Volume 1 Instruction Manual For Ship Unloader Stacker&reclaimer Coal Handling System Final PDF

P.T.
CENTRAL JAVA POWER

TANJUNG JATI B COAL-FIRED
POWER STATION UNITS 3 & 4
INSTRUCTION MANUAL
FOR
SHIP UNLOADER,
STACKER & RECLAIMER,
COAL HANDLING SYSTEM
(FINAL)
VOLUME 1
145236.61.0401
CHINA HUADIAN ENGINEERING CO.,LTD
No.91, North Road, Xi San Huan, Beijing,
100048, P.R.China
BLACK VEATCH
PO TITLE: SHIP UNLOADER, STACKER & RECLAIMER,

COAL HANDLING SYSTEM SUPPLY
PO NO.: 145236.61.0401
DOCUMENT: Coal Handling System Table Of Contents
DOCUMENT NO.: IM0401-1
CHINA HUADIAN CORPORATION
CHEC China Huadian Engineering Co., Ltd
APPROVED FOR CONSTRUCTION
1/5
COAL HANDLING SYSTEM INSTRUCTION MANUAL

TABLE OF CONTENTS
SECTION
DOC. No.
DOCUMENT TITLE
Table of Contents
IM0401-1
Coal Handling System Instruction Manual

Table Of Contents
IM0401-2
Coal Handling System General Description
Coal Handling
System General
Description
Equipment
3.1
Ship Unloader
IM0401-3.1.1-1
Ship Unloader Erection & Commissioning

Manual(Mechanical)
IM0401-3.1.1-2
Ship Unloader Operation & Maintenance

Manual(Mechanical)
IM0401-3.1.2-1
Ship Unloader Erection & Commissioning

Manual(Electrical)
IM0401-3.1.2-2
Ship Unloader Operation & Maintenance

Manual(Electrical)
IM0401-3.1.3-1
Grab Instruction Manual
IM0401-3.1.3-2
Motor Instruction Manual
IM0401-3.1.3-3
Gearbox Instruction Manual
IM0401-3.1.3-5
Brake Instruction Manual
IM0401-3.1.3-6
Rail-Clamper Instruction Manual
IM0401-3.1.3-7
Hydraulic system Instruction Manual
IM0401-3.1.3-8
Spraying&lubricating Instruction Manual
IM0401-3.1.3-9
Maintenance Crane Instruction Manual
3.1.1 Mechanical Part
3.1.2 Electrical Part
3.1.3 OEM
VOL.No.
IM0401-3.1.3-10 Cable reel Instruction Manual
IM0401-3.1.3-11 Vibration feeder Instruction Manual
IM0401-3.1.3-12 Scale sensor Instruction Manual
IM0401-3.1.3-13 Elevator Instruction Manual
IM0401-3.1.3-14 PLC Instruction Manual

2/5
///

TABLE OF CONTENTS
SECTION
3.2
3.3
3.4
Conveyor
Pipe Conveyor
DOC. No.
3.4.2 Electrical Part
3.4.3 OEM Manual
VOL.No.
IM0401-3.1.3-15 Inverter Instruction Manual
IM0401-3.1.3-16 Transformer Instruction Manual
IM0401-3.1.3-17 MV Switchgear Instruction Manual
IM0401-3.2-1
Conveyor Instruction Manual
IM0401-3.2-2
Steel Cord Conveyor Belt Vulcanization

Instruction Manual
IM0401-3.2-3
Multi-plied Conveyor Belt Vulcanization

Instruction Manual
IM0401-3.3-1
Pipe Conveyor Erection & Commissioning

Manual
IM0401-3.3-2
Pipe Conveyor Operation & Maintenance

Manual
IM0401-3.3-3
Pipe Conveyor Belt Vulcanization

Instruction Manual
IM0401-3.4.1-1
Stacker&Reclaimer Erection &

Commissioning Manual(Mechanical)
IM0401-3.4.1-2
Stacker&Reclaimer Operation &

Maintenance Manual(Mechanical)
IM0401-3.4.2-1
Stacker&Reclaimer Erection &

Commissioning Manual(Electrical)
IM0401-3.4.2-2
Stacker&Reclaimer Operation &

Maintenance Manual(Electrical)
IM0401-3.4.3-1
Slewing bearing Instruction Manual
IM0401-3.4.3-2
IM0401-3.4.3-3
IM0401-3.4.3-4
Hydraulic Coupling Instruction Manual
IM0401-3.4.3-5
IM0401-3.4.3-6
Rail-Clamper Instruction Manual
IM0401-3.4.3-7
Hydraulic system Instruction Manual
IM0401-3.4.3-8
Spraying&lubricating Instruction Manual
Stacker & Reclaimer /
3.4.1 Mechanical Part
DOCUMENT TITLE
3/5

TABLE OF CONTENTS
SECTION
DOC. No.
DOCUMENT TITLE
IM0401-3.4.3-9
Planet gearbox Instruction Manual
VOL.No.
IM0401-3.4.3-10 Cable reel Instruction Manual
IM0401-3.4.3-11 Belt scale Instruction Manual
IM0401-3.4.3-12 PLC Instruction Manual
IM0401-3.4.3-13 Inverter Instruction Manual
IM0401-3.4.3-14 Transformer Instruction Manual
IM0401-3.4.3-15 MV Switchgear Instruction Manual
3.5
Vibration Screen
IM0401-3.5
Vibration Screen Instruction Manual
3.6
Crusher
IM0401-3.6-1
Crusher Instruction Manual
IM0401-3.6-2
Crusher OEM Instruction Manual
3.7
Tripper
IM0401-3.7-1
Tripper Instruction Manual
3.8
Others
IM0401-3.8-1
IM0401-3.8-2
IM0401-3.8-3
Hydraulic coupling Instruction Manual
IM0401-3.8-4
Magnetic separator Instruction Manual
IM0401-3.8-5
Coal sampling unit Instruction Manual
IM0401-3.8-6
Belt weigh scale Instruction Manual
IM0401-3.8-7
Electric Hoist Instruction Manual
IM0401-3.8-8
Manual Hoist Instruction Manual
IM0401-3.8-9
Belt cleaner Instruction Manual
IM0401-3.8-10
Vulcanizer Instruction Manual
IM0401-4-1
Transformer Instruction Manual
Electrical
4/5

TABLE OF CONTENTS
SECTION
5.1
I&C
OEM Instruction
HVAC/Water/Dust
Collection
DOC. No.
DOCUMENT TITLE
IM0401-4-2
MV Switchgear Instruction Manual
IM0401-4-3
LV Switchgear Instruction Manual
IM0401-4-4
DC Instruction Manual
IM0401-4-5
Busduct Instruction Manual
IM0401-4-6
Resistor Instruction Manual
IM0401-4-7
Grounding Instruction Manual
IM0401-5-1
Control System Operation Manual
IM0401-5-2
Control System Maintenance Manual
IM0401-5.1-1
PLC Hardware Manual
IM0401-5.1-2
PLC Programming Manual
IM0401-5.1-3
HMI Programming Manual
IM0401-5.1-4
PLC User Manual
IM0401-6
HVAC/Water/Dust Collection Instruction

