge visual
Condition acceptable results
o o
Oil temperature thermometer 15 C min. 55 C max.
o
Inputmetal temperature Dotting type thermometer visual 100 C max Record required
o
Thrust pad temperature Dotting type thermometer visual 80 C max Record required
Thrust pad total oil flow
Oil flow Flow indicatoin
185 l/min
No abnormal chage than No record required for
Vibration Periphery of casing Sensory
usaual acceptable results
No abnormal chage than
Sound Periphery of gear reducer Sensory
usaual
Periphery of casing, pipings, input No oil leaks
Oil leaks visual
shaft
Check for 0.15 Pa max. in pressure
Contamination in lubricating oil Oil strainer pressure loss loss
in oil strainer
Bolt looseness Each bolt hammering No looseness
Daily inspection: Conduct inspection every day and put the status of operation on record in accordance with annexed drawing 14.
 B - 22

5.1 Periodical: Inspection during mill shutdown

Inspection Item Location Method Reference Criteria Recording Check

Tooth contact of Even contact over the No record required for
Gear Tooth surface of bevel gear sketch
bevel gear whole tooth width acceptable results
No abnormalities such as No record required for
Appearance visual
pitting acceptable results
No iron dust No record required for
Roller bearing No metal dust acceptable results
Return oil filter Overhaul and
oil strainer cleaning No metal dust No record required for
Sliding bearing acceptable results

Thrust pad Lubrication oil Return oil filter, oil strainer Overhaul and No metal dust No record required for
for thrust pad cleaning acceptable results

Amount of wear Clearance No abrupt change (0.2 Record required

gauge (allow mm) X-X
match marks XX-XX
Upper casing to mate XXX-XXX
output flang XXXX-XXXX
Oil flow Flow switch Visual Within allowable limit No record required for
acceptable results

Ask oil maker Oil maker's instruction Record of date of

Properties of lubricatin oil Sampling oil
for checking replacement required
Within allowable limit No record required for
Oil level in oil tank Oil level gauge Visual
acceptable results
Dial gauge, Within allowable limit Record required
Alignment of input coupling Input coupling thickness
gauge
Refer to Refer to chapter 8 No record required, iof
Input coupling T- grid member
chapter 8 satisfactoryy
Breaking of high - pressure rubber No deterioration and No record required for
high - pressure rubber hose visual
hose crack of rubber acceptable results
No looseness No record required for
Loose bolt Each bolt Hammering
acceptable results
 B - 23

Periodical inspection:

Conduct inspection once every 3 months and keep the record.

Even if no abnormality is detected under daily inspection and even when operation is not allowed to stop due to the necessity of continuation

of production run, be sure to conduct inspection at least once every 6 month.

 B - 24

Lubrication Oil

Conduct the test on properties such as foreign matter, viscosity, oxidation, additives,

etc. of lubricating oil and replace lubricating oil 2,000 hours after starting the operation

for the first time and at intervals of approx. 4,000 hours thereafter.

In conducting the lubricating oil test, it is recommended to ask the oil maker for

assistance.

If lubricating oil is judged to be unsuitable for use, replace the whole of the oil with fresh

oil. Replenish the machine with lubricating oil whenever reduction in oil level is

discovered. When replacing the oil, fully open the drain oil cock of the oil sump of thrust

plain bearing to remove the oil of its respective part. Thereafter, be sure to close this

cock totally. Use the same brand of lubricating oil uninterruptedly. Where it is inevitable

to replace one brand with another, remove the existing oil totally. Never intermix two or

more different brands of oil since there is a possibility of accelerating the deterioration

of oil.

If lubricating oil reduces abnormally, check if oil leaks are caused in the pipeline.

Especially in the case where the cooling pipe inside the oil cooler is corroded, oil is

intermixed into cooling water to flow out. To prevent this, check the cooling water also.

This cooler is for fresh water (water for industrial use is contained) use and sea water
can not be used.

Others

On the occasion of the initial periodical inspection, retighten anchor bolts and such

bolts around the casing as clamping bolts for upper and lower cases, etc. At the same

time, replace the locking steel wire applied to these bolts.

 B - 25

Special Remarks for the Care during Shut Down

1. For 8 Weeks (or less) Shut Down

1) Lubrication Oil Unit to be operated once a week so that the metal surface inside
the reduction gear can not be dried but can be covered with lubrication oil.

2) Cooling water to be drained out of the Oil Cooler completely.

2. For 3 Months (or more) Shut Down

1) In case shut down extending 3 months or more is planned, all of the openings

(such as Air Breather of Reduction Gear, Output Labyrinth, Air Breather of

Lubrication Oil Unit) to be sealed completely and Vapor Phase Inhibitor

Solvent (Vaporized Anticorrosive Solvent) to be inserted into the inside of the

Gear Reducer in accordance with the procedure for Long Term Storage.

2) Cooling water to be drained out of the Oil Cooler completely.

3) When resuming operation of the reduction gear, same procedure as specified

for the commencement of operation to be taken especially for confirmation of

oil lubrication stability and recorded thereof to be kept.

 B - 26

* Ref. Page B-22 Clearance Check for Defacement of Thrust Pad

Fig. 1: Clearance check for defacement of thrust pad

key
1 Clearance check for defacement of thrust pad 6 Disk
2 Motor side 7 Casing
3 View from upper casing side 8 Unit [mm]
4 Actual clearence 9 clearance
5 Thrust pad
 B - 27

Emergency Contact

Seisa, as the supplier of this Gearbox (Gear Reducer), are advising the following:

In case any trouble or any abnormal phenomenon be found, please inform the same to

the party(s) in accordance with the service network established.

The following are SEISA, the supplier, emergency contact:

(1) To International Operations, SEISA Gear, Ltd.

Attention:

(Mr.) T. Kiku, Business Development Coordinator ( person in charge)

e-mail: Tdy_Kiku@SEISA.shi.co.jp

and / or

(Mr.) H. Yoshimoto

e-mail: Hry_Yoshimoto@shi.co.jp

TEL 81-72-439-1151

FAX 81-72-431-0846

(2) To engineering Dept., SEISA Gear, Ltd.

Attention:

(Mr.) J. Murata, General Manager

e-mail: Jyn_Murata@SEISA.shi.co.jp

TEL 81-72-431-5708

FAX 81-72-436-3227

(3) Mailing & Street Address

16-1, 4-Chome, Wakihama, Kaizuka City, Osaka (597-8555) , JAPAN

 B - 28

Chapter 6 Disassembly and Reassembly

Disassembly and reassembly work shall be done only under supervision of Loeesche

representative and / or supplier (SEISA) representative.

 B - 29

Chapter 7 Alarm and Interlock

For the protection of the gear reducer and individual equipment, the following contacts

are provided.

A control circuit should be provided on your side. (For No. of detecting instrument, refer

to flow diagram MPA190L-E100A201/E100B201)

1. Starting Conditions of Main Motor

Make the main motor ready for starting when the following conditions are all satisfied.

Detector instrument
Mechanical condition
Name No.

When oil pressure of the gear reducer has PRESSURE

1 1/19
exceeded 0.2MPa of nominal pressure rate. SWITCH
When a period of not less than 5 minutes
2 has elapsed after starting all of 6 high-pressure
pump motors.
50
When a temperature of the input shaft RESISTANCE
3 51
bearing is 100or below and above 10. BULB
52
When temperature of thrust pads RESISTANCE 1/53
4
is 80or below and above 10. BULB 2/53
When temperature in oil tank is 65or RESISTANCE
5 43
below. BULB
When temperature in oil flow is 65or RESISTANCE
6 2/12
below. BULB
When oil flow to thrust pads has
7 exceeded 75%(185 L/min) of nominal FLOW SWITCH 54
flow rate.
 B - 30

2. Emergency Stop of Main Motor

When any one of the following conditions is satisfied, bring the main motor to an

emergency stop because there is a critical trouble.

Detector instrument
Mechanical condition
Name No.
When oil pressure of the gear reducer has PRESSURE
1 2/19
fallen below 0.15MPa of nominal pressure rate. SWITCH
When temperature of the input shaft RESISTANCE 50
2 bearing has risen up to 110 and BULB 51
above. 52
RESISTANCE
When temperature of thrust pads has risen
3 BULB 53
up to 90 and above.