Manual
5/5
VOL.No.
//

PO NO.: 145236.61.0401
DOCUMENT: Coal Handling System General Description
DOCUMENT NO.: IM0401-2
0
REV.
2010-1-20
DATE
FOR
CONSTRUCTION
37
DESCRIPTION
TOTAL
PAGES
1 of 37
PREPARED
CHECKED
APPROVED
COAL HANDLING SYSTEM OPERATING & MAINTENANCE INSTRUCTION

Note: The users of the plant are reminded that the coal and ash handling plant supplied are designed
to handle coal with qualities as stated in the main contract. Should the user decide to use coal
which is of an inferior quality to that specified, the agreement of the CHEC must be sought in
advance. CHEC will not be held liable for any damages to the plant or power station equipment
as a result of using of poor quality coal.
ADMIN
The Coal Handling System Operating and Maintenance Instructions are included in one volume
which is in turn divided into parts and sections.
Volume 1 contains information on the equipment used to transfer the coal from the jetty to the coal
bunker tops.
All contract drawings that are referred to throughout the Volume are shown in the List of Drawings of
Section 5. Only General Arrangement (GA) drawings and flow diagrams are included in Section 5.
VOLUME
PART
SECTION
COAL HANDLING SYSTEM

1
1- Contents
2- Description
3- Operating Instructions
4 - Maintenance Instructions
5- Drawings
6- Manufacturers Publications
2 of 37
HEALTH AND SAFETY INFORMATION
During the operation and maintenance of the Coal Handling System, every effort must be made
to eliminate hazards and any risks to the health and safety of the personnel carrying out the work.
Where total elimination is not possible, the risk is to be minimized as far as is reasonably practicable
and suitable protective action taken to ensure the health and safety of the workforce. In particular,
all local and site statutory health and safety requirements must be adhered to, in addition to the
requirements given in this manual.
Before any lifting operation commences, all equipment to be used is to be checked for its suitability,
safe working load and current test certificate.
Certain materials and processes on the site may contain substances hazardous to health, eg.
paint, belt vulcanizing materials, welding fumes etc. Precautions must be taken to prevent, any
danger to the workforce.
When welding and burning operations are to be carried out, the necessary care and fire precautions
need to be taken.
All warning, cautions, and other safety related notices that are given in the Operating and Maintenance Manual, including manufacturers publications listed and referred to, must be observed. The
following warnings, which cover safety precautions and safe working practice, must also be observed in addition to those that appear throughout the manuals.
GENERAL
WARNING THE FOLLOWING GENERAL SAFETY'PRECAUTIONS MUST BE OBSERVED AT
ALL TIMES FOR THE PROTECTION OF PERSONNEL.
Provide safe access to all equipment.
Provide adequate and approved head, face, hand and body protection.
Maintain all areas clean of oil, water debris, refuse, etc. which could cause accidents,
Ensure that the area around all the equipment is free of obstruction and is adequately ventilated to permit personnel to operate, inspect and have access to the equipment for maintenance.
3 of 37
Personnel access to pump rooms, sumps, pits, tanks vessels and all other areas where
gases and fumes are a potential hazard must be strictly controlled monitored and supervised.
Hazardous gases and fumes must be eliminated and the working area ventilated and monitored to
ensure that a life-sustaining level of oxygen is present and stable before personnel access is permitted. Adequate and approved breathing apparatus must be available to be worn by personnel
when monitoring indicates this to be necessary.
Post appropriate CAUTION, DANGER or WARNING signs to alert all personnel to hazards
and to advise personnel not directly involved with the work being performed.
Provide adequate protection to prevent injuries from pipes, cables, ropes, levers, chains
or other equipment which may extend into normal walk ways.
Inspect all equipment, including piping, braces, supports, anchors, etc. at regular intervals. Any repairs required should be performed as soon as possible to prevent damage to
the equipment and injuries to personnel.
Use only approved lifting equipment and methods when moving any equipment.
Use only approved tools, materials and techniques related to the specific equipment being
serviced.
Only qualified personnel, as established at your facility, should be authorized to operate

and maintain the equipment,
Provide adequate approved safety barricades around pits, trenches, holes, etc.
In addition to the specific operating and maintenance instruction, observe all plant safety
procedures and normal safety precautions when operating and maintaining all types of
equipment.
Instruct and train personnel in the operation and maintenance of equipment and any
emergency procedures that may be required.
Do not tamper with or bypass any interlocks whether they are electrical or mechanical.
Bypassing an interlock defeats its purpose, and may cause damage to the equipment, serious
injury to personnel, or both.
4 of 37
ELECTRICAL EQUIPMENT
This category includes equipment and devices powered by an electrical source such as solenoid valves, vibrators, motors, timers, pushbutton stations, control panels and control equipment.
WARNING THE FOLLOWING SAFETY PRECAUTIONS MUST BE CARRIED OUT AT ALL
TIMES FOR THE PROTECTION OF PERSONNEL,
Only qualified personnel, as established at your facility, should be authorized to operate and
maintain the equipment,
Unless absolutely necessary (adjustments, calibration, etc), never install or repair equipment
unless its power source has been disconnected.
Ensure that all circuit breakers associated with the equipment being serviced are locked in the
OFF position.
Tag OUT OF SERVICE all circuit breakers and related equipment being serviced.
Exercise extreme care when maintenance or adjustment is necessary with the equipment energized
and/or operating.
EQUIPMENT WITH MOVING PARTS

This category includes items such as reclaimers, conveyors, Sampling systems, crushers, stackers,
unloaders and all similar equipment.
WARNING THE FOLLOWING SAFETY PRECAUTIONS MUST BE CARRIED OUT AT ALL
TIMES FOR PROTECTION OF PERSONNEL.
maintain the equipment,
Do not proceed with any installation or repairs unless power sources to the related equipment are
disconnected.
Ensure that all circuit breakers associated with the equipment being
maintained are locked in the OFF position.
Tag OUT OF SERVICE all circuit breakers and related equipment.