If any two or more of the high-pressure

4
pump motors fails.
When pressure of the high-pressure oil to PRESSURE
any three or more of the thrust pads or TRANSMITTER
each two of the thrust pads next to each
1/14
5 other has reduced to 2.45MPa or below for
12/14
a period of not less than 5 seconds under
the working condition of mill operation.
(tension pressure acts)
When oil flow to gear reducer has FLOW
6 Fallen below 75%(185L/min) Stop software SWITCH 54
Fallen below 65%(160L/min) Stop hardware

Even in the case where the main motor has been brought to a stop, keep the lubrication
system running.
 B - 31

3. Alarm

When any one of the following conditions is satisfied, raise an alarm because there is a

minor trouble.

Detector instrument
Mechanical condition
Name No.
When oil pressure of the gear reducer has PRESSURE
1 1/19
fallen below 0.2MPa of nominal pressure rate. TRANCEMITTER
RESISTANCE 50
When a temperature of the input shaft
2 BULB 51
bearing is 100 or above.
52
When temperature of thrust pads RESISTANCE
3 53
is 80 or above. BULB
When oil temperature in the oil tank RESISTANCE
4 43
has risen up to 65 or above. BULB
When oil temperature in the oil flow RESISTANCE
5 2/12
has risen up to 65 or above. BULB
When oil level in the oil tank LEVEL SWITCH
6 10
has dropped below 2100L.

4. Stop conditions of low-pressure pump

Detector instrument
Mechanical condition
Name No.
Heater and low-pressure pump trip if oil level in
LEVEL SWITCH
1 the oil tank has dropped below 2100L. 10
(Main Motor trips automatically)
 B - 32

5. Control of heater

Turn ON/OFF the heater manually.

Make the following circuits ready fo use with the oil heater

Detector instrument
Mechanical condition
Name No.

When oil temperature to high-pressure pump is RESISTANCE

1 2/12
not less than 20. BULB
When pressure of high-pressure line is PRESSURE
2 13
0.05MPa and above. SWITCH
When the low-pressure pump motor is
3
running.

6. Detection of Clogging in Oil Strainer

Raise an alarm of clogging in oil strainer on the following conditions.

Detector instrument
Mechanical condition
Name No.
When pressure of high-pressure line has PRESSURE
1 13
dropped below 0.05MPa. SWITCH

7. Starting Conditions of No.68 Fan Motor

Detector Instrument
Mechanical Condition
Name No.
When oil temperature for oil flow is RESISTANCE
1 2/12
40 or above. BULB

8. Stop Conditions of No.68 Fan Motor

Detector Instrument
Mechanical Condition
Name No.

When oil temperature for oil flow is RESISTANCE

1 2/12
35 or below. BULB
 B - 33

9. Derection of Clogging in Oil Strainer

Raise an alarm of clogging in oil strainer on the following conditions.

Detector Instrument
Mechanical Condition
Name No.
When differential pressure measured
DIFFERRENTIAL
before And behind oil strainer has
PRESSURE 11
exceeded 0.15 MPa.
1 SWITCH
Release of clogging signal
(RESISTANCE (2/12)
if temperature 30 or above
BULB)
at No.2/12 RESISTANCE BULB
 B - 34

Chapter 8 Instruction manual SF Coupling

Instruction manual

of

SF coupling 1180T10 Type

SEISA Gear, Ltd.

 B - 35

Input shaft coupling

For centering coupling, attach a dial gauge to a coupling on side of a motor and
measure the OFFSET on the outer circumference of the centering datum surface for a
coupling on side of a reducer.

Measure the OFFSET on the surface by a thickness gauge.

Make certain the OFFSETS of the outer circumference and the surface are within the
allowable values. After centering, pack fully grease into clearance and tooth spaces.

Insert gradually grid members between both couplings so as to cover the outer
circumferences by knocking the grid members with a wooden or plastic hammer and
spreading little by little the grid members from their ends. Apply the spaces around the
grid members with as possible.

Remove an excess of grease flush with top of the grid members.

At the time apply a little grease to the outer circumference of a boss on hub so that a
cover enters smoothly. Put a gasket between both covers and tighten bolts. Then
grease sticks out, consequently wipe off it after tightening.

See the attached Fig.15 for grease to be applied.

Check the revolution direction before connecting the main motor and the reducer by the
SF coupling.

Grease to be added in every 6 months.

 B - 36

SF Coupling 1180T10 Type

Fig 2: Dimension between surface

Fig. 3: Maximum error for angle

Fig. 4: Maximum error for parallelis

Note

o
Errors for angle of Fig. 2 shll be measured on the positions at a distance of 180
B - 37
 B-38

Chapter 9.

Instruction Manual of Flow Monitor

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Chapter 10
Instruction manual of Resistance Bulb
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B-77
Chapter 11 Inching Device

1. Do not operate main motor ( mill motor ) when the chains are installed.
2. To lubricate recommended oil to the gear reducer properly even during inching
device in operation.
3. To apply specified oil to the gearbox for inching device in accordance with the oil
list attached to this manual, since this equipment has been shipped after
lubrication oil having been discharged.
4. To apply grease to the chains properly.
5. To ensure that rotating direction of the ( main ) gear reducer to be kept normal.
even during the inching device being in operation.
6. To carefully observe the cautions and the instructions as described in the
annexed drawing 03 when the chains to be attached to or detached from the
inching drive.
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DWG. No.1
C-1
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C-2
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C-3
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C-4-1
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DWG. No.10
C-6-2
DWG. No.11
C-7-1
DWG. No.12
C-7-2
DWG. No.13
C-8-1
DWG. No.14
C-8-2
DWG. No.15
C-9
DWG. No.16
C-10
DWG. No.17
C-11
 DWG. No.18 C 12

Operation Record of gear reducer

Input
Time Main Motor Temperature Bearing & Pad Lubrication Equipment
speed
o
Volt Ampere No.1 No.2 No.3 No.4 No.5 Temperature C Pressure MPa Oil Flow Oil Press. Note
-1
hh:mm min V A
T1 T2 T3 T4 T5 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 FL1 L/min PG1 MPa

Please keep the record of checking result as per this sheet and store such record within at least the warranty period of the gearbox, and please forward it to the supplier (SEISA) upon request so necessitated.
Lubrication oil list

Lubricant Amount Interval

ITEM PARTS to be Method of ESSO

EQUIPMENT
No. supplid Application SHELL OIL MOBIL OIL STANDARD
Charge Renewal Initial After
CO.,LTD CO.,LTD OIL
CO.,LTD

GEAR SHELL
GEAR AND FORCED MOBILE SPALTAN
REDUCER OMARA S2 G 5000L 5000L 2000Hrs 4000Hrs
BEARING LUBRICATION GEAR 632 EP320
AND OIL UNIT 320

SHELL
SF
HUB & HAND-FILL ALVANIA MOBILE LITHTAN
COUPLING 910g 910g 1000Hrs 2000Hrs
GRIDMEMBER OIL BATH GADUS S2 PLEX47 EP2
1180T10
V 100 2

DWG. No.19
C-12
 AMOUNT OF OUTPUT FLOAT BY HIGH PRESSURE OIL

LUBRICATION OIL : JIS K 2219 GEAR OIL ISO VG 320

OIL TEMPERATURE : 40
Amount of float OIL FLOW : 2.1L/min/1PCE.
(mm)
0.5

0.4

0.3

0.2

0.1

0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000 11000 12000 13000 14000 15000 16000 17000 18000 19000 20000

DYNAMIIC LOAD (MIN) DYNAMIC LOAD (MAX)

5800kN (591 ton) 13500kN (1377 ton)

TOTAL THRUST ACTING ON THRUST PLAIN BEARING (kN)

DWG.No. 20
C-14
 C-15-1
DWG. No.21-1
 C-15-2
DWG. No.21-2
 C-15-3
DWG. No.21-3
 C-15-4
DWG. No.21-4
 D-0

OPERATION AND MAINTENANCE

MANUAL

LUBURICATION OIL UNIT

NOTES TO THE CUSTOMER

Before handling the machine, this instruction manual should be read

through carefully to familiarize yourselves with contents of the manual.
The machine should be handled by skilled operators and staffs.
Consideration should be taken so that this instruction manual should reach
to the persons in charge.
This manual should be kept in file so as to be serviceable at any time
 D-1

A. Construction ...........................................................................................................................3
B. Operation ................................................................................................................................3
C. Explanation of Each Equipment ...........................................................................................5
) Low Pressure pump...........................................................................................................5
) HIgh Pressure pump..........................................................................................................7
) Oil Cooler...........................................................................................................................8
) Oil Strainer.........................................................................................................................8
) Others................................................................................................................................9
D. Lubrication Unit Flow Diagram 10
E. Lubrication Unit AssDwg 11
F. L.O.Unit Electric Circuit Diagram 12
G. Air Coller Assembly 13