5 of 37
Isolate equipment being maintained by closing all cut off gates,

isolating gates, or any other isolating equipment associated with it.
Tag this isolating equipment OUT OF SERVICE.
Fully close all supply valves for the solenoid valves associated with the equipment being serviced to
prevent liquids, gases or material from flowing through the equipment.
Exercise extreme care when removing or installing springs.
When performing maintenance or adjustments which require that the equipment be operating,
observe the precautions listed in the specified equipment instructions. Never place any part of your
body or clothing in the operating path of the equipment.
PIPING, FITTINGS AND HARDWARE
This category includes hydraulic, pressure and vacuum transport piping, fittings, adapters, couplings,
flanges, gauges, valves and similar equipment.
WARNING
THE FOLLOWING SAFETY PRECAUTIONS MUST BE CARRIED OUT AT ALL
TIMES FOR PROTECTION OF PERSONNEL,
maintain the equipment.
During installation or dismantling of any piping, be certain that the related piping and equipment
is adequately secured until task is complete.
Do not service transport lines when the system is in operation unless the branch line to be serviced
is completely isolated and all controls, valves, etc. associated with this branch line are tagged
OUT OF SERVICE.
Never remove or service a gauge without isolating its supply lines.
Piping and equipment which is subjected to high temperatures must be allowed to cool to a safe
temperature before servicing the equipment.
HYDRAULIC OR PNEUMATIC DEVICES AND SUPPLY LINES

This category includes air, oil or water cylinder operated equipment, associated supply lines,
supply source and all similar equipment.
6 of 37
WARNING
THE FOLLOWING SAFETY PRECAUTIONS MUST BE CARRIED OUT AT ALL
TIMES FOR PROTECTION OF PERSONNEL.
Only qualified personnel, as established at year facility, should be authorized to operate and
maintain the equipment.
Ensure that all circuit breakers associated with the equipment being
serviced are locked in the OFF position,
Tag OUT OF SERVICE all circuit breakers and related equipment.
Close and tag OUT OF SERVICE all supply valves associated with the
equipment.
If equipment to be maintained is heated, allow temperatures to cool

until safe to handle.
Relieve any residual pressure prior to servicing the equipment.
CARE AND UPKEEP OF OPERATING AND MAINTENANCE MANUALS

It is important that Operating and Maintenance manuals be regarded as part of the product. All manuals must be kept for the life of the product and should be available to all persons involved with the
operation and maintenance of the plant and control systems.
Holders of instruction manuals must ensure that any amendments are properly incorporated.
Should the product or part-product be passed on to a subsequent holder or user, then the relevant manual should also be given to the new holder or user.
7 of 37
CONTENTS
1.0 CONTENTS
Refer to IM0401-1
ABBREVIATIONS AND DEFINITIONS

Refer to TOSHIBAs document No. LST-GCH-XIT3-0001 ABBREVIATION LIST FOR DESCRIPTION
8 of 37
DESCRIPTION
2.0 DESCRIPTION
Purpose of the System
The purpose of the Coal Handling System is the off-loading of coal from ships and the conveyance of coal to the boiler bunkers or to the coal storage yards.
The coal handling system functions are:
(a)
Unloading and conveying coal inside the power station.
(b)
Stacking and reclaiming in the coal storage yards.
(c)
Screening and crushing of raw coal.
(d)
Weighing and sampling coal.
(e)
Removing metal from coal.
SYSTEM DESCRIPTION
The coal is discharged from vessels by ship unloaders that operate in conjunction with the
jetty conveyors. These conveyors run most of length of the jetty to receive coal from the unloaders for the complete working travel distance of the unloaders. The two grab unloaders
have 2 position diverted gates in their outlet chutes allowing coal to be fed to either jetty
conveyor.
Coal is fed onto either conveyor 101A or conveyor 101B while only one grab unloader is
operating. Coal is fed onto both conveyor 101A and 101B when two grab unloaders are
operating.
Conveyors 101A and 101B discharge over their head pulleys onto the loading points of
conveyors 102A and 102B in Transfer Tower (TT) TT101,
Conveyors 102A and 102B transport the coal from TT101 to TT102. The conveyors 102A
9 of 37
and 102B discharge over their head pulleys in TT102 to the loading points of conveyors
103A and 103B.
Conveyor 103A discharges to either the loading point of conveyor 104 or the loading point
of stockyard conveyor 105A via a diverted gate in TT103, Conveyor 103B discharges to
either the loading point of conveyor 104 or the loading point of stockyard conveyor 105A
via a diverted gate in TT103.
Conveyor 104 discharges over the head pulley onto the loading point of stockyard conveyor 105B in Transfer Tower TT104.
The stockyard conveyors 105A and 105B feed coal onto the stockpile via the travelling
stacker/reclaimer. Each stacker stacks the coal onto a short term pile. Coal from the short
term piles is spread to form long term piles using scrapers and bulldozers. The stockyard
conveyors 105A and 105B feeds coal onto the stockpile via the slewing bucket wheel
stacker/reclaimer or passes the coal through the stacker/reclaimer back onto the stockyard conveyor belts and feeds either the loading points of conveyor 106A or conveyor
106B directly.
Coal is reclaimed from the stockpiles by the bucket wheel stacker/reclaimers and then
back onto the stockyard conveyor belts 105A or 105B.
Coal shall be capable of being blended within the blending ratio range of 35:65%
to
65:35% and conveyed to the coal silos.

Conveyor 105A discharges onto either the loading points of conveyors 106A or conveyor
106B via the diverted gate in TT106.
Conveyor 105B discharges onto either the loading points of conveyors 106A or conveyor
106B via the diverted gate in TT105.
Conveyors 106A and 106B receive coal from the stockpile by either conveyor 105A or
conveyor 105B and discharge over their head pulleys onto the vibrating screens in the
crusher building. The oversize material from the screens is directed by chutework into the
crushers for reduction to 50mm max and discharge onto the loading points of either
10 of 37
conveyor 107A or conveyor 107B. The sized product from the screens is also discharged
onto the loading points of either conveyor 107A or conveyor 107B.
Conveyor 106A feeds Screen A, Crusher A and either conveyor 107A or conveyor 107B.
Conveyor 106B feeds Screen B, Crusher B and either conveyor 107B or conveyor 107A respectively.
Conveyors 107A and 107B discharge onto the respective loading points of pipe conveyors
108A and 108B in TT107.
Pipe conveyors 108A and 108B discharge onto the respective loading points of belt conveyors 109A and 109B in TT108.
Conveyors 109A and 109B discharge onto the loading points of either belt conveyor 110A
or 110B via the diverted gate in TT109.
Conveyors 110A and 110B are mounted directly on top of the boiler bunkers and discharge
into the bunkers of units 3 and 4 via travelling trippers 110A or 110B.
Magnetic separators are installed at the head of conveyors 101A and 101B, 105A and
105B, also installed at the middle of conveyor 107A and 107B.
Coal sampling equipment is located at the head of conveyors 102A and 102B, 107A and
107B.
Belt weighers are located on conveyors 102A and 102B, 107A and 107B. Weigh idlers are
installed on belt weighers.
The Coal Handling System is controlled from a control room located near the stockyard.
Its control extends from the ship unloader to the coal bunker and includes the coal yard.
Programmable logic control (PLC) is adopted to perform programming control and manual
control. Local pushbuttons are used for emergency stopping. Interlock and protective devices are utilized. The conveying control system includes sensors for belt speed, belt
deviation, clogging in chutes/hoppers. Belt conveyors have pull cord switches.
The control system performs data acquisition and signal display. An control console is
installed in the coal control room. The control mode for the stacker is semi-automatic with
11 of 37
manual local pushbuttons being provided for emergency stopping.