Contents

1 OIL PUMP(L.P) a

2 ELECTRIC MOTOR (L.P) b

3 OIL PUMP(H.P) d

4 ELECTRIC MOTOR (H.P) e

5 OIL STAINER f

6 OIL COOLER g

7 LEVEL SWITCH h

8 DIFFERENTIAL PRESS. SWITCH i

9 RESISTANCE BULB j

10 PRESS. SWITCH k

11 PRESS. TRNASMITTER l

12 TERMINAL BOX m

13 PRESS.REDUCING VALVE o

14 SAFETY VALVE p

15 THERMOMETER q

16 AIR BREATHER r
 D-2

17 PRESS GAUGE s

18 GAUGE VALVE t

19 TEMP. CONTROL VALVE u

20 BUTTERFLY VALVE v

21 GATE VALVE w

22 LEVEL GAUGE x

23 AIR COOLER y
 D-3

INSTRUCTION MANUAL

LUBRICATION OIL UNIT (LOU)

FOR GEAR REDUCER

A. Construction

This LOU for the gear reducer consists of the oil tank, the low-pressure pump with
motor, the high-pressure pumps with motor, the oil strainer, the oil cooler,
regulating valves and instruments as shown in the drawing.

B. Operation

a) Oils sent out from the low pressure pump and the high pressure pumps
are delivered to the gear reducer through the oil strainer, the oil
cooler, and then return to the oil tank.

b) Parts of the purified oils through the oil strainer are led to the
suction port of the high pressure pumps through pressure reducing
valve and then are sent out from the delivery port of the high
pressure pump to the gear reducer.

c) When the oil's temperature is less than 10 (in case of equivalent

ISO VG320 oil),oil should be circulated by using the low press oil
with 20 and then to normal running.
Starting up of the high pressure pumps can be done only when the oil
temperature is over 20.
This precaution is needed in order to avoid over-load of the low
pressure pump.

d) The oil pressure, temperature and flow capacity of low pressure oil
are indicated by the each gauges fitted on the gauge panel or piping.

e) The oil's pressure which is boosted from the low pressure pump to
the high pressure pump through the oil strainer is able to be regu-
lated by the reducing valve fitted on the high pressure pump suction.
But usually, this valve has already been regulated at the shop, so that
 D-4

it is not necessary to touch unless any particular reason.

f) When the differential pressure between the low pressure pump outlet
and the oil filter outlet is going over correct point, it is required
to change over the lever of oil strainer. And open the cover of the
stained chamber and lift up the clogged wire net for cleaning.

g) Special Notes (1) -When starting the gear reducer, to make sure the
lubrication oil unit in normal operating condition.
The following steps to be taken.

To start-up low pressure pump when the oil temperature rises over 1
0 and confirm the oil temperature over 20 which secures readine
ss for operating high pressure pumps and to ensure stable condition
being
Achieved and thrust pad chamber being filled up with oil.

Then to start-up the high pressure pumps to ensure each equipment
being ready for starting operation.

When such stable condition and readiness are secured, it becomes re
ady for the mill motor to start.

h) Special Notes (2) When operation being shut down scheduled or even
though non-scheduled, the following to be taken care.

In order to secure sufficient oil volume filled up in the thrust pad

chamber ( in case such volume becomes insufficient, there is
possibility of being rusted), low pressure pump to be operated once a
week for minimum 20 minutes.

To take exactly same procedure when restart after shut down.

In particular carefully to confirm that lubrication oil has been
Filled up in the gear reducer itself with required volume.
 D-5

C. Explanation of Each Equipment

) Low Pressure pump

a) Construction

The pump is one of horizontal type gear pump with modified Sin curve.
It consists of casing, casing cover, two wheel shafts and safety
valve.
Bearing metal and mechanical seal are used.

b) Precaution of Operation

Confirm the centering of pump and motor.