Most the equipment for the coal plant is controlled from the control room. Motor switches
for dust collecting equipment are interlocked with the coal handling equipment and local
pushbutton control.
12 of 37
COAL HANDLING SYSTEM TECHNICAL PARTICULARS

Material handled
Coal
Density
0.85t/m3
Max lump size
150mm
Angle of repose
40 degrees
Grindability
HGI 45
Moisture content
refer to coal C
Capacity jetty to stockyard
1500t/hr
Capacity to boiler bunker
1000t/hr
Height of stockpile
15m
Annual average temperature
27.0 C
Monthly average temperature
25.4 to 31.9 C
Design ambient temperature
40 C
Relative humidity
50 -92%
Max. Wind Speed (at plant site +10m level)
21.0 km/h
Max. Monthly Average Wind Speed
15.5 km/h
Min. Monthly Average Wind Speed
9.7 km/h
Stockyard capacity
60 days of coal for 2 boilers

when operating at BMCR
per boiler) for 20 hours per day.
13 of 37
2.1
History
CHEC have responsibility for the design and supply of the Coal Handling System for the TANJUNG JATI B
COAL FIRED POWER PLANT (UNIT 3&4). To meet these responsibilities subcontractors, listed below
have been contracted to supply certain equipment.
(NOT USE)
14 of 37
2.2
Performance Data Settings

(NOT USE)
15 of 37
2.3
Mechanical Description
Coal is unloaded from ships by two grab unloaders operating on a jetty situated approx 1500m from the
shore. The unloaders operate on rails and are located above the jetty conveyors 101A and 101B. Coal
is fed onto either conveyor 101A or conveyor 101B when only one grab unloader is operating. Coal is fed
onto both conveyors 101A and 101B when two grab unloaders are operating. Conveyors 101A and 101B
transport the coal to Transfer Tower (TT) 101 located at the platform. The coal is discharged from conveyers 101A and 101B on to .conveyors 102A and 102B, The following equipment is located in TT101.
Conveyor 101A and 101B head units and drive mechanism
Magnetic separators
Dust suppression
Transfer chutes
Conveyors 102A and 102B loading points and tail units
Conveyors 102A and 102B transport the coal from the jetty to TT102 located on the shore. Conveyors
102A and 102B discharged onto conveyors 103A and 103B,in TT102.. The following equipment is located in TT102.
Conveyor 102A and 102B head units and drive mechanism
Belt weighers located on conveyors 102A and 102B
Dust suppression
Transfer chutes
Conveyor 103A and 103B loading points and tail units
Sampling system
Conveyors 103A and 103B transport the coal from TT102 to TT103. At TT103 conveyor 103A discharges onto conveyors 104 or 105A and conveyor 103B discharges onto conveyors 104 or 105A.
Conveyor 105A is a stockyard conveyor and passes through the bucket wheel stacker/reclaimer that
forms the stock pile. A diverted gate permits cross feeding of conveyors The following equipment is located in TT103.
Conveyors 103A and 103B head units and drive mechanism
Dust suppression
Conveyor 105A loading points and tail unit
16 of 37
Conveyor 104 loading points and tail units

Diverted gates
Transfer chutes
Conveyors 104 transports coal from TT103 to TT104. At TT104 the coal is discharged on to conveyors
105B. Conveyor 105B is a stockyard conveyor and transports coal to the bucket wheel stacker/reclaimer
that forms the stock pile. The following equipment is located in TT104.
Conveyor 104 head unit and drive mechanism
Dust suppression
Conveyor 105B loading point and tail unit
Transfer chutes
The stockyard conveyors 105A and 105B feed coal onto the stockpile via the travelling bucket wheel
stacker/reclaimer. The stacker stacks the coal onto a short term pile. Coal from the short term piles is
spread to form long term piles using scrapers and bulldozers. The stockyard conveyors 105A and 105B
feeds coal onto the stockpile via the slewing bucket wheel stacker/reclaimer or passes coal
through the bucket wheel stacker/reclaimer directly to either conveyor 106A or conveyor 106B.
Coal is reclaimed from the stockpiles by the bucket wheel stacker/reclaimer and then back onto the
stockyard conveyor belt conveyor 105A or conveyor 105B.
Coal shall be capable of being blended within the blending ratio range of 35:65% to 65:35% and
conveyed to the coal silos.
Conveyor 105A discharges onto the loading points of either conveyor 106A or conveyor 106B via the
diverted gate in TT106. The following equipment is located in TT106.
Conveyors 105A head unit and drive mechanism
Dust suppression
Magnetic separator
Transfer chutes
Conveyors 106A and conveyor 106B mid conveyor loading points
Conveyors 105B discharges onto the loading points of either conveyors 106A or conveyor 106B via
the diverted gate in TT105. The following equipment is located in TT105.
17 of 37
Conveyors 105B head unit and drive mechanism

Dust suppression
Conveyors 106A and 106B loading points and tail unit
Magnetic separator
Transfer chutes
Conveyors 106A and 106B receive coal from the stockpile by either conveyor 105A or conveyor 105B
and discharge over their head pulleys onto the vibrating screens in the Crusher Building. The oversize
material from the screens is directed by chutework into the crushers for reduction to 50mm max and discharge onto the loading points of either conveyors 107A or conveyor 107B. The sized product from the
screens is also discharged onto the loading points of either conveyors 107A or conveyor 107B.
Conveyor 106A feeds Screen A, Crusher A and either conveyor 107A or conveyor 107B. Conveyor
106B feeds Screen B, Crusher B and either conveyor 107B or conveyor 107A respectively. The following equipment is located in crusher building.
Dust extraction system
Vibrating screens
Coal crushers
Magnetic separators
Diverted gates
Transfer chutes
Conveyors 107A and 107B discharge onto the respective loading points of pipe conveyors 108A and
108B in TT107. The following equipment is located in TT107.
Dust suppression
Pipe conveyors 108A and 108B loading points and tail units
Coal sampling system
Transfer chutes
Pipe conveyors 108A and 108B discharge onto the respective loading points of belt conveyors 109A and
18 of 37
109B in TT108. The following equipment is located in TT108.

Pipe conveyors 108A and 108B head units and drive mechanism
Dust suppression
Transfer chutes
Conveyors 109A and 109B discharge onto the loading points of either belt conveyor 110A or 110B via the
diverted gate in TT109. The following equipment is located in TT109.
Dust suppression
Conveyors 110A and 110B loading points and tail units
Diverted gates
Transfer chutes
Conveyors 110A and 110B are mounted directly on top of the boiler bunkers and discharge into the bunkers
of units 3 and 4 via travelling trippers 110A or 110B. The following equipment is located in bunker.
Travelling trippers 110A and 110B
Discharge chutes
Magnetic separators are installed at the head of conveyors 101A and 101B, 105A and 105B, also installed
at the middle of conveyor 107A and 107B. These are designed to remove magnetic tramp iron from the coal
and prevent the tramp iron from damaging the coal crushers.
Belt weighers are located on conveyors 102A and 102B,107A and 107B.
Coal sampling system equipments are located at the heads of conveyors 102A and 102B, 107A and 107B.
Samples are taken from whichever conveyor(s) is in use. Sample cutters are used, one on each conveyor,
but only one cutter will be working at any time. Discarded material and surplus sample material is returned
to the conveyor(s) in use.
The control room for the Coal Handling System is located adjacent to the stockyard. The extent of control
is from the unloaders to the coal bunkers and stock piles. Programmable logic control (PLC) is used to
perform programmed control and manual control. Local pushbuttons are used for emergency stopping.
19 of 37
Dust equipment is controlled from the control room.

2.3.1
Conveyors
A total of 19 conveyors are used between the unloading jetty and the bunker. Only 1 conveyor is described with detailed technical particulars given for each conveyor.
A. The conveyor belt is to be constructed from fire resistant covers. All belts are to be joined by vulcanized splices.
B.
The conveyors will be driven by a self contained drive unit mounted on a combination bedplate
with coupling guards. The drive unit will be comprised of:
Electric motor (various ratings)
High speed coupling
Gearbox
Low speed flexible coupling
C. The conveyor pulleys will be fabricated steel drum from mild steel. All drive pulleys will be
covered with vulcanized rubber - minimum thickness of 10mm deep grooved. Pulleys in contact
with the dirty side of the belt will be covered with 10mm thick vulcanized rubber. Take-up pulleys are lagged and are constructed of steel. Head pulley shells on some conveyors are to be fabricated from stainless steel.
D.
Self aligning ball or double spherical roller pillow block type bearings will support the pulley
shafts.
These will be sized according to load and sealed to prevent the ingress of dust, grit
and moisture.
E.
All conveyor idlers will be of the sealed for life type.
X types of idlers are used.
The troughing idlers - these are the carrying idlers. These will comprise three equal length rolls with the outer
rolls inclined at 35 degrees to the horizontal. The roller shells are of welded construction with fire resistant
seals and are mounted on ball bearings which are sealed to prevent the ingress of water and dust
The impact idlers ~ these, are fitted at the fixed load points and are similar to the troughing idlers.
The return training idlers - fitted to all conveyors, a minimum of 2 fitted to short conveyors, on long
conveyors fitted approximately every 6th idler.
20 of 37
The return idlers - these are of the flat idlers.

F. The chutes will be constructed from 8mm steel plate. The minimum slope to be 60 degrees to the
horizontal. The wearing surfaces are to be lined with 10mm thick abrasion resistant liners.
G.
All pulley and wheel bearings will have grease nipples for lubrication. Conveyor idlers will
be lubricated for life. All high speed gears will be enclosed in gearboxes and with the gearbox,
bearings will be splash lubricated
H. Conveyor gantries will generally be of the deck bridge type. Some will have curved covers others
will be open. The deck bridge will have open grid walkways or chequer plate walkways.
J.
All transfer towers will be of steel construction.
K. Each conveyor belt is tensioned by a tensioning unit located on the belt return near the drive
head. The tensioning unit consists of three pulleys with the centre pulley, under which the belt runs,
sliding up and down. Weights attached to the centre pulley apply a gravitational force to the pulley
and tension the belt.
(Refer to O&M of conveyor)
2.3.2
Ship unloaders
(Refer to O&M of Ship unloader)
2.3.3
Magnetic Separators
Magnetic separators installed on conveyors discharges will remove the tramp iron from the coal. The
magnetic separators are of the suspended Electro self cleaning type and provide automatic removal of
tramp iron to a container. For further information refer to the manufacturers publication.
2.3.4
Sampling system
Two rotary sampling systems are installed at the head ends of conveyors 102A/102B and 107A/107B.
For further information refer to the manufacturers publication.
2.3.5
Belt Weighers
Multi-idler belt weighers are installed to measure the coal rate of flow. Belt weighers are installed on
conveyors 102A and 102B and belt weighers are installed on the tail ends of conveyors 107A and 107B.
21 of 37

2.3.6
Screen and crusher

Two crushers are provided and they are both located in Crusher Building between the head ends of
conveyor 106A and 106B and the tail ends of conveyor 107A and 107B. The crushers will reduce the
coal to under 50mm.
The Crusher will consist of: Frame, Frame liners, Rotor Shafts, Rotor discs, Hammers, Bearings, Breaker
plate, Screen plates, Tramp iron pocket, etc.
Large hydraulically operated access doors at the front and rear provide access for inspection and cleaning of
the tramp iron pocket. Doors on the sides above the rotor shaft permit removal of the rotor without completely
dismantling the machine. The drives are electric motor via a delay fill fluid coupling. Bearing temperature and
vibration detection is included.
Two screens are installed in crusher building between the discharge from conveyor 106A and 106B and two
crushers. The screen removes the coal which is less than 50 mm in size. The screens are of the inclined
deck type with the vibrator mechanism positioned.
The screens have roller bearings and rubber mountings to reduce noise and a dust hood reduces the dust
level.
2.3.7
Stacker/Reclaimer
The stacker/reclaimer with intermediate trailer conveyor and retractable tripper car is used to stack and
reclaim coal from the stockpiles and travels on a rail track.
(Refer to O&M of S/R)
2.3.8
Travelling Trippers
Conveyor 110A and 110B each incorporate a travelling tripper, located in the bunker house. This enables the
coal on conveyors to be transferred into the coal bunker silos. The trippers are of steel construction
mounted on six double flanged wheels, with a central discharge chute.
Control and power cable reels are mounted on the side of the tripper structure. A dust extraction filter and
air compressor are mounted adjacent to the top of tripper central chute.
22 of 37
2.3.9
Dust Control Plant

The Coal Handling System is designed to minimize dust generation by using dry dust extraction and wet
dust suppression systems. To prevent dust movement all head chutes are fitted with rubber curtains and
all conveyors have enclosed skirts at their fixed load points.
A.
Dust Extraction
Insertable type dust collectors are installed at the following points.