Confirm the tightening of bolts and nuts.
Try to turn the pump coupling by hand and confirm its smooth
movement.
Turn on the starting of electro-motor for a few seconds ,and confirm
its correct revolutionary direction.
The safety valve is adjusted as 0.88MPa. Do not place hands unless
necessary.
When the suction performance in the beginning of pump running is
not sufficient, pour oils into the inside of the pump casing.

c) Troubles in Pump Running

The causes are as follows:

Vibration of pump

1) Excessive suction loss

2) Air mixture at the suction pipe
3) Improper installation
4) Vibration of coupling shaft (insufficient centering)

Temperature raise at the gland

1) Improper installation
2) Extraordinary friction at the gland part (because of a foreign
matter adhesion or seal damage)
3) Vibration of shaft

Oil leakage from the shaft seal

1) Mechanical seal damage

2) Vibration of shaft
 D-6

Overload of motor

1) Excessive revolution
2) Over pressure
3) Lower voltage
4) A foreign matter in the gear wheel
5) Closure of the delivery line
6) High oil viscosity
7) Non-action of safety valve

Temperature raise at the bearing

1) Excessive revolution
2) Vibration of shaft
3) Wear, damage of bearing metal

A little delivery of pump

1) Excessive delivery head

2) Excessive suction loss
3) Lower revolution
4) Lower voltage
5) Air mixture at the suction side
6) Out of order in safety valve

7. No-delivery of pump

1) Excessive suction loss

2) Reverse revolution
3) Excessive air mixture
4) Closure of the suction side
5) High oil viscosity

8. Cavitation of pump

1) Excessive suction loss

2) High oil viscosity
3) Air mixture in suction line
4) Our of order in safety valve (insufficient touch of valve and
valve seat)
 D-7

) High Pressure pump

a) Construction and General Action

The pump is one of horizontal type gear pump for high press purpose.
It consist of casing, casing cover, gear, shaft and oil seal.
Pump shaft is driven by a motor with flexible coupling.
No relief valve is incorporated in the high pressure pump. To prevent
damage to the pump, therefore, ensure that the discharge piping remains
unobstructed at all times.

b) Operation

Pure oils should be used.

Check the discharge piping line of the pump for blockage. If there
is any obstruction in the line, the high pressure pump may become
overloaded.
Try to turn the pump coupling by hand and confirm it's
smooth movement.
Turn on the starting switch of the electro-motor for a few
seconds and confirm it's correct revolutionary direction.
The high pressure pump is designed with minimum operational
temperature of 20. If it is to be used under low temperature
conditions, raise the oil temperature with circulating operation
of the low pressure pump only and with an electric heater before
stating the high pressure pump, as described above.

c) Inspection

If oil is not discharged or the designated discharge pressure is not attained,

check the following and take proper measures.

Any other cause besides pump

1) Oil viscosity is excessively high.
2) Suction pressure is very low.

Cause of pump itself

1) Gear sticks.
2) Oil seal damaged.
 D-8

Oil Cooler

a) Construction

This oil cooler consists of the shell, water chamber, tube

plate, baffle plates and cooling tubes.
Oil flow speed inside cooler is regulated by the baffle plates
to gain high cooling efficiency. Circulating lubrication oil shall
shall be kept on suitable temperature through the cooler.

b) Operation

1. Open the water valve and lead water with specified quality
into cooler.
2. Open the air vent plug on the chamber for air release.
3. Close the air vent plug after completion of air release
from the chamber.
4. It is easy for dead air to remain in the top of shell inside.
Cooling performance is not efficient if there is dead air.
5. Each valve should not be operated quickly to prevent water
hammering.

c) Shut down

It the cooler shall be shut down for a long time, it is required

that water and oils in the cooler are put out perfectly.
If the cooler shall be shut down temporarily when it is so cold
as water may be frozen, it is also required that water in the
cooler is put out.

Oil Strainer

a) Construction

The strainer consists of two separated chambers with complete

filter elements. One is in service while the other is available
for cleaning.

b) Operation

When the differential pressure between the suction side and

delivery side shall be over the regular point, it is required
to change over the lever of strainer.

Changing over is as follows:

1. Oils flow to the direction marked on the top face of change

over lever.
2. Turn the lever handle to the stopper position at opposite
side.
3. After lever handle was changed over, it is required that
stained chamber's wire mesh should be take out and cleaned.
 D-9

c) Cleaning of filter

Stained wire mesh filter must be cleaned in a vessel with clean

kerosene and be blown with compressed air.

Others

Description of the parts and instruments are refer to each operation

and maintenance manual.
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OIL PUMP(L.P)
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OIL COOLER
h-1
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LEVEL SWITCH
h-4
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 i-5

DIFFERENTAL PRESS. SWITCH

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PRESS. REDUCING VALVE

 p-1

SAFETY VALVE
p-2
p-3
 p-4

SAFETY VALVE
q-1
r-1
s-1
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