Crusher building and bunker silo.
One dust extraction system is installed In the crusher building. The system is complete with dry dust filter, a
screw conveyor to return collected dust, to the conveyor system and steel ductwork with balancing dampers
and transition ducts.
Two dust extraction systems are installed in the bunker house, one for each set of six silos. The bunkers
are interconnected via ducting through which the dust extraction system removes any dust. Each of the
systems is complete with dry dust filters valves, fan, screw conveyors which return dust particles to the silos
and steel ductwork.
Dust Suppression
Dust suppression systems are fitted in the following areas:Transfer Tower TT101
Transfer Tower TT102
23 of 37
Ship unloader
Stacker/Reclaimer
Stockpile Sprays
These systems reduce the dust nuisance by the addition of moisture together with a special wetting
agent. The spray bars are located at positions where the material (coal) presents its greatest surface
area.
24 of 37
2.4
Control Description
The TANJUNG JATI B COAL FIRED POWER PLANT(UNIT 3&4) Coal Handling System is controlled by an
Allen Bradley PLC located in the Main PLC Cubicle Panel. A second PLC is provided in the Panel as a
standby. Also located in the Panel are three chassis containing input/output modules to receive information
from, and supply operational commands, to all the plant. The information and the operational commands
are handled by modules mounted in chassis located in PLC Cubicle Panel.
With the exception of the Local and Switchgear controls, which are located on either the motor control centers or on the panel local to the equipment, all the operator controls are located on the operators control
console. With AUTOMATIC selected control is by a keyboard and free -standing computer monitor. With
SEMI-AUTOMATIC selected control is by the touch buttons displayed on a Panel view. Note that a separate
programmable controller, a compact type HD, drives the graphics on the free-standing computer monitor.
This PC is located on the control console.
Some of the major items of plant eg, the ship unloaders, the stacker/reclaimers etc, are controlled by their
own individual programmable controllers. When these items of plant are correctly positioned Ready to
Start, signals are passed to the main PLC to inform the main PLC, and Start Permissive signals are returned
to the plant operators that all the downstream plant eg, conveyors and their ancillary equipment, is running
and ready to receive coal.
(Refer to O&M of Control)
2.4.1
Modes of Operation
2.4.2
Boiler Bunker Level Controls

2.4.3
Conveyor Controls
2.4.4
Diverter Chute Controls

25 of 37
2.4.5
Magnetic Separators
2.4.6
Ship Unloaders
(Refer to O&M of Ship unloader and O&M of Control)
2.4.7
Belt Weighers
2.4.8
Stacker/Reclaimer
(Refer to O&M of S/R and O&M of Control)
2.4.9
Screen and Crusher

2.4.10
Trippers
2.4.11
Dust Suppression System

2.4. 12
Routes Sequences

2.4.13
Stacking Mode

2.4.14
Reclaim Mode

2.4.15
Sampling system System

2.4.16
Alarms
26 of 37

2.4.17
Control Equipment
27 of 37
OPERATING
3.0
OPERATING INSTRUCTIONS
Operating instructions for the belt conveyors and coal reclaiming system are included below.
3.1
General
The order in which unloading operations are performed are as follows:
A. The ships captain, or the officer in charge of unloading the ship, determines the order in which the
ships holds are to be unloaded and so informs the Coal Handling System operators.
B. The grab unloaders are positioned in the selected ships hold. The unloader conveyors may be
started but the wheel bucket must not be started.
C. At the Coal Handling System control console, the operator selects mode of operation and selects the
required coal route. The on-shore conveyors and their ancillary equipment including if necessary
the stacker/reclaimer are run up to speed in order according to the selected route.
D. At the ship unloader, the command is given verbally to start unloading coal on to the running conveyors 101A or 101B.
E. If required, the both grab unloaders can be used simultaneously to clear the ship at a rate of
3000TPH maximum capacity using both jetty conveyors 101A and 101B.
3.1.1
Grab Unloader
Details to operate the grab unloaders are contained in Manufactures Publication.
3.1.2
Stacker/Reclaimer
Details to operate the Stacker/Reclaimer are contained in Manufactures Publication .
3.1.3
Other Equipments
Details to operate are contained in relative Manufactures Publication..
3.2
Mode of Operations
Several modes of operation are available on the system, these are not all controlled through the PLC
but are described for completeness.
3.2.1
LOCAL OPERATION
28 of 37
Local control is selected, in most cases on local control panels, but in a few cases this is on the MCC panels.
When selected. Push button controls located adjacent to the drive or conveyors are used for stopping and
starting. This mode in all cases shall remain operational with the coal handling system PLC switched off.
3.2.2
REMOTE INDIVIDUAL OPERATION

Remote individual operation is enabled by selecting the mode selector switch on the CHS operation station
to 'Remote individual'. When selected, individual equipment is started and stopped without interlocking,
using the operator interface on the CHS operation station.
Pressing the emergency stop pushbutton causes all Equipments to immediately stop.
3.2.3
AUTOMATIC OPERATION
Automatic control is enabled by selecting the mode selector switch on the CHS operation station to automatic. When selected, groups of conveyors and drives arc started and stopped as complete routes using
the keyboard and VDU of the computer system on the coal handling system control console.
As routes are selected, items of equipment such as diverters and trippers, are positioned by performing a
route set from the keyboard that is valid under the current operating conditions . Only when all equipments
in the selected route have been correctly positioned and available to run, shall the route ready message be
displayed.
When this condition has been fulfilled, performing a sequence start causes the route ready message to be
extinguished, the route starting message is displayed, and the route to starts. Once running the message
changes to route running, Should any item of plant become faulty or not available, upstream items of plant
are stopped, the route not ready message is displayed along with route hold, the faulty item of equipment is
inhibited from restarting until the fault has been cleared.
This condition, of being ready to restart, is indi-
cated by the route ready message being displayed and the route not ready message being extinguished,
This is cleared by performing a sequence start, causing the held part of the route to restart; the route hold
message to change to route running and route ready message to extinguish.
Pressing the emergency stop pushbutton causes all routes to immediately stop, extinguishing the route
running message and leaving all conveyors full of material.
Performing a sequence stop operation causes the route to stop by clearing all the belts of material, with a
29 of 37
route stopping massage being indicated on the computer and changing to stopped when the route has
cleared. Two fields on the start-up page of the computer are capable of displaying the neccesary messages.
3.3
Operating Attention
This part is an information or instruction (mandatory or prohibitive) to prevent equipment damage to the
machine.
3.3.1
Coal Mixed
As per contract requirement, the reclaiming coal from stockyard shall be capable of being blended within the
blending ratio range of 35:65% to 65:35% and convey to the coal silos. It is required that both bucket
wheel stacker/Reclaimers can be used simultaneously when reclaiming the required capacity and using
both conveyor 105A and 105B. The stacker-reclaimer can be controlled to reclaim at a desired rate between
350 t/h and 650 t/h with reasonable accuracy.
3.3.2
Transient Wind Case

The ship unloader and stacker-reclaimer shall be capable of operating in wind speed up to 20 m/s. However the ship unloader and stacker-reclaimer shall be able to move to tie-down location in a wind speed up
to 30 m/s. Once tied down and locked, the ship unloader and stack-reclaimer shall be able to withstand wind
speed up to 55 m/s. The wind speed is defined as instantaneous gust velocity at the anemometer.
Except in the areas where the SU and SR operate, conveyors in the open air are protected by cover hood
from the influence of strong wind by hood covers. SU and SR shall be capable of operating in wind speed
up to 20 m/s. The wind speed is defined as instantaneous gust velocity at the anemometer. Conveyors relating to the SU and SR will follow corresponding conditions too. Therefore, when the wind speed is no
more than 20 m/s, CHEC will guarantee that conveyor belts shall not be damaged by wind related problems.
However, when the wind speed exceeds 20m/s, SU, SR and all conveyors shall stop coal system operations. To protect conveyor belts, windbreak chains shall be installed in the area where cover hood is not
provided. Windbreak chains shall be employed manually to tie the belt on the conveyor frame when the
conveyor stops.
3.3.3
Stacker/Reclaimer
There are two take-up towers of conveyors 105A and 105B nearby the southern end of the foundations of
stacker/reclaimers. Its height exceeds 8 meters and locates within Stacker/reclaimers operating range. We
30 of 37
mark these areas as extra operation area. To prevent equipment damage from take-up towers of conveyors 105A and 105B, The S/R boom forbid across the C105 conveyor when the S/R stay in extra operation area as per CHECs drawing No. F558S-M0422 GENERAL ARRANGEMENT OF THE COAL YARD.
31 of 37
MAINTENANCE
4.0 MAINTENANCE INSTRUCTIONS
Operating instructions for the conveyors and reclaiming coal are contained in.
4.1
General
This section covers the maintenance of the equipment described in section 2.0. For details of maintenance
on proprietary equipment reference to the particular Manufacturer's Publication is made, however this manual should be referred to in the first instance.
Before any maintenance work is undertaken, the plant must be in a safe state for work to proceed. Power
supplies must be off and terminals disconnected to isolate the appropriate drive/sub assembly. Where applicable, any pressure vessel, tank or containment must be at atmospheric pressure before any joint is
broken, and where the pressure vessel, tank or containment is contaminated, it must be purged to clear residual gas or noxious liquid.
Any potential hazard must be investigated to ensure that no danger exists when personnel commence
dismantling of the plant. It is assumed that personnel employed on maintenance will equipped with any
suitable protective clothing required.
Warnings and cautions given in the manufacturers publications must be strictly obeyed.
4.1.1
Grab Unloader
A. Mechanical maintenance, refer to the Manufactures Publication VOL Mechanical Maintenance Instructions.
B. Electrical maintenance, refer to the Manufactures Publication VOL Electrical Maintenance Instructions.
4.1.2
Conveyor
Maintenance of the conveyors is contained in the following manufacturer's publications.
Spare parts and installation leaflet for totally enclosed fan ventilated cage motors.
Assembly and lubrication instructions.
32 of 37
Installation and maintenance instructions for Motors.

Service manuals for Flexible Gear Couplings Speed Reducers, Hydrodynamic Couplings and Gear Units.
Operation and Maintenance Instructions for conveyor pulleys.
Installation, Operation and Maintenance Instructions for troughing and return idler equipment.
Vulcanizing Splicing instructions for fabric and services steel cord belting.
Owner/Operator manuals for belt cleaner and reversing belt cleaner. Owner/Operator manuals for Permatwist tensioner and apron seals.
Technical document for vulcanising press.
4.1.3
Magnetic Separator
For mechanical and electrical maintenance refer to the manufacturer's publications.
4.1.4
Belt Weiehers
A. Mechanical Maintenance. Refer to Belt Scale System Manufacturer's Publication for the mechanical
maintenance on the weight carriages.
B. Electrical. Refer to the Belt Scale System Manufacturer's Publication for the electrical maintenance
on the integrators, digitizer and speed sensor.
4.1.5
Stacker/Reclaimer
A. Mechanical maintenance, refer to the Manufactures Publication VOL Mechanical Maintenance Instructions.
B. Electrical maintenance, refer to the Manufactures Publication VOL Electrical Maintenance Instructions.
4.1.6
Other equipments
Refer to the relative manufacturer's publications.
4.2
Isolation and Restoration

Before any work is undertaken the plant or section of plant to be worked on must be isolated. Checks after
maintenance or repair are to be carried out after a fault has been detected and corrected to ensure the
plant is safe for restoration to operational use.
33 of 37
4.3
Inspection and Diagnosis

The initial fault assessment action is to check all operating sequence indicating lamps and interlocks associated with the operation. If a fault condition still exists after these checks it is then necessary to determine whether the fault is mechanical or in the associated control system equipment.
4.3.1
Grab Unloader
refer to the Manufactures Publication for lubrication, inspection assembly and installation instructions.
4.3.2
Conveyors
Refer to the manufacturer's publication listed below for dismantling, adjusting, reassembly, fault diagnosis and lubrication of conveyor equipment.
Assembly and lubrication instructions.
Lubrication and overhaul of cage induction motors.
Installation and lubrication instructions for flexible gear couplings, speed reducers, hydrodynamic
couplings and gear units.
Installation, lubrication and fault diagnosis for belt cleaner, apron seals and reversing belt cleaner.
Spare parts and installation leaflet for totally enclosed fan ventilated cage motors.
4.3.3
Magnetic Separator
Refer to the manufacturer's publications for installation and lubrication.
4.3.4
4.3.4
Belt Weighers
Visual inspection and fault finding data for the Weigh carriage is contained in belt scale system manufacturer's publication.
Visual inspection and fault finding data for the Load Cell Digitizer is contained in the belt scale system
manufacturers publication.
Visual inspection and fault finding data for the integrator is contained in belt scale system manufacturers
34 of 37
publication.
4.3.5
Crusher
Refer to the manufacturer's publication for details on removal, installation and lubrication on the granulator (crusher).
Refer to manufacturers publication for installation, operation and maintenance of Motors.
4.3.6 Sampler System

Refer to the Manufacturers publication for the lubrication schedule.
4.3.7 Stacker/Reclaimer
Inspection and diagnostic information for the stacker/reclaimer is contained in the manufacturer's publications. Individual component information is given in relative Sections.
4.3.8 Travelling Trippers
Refer to the Manufacturer's publications listed below for replacement, cleaning and lubrication of
equipment fitted to the travelling trippers.
Hose reels
Control Reels
Owner/Operator manuals for belt cleaner and tensioner.
Service Manual for geared motors and gear units
4.3.9 Dust Control Plant
Dismantling and assembly of lnsertable dust extraction units In crusher building and bunker house are
contained In the manufacturers publication.
4.3.10 Screens
Removal and replacement procedures for the vibrating screens are contained In the manufacturer's
publication.
4.3.11 Other equipments
35 of 37

4.4
Maintenance Equipment and Replacement Parts

When ordering replacement parts information on model type and serial number for the equipment is necessary to ensure the correct replacement item is supplied.
4.4.1
Grab Unloader
For replacement parts refer to the Manufactures Publication.
4.4.2 Conveyors
Recommended spares for belt cleaner, reversing belt cleaner, apron seals and tensioner are contained In
the owner/operator manuals.
4.4.3 Magnetic Separators

There is no recommended spares lists for the magnetic separators.
4.4.4 Belt Weighers
Recommended spares for the belt weighers are contained in the Belt Scale System manufacturer's publication.
4.4.5 Crusher
Recommended spares for the granulator (crusher) are contained In the manufacturer's publication.
4.4.6 Sampling System
Spare parts listings for the sampling system are contained in the manufacturer's publications.
4.4.7 Stacker/Reclaimer
Replacement parts for the stacker/reclaimer are given in the manufacturer's publications for the stacker/
reclaimer and hydraulic system manuals.
4.4.8 Travelling Trippers
Replacement parts for the travelling trippers are given in the following manufacturer's publications.
36 of 37
Hose reels
Control Reels
Owner/Operator manuals for belt cleaner and tensioner.
Service Manual for geared motors and gear units
4.4.9 Dust Control Plant
Recommended spares for the insertable dust extract units in crusher building and bunker house are contained in the manufacturers publication.
Recommended spares for the screw conveyor, gravity diverter valves and rotary valves are contained in
the Manufacturer's publications.
4.4.10
Screens
Recommended spares for the vibrating screens are contained in the manufacturer's publication.
4.4.11
Other equipments
4.5
Recommissioning
This section give details of recommissioning procedures which may be necessary after major overhaul.
Refer to the Manufactures Publication.
4.6
Lubrication Schedule
The attached Lubrication Schedule which follows is included as a reference document only, For details on
where to lubricate individual items refer to the Manufactures Publication listed in appropriate volume. This
is a complete lubrication schedule for the coal handling system and it is referenced to in other volume.
37 of 37

PO NO.: 145236.61.0401
DOCUMENT:Ship Unloader Erection & Commissioning
Manual(Mechanical)
DOCUMENT NO.: IM0401-3.1.1-1
0
REV.
2009-12-08
DATE
FOR
CONSTRUCTION
DESCRIPTION
235
TOTAL
PAGES
- 0 -
PREPARED
CHECKED
APPROVED
Tanjung Jati B Units 3 & 4 600 MW Coal-Fired Project

GSU150035/22 GRAB SHIPUNLOADER
This document is used for the installation and commissioning
OBJECTIVE:
of the GSU150035/22 Grab Shipunloader.
In order to improve both the format and the overall understanding
SCOPE:
of the erection and commissioning, the document has been

separated into five sections.
i)
General Documentation
ii) Erection Documentation

iii) Commissioning Documentation
iv) Instructions from OEMS
v) Machine Drawings
- 1 -
Part I: General Documentation
- 2 -
CONTENTS
NO.
1
Title
Page
General
Symbol Definition
General Description
Safety Note
Goods Receiving, Handling and Storage
- 3 -
General
This Erection Manual is prepared for personnel having responsibility for erection, installation and
pre-commissioning works.
This manual is prepared by CHEC. It is assumed that the personnel of erection, installation and
pre-commissioning are experienced and skilled.
The manual gives all types of warnings / tips, each of the warning / tip is illustrated by symbols and
titles. The design for each warning/tip varies according to the types, characteristics and degrees of
dangers
2
2.1
Symbol Definition
General definition of symbols
CHEC =
BVI
TPSC =
GSU
2.2

BLACK & VEATCH
TOSHIBA PLANT SYSTEMS & SERVICES CORPORATION
Grab Shipunloader
Drawing No. Definition
2.2.1 Machinery Drawing No.

GSU 0702.Erc.01.01. .01-1
Part Drawing NO. . 1,2,3,,n
Class n Assembly Drawing NO. 01,02,03,,n
Class II Assembly Drawing NO. 01,02,03,,n
Class I Assembly Drawing NO. 01,02,03,,n
For example:
GSU 0702.Erc.00 = General Assembly Drawing of GSU for Erection
GSU 0702.Erc.01 = General Assembly Drawing of Steel Structure for Erection
Erc = Drawing for Erection
GSU 0702 = CHEC Drawing NO. for GSU of TJB Project
2.3 Warning Signs and Symbols
This manual uses the following warning signs and symbols to indicate the importance of some
descriptions:
- 4 -
Danger!
This symbol indicates that the described action may be accompanied with danger. The
danger or situation indicated by the Danger symbol may cause harm to people. Should any
person be in this type of risk, it may cause serious injury or death. Hence, safety regulations
must be strictly enforced with high degree of attention.
Caution!
This symbol indicates that the described action may be accompanied with risk. Violation of the
actions with Caution sign may lead to damage of machinery or other facilities.
Warning!
This symbol indicates that the described action may be accompanied with risk. Violation of
the actions with Warning sign may lead to faulty action.
3.
General Description
3.1 General
This Erection Manual is prepared for personnel having responsibility for erection, installation and
pre-commissioning works.
All the installation, assembly, and pre-commissioning personnel associated with the
grab shipunloader must read and understand this document with full abidance of the
relevant instructions. We shall not be liable for any harm caused by failure of
observance of the instructions stated in this document. Should any equipment or part
be damaged as a result, we shall lodge a claim.
This manual excludes details for working procedures, erection equipment evaluation or labour
requirements, all of which shall be updated and perfected during the erection process following the
requirements of the erector.
During erection, CHEC will supervise various erection activities, for example, major lifting and
installation of CHEC components. The erector is supposed to be an experienced and professional
company who understands major safety regulations and standards well.
The erector is supposed to know equipments that they are to erect well. In addition, it shall be
equiped with sufficient labors, tools etc to gurantee the erection schedule.
- 5 -
The first important stage is that the Erection Company prepares the detailed erection plans
for the review of the CHEC supervisors.
3.2 Technical Modifications
CHEC reserves the right to modify the engineering design due to technical
development. Drawings and text in this manual may not include the latest modifications.
3.3 Copyright
CHEC solely owns the copyright of this manual. Without CHECs written permission, this document shall
not be disclosed to third parties, nor be copied or applied to unauthorized objectives.
Any technical consultation can be made to the following address:
CHINA HUADIAN ENGINEERING CO., LTD
Shanghai R&D Center of Material Handling
Add:
Room 702D,Dongfang Building,No.1500 Century Avenue,Shanghai,China
Tel 0086-021-68416301
Fax0086-021-68416303
CHEC on-site technical services staff can also be consulted .
4 Safety Note
4.1 General
The manual supports the erection of the GSU in a safe and correct ways.
GSU erection was certain degree of risk. Incorrect erection may lead to accidents. We must attach
great importance to this. Erection shall be carried out to comply with safety regulations.
During erection CHEC will supervise various erection activities such as major lifting and assembling
of CHEC components.
The experienced erection company should be speciality , and knew very well that the erection each
kind of item, wants the clear main safe stipulation and standard especially.
4.2 Erection responsibilities

The installation personnel shall read and understood this Manual and shall strictly comply with the
provisions to assure:
- Avoidance of casualties, work injuries, or damage of equipment and parts;
- Safe and proper installation
-
Avoidance of interruption of work or damage to the environment as a result of incorrect

installation.
- 6 -
During the process of storage, handling, assembly, and installation, pay close attention to
observance of safety and environmental requirements at all times.

l
Installation can only be carried out by the authorized, trained, and qualified personnel.
All works must be carried out cautiously and thoroughly with attention to safety requirements.
A sound safety management system and safety inspection system must be present to
strengthen the safety education for all installation personnel and to assure the
implementation of all safety measures, preventing occurrences of major accidents.
Construction personnel for lifting, welding, and electrical works must comply with the safety and
management requirements of the relevant professions accordingly.
Construction personnel are prohibited from drinking alcohol or using narcotic drugs prior to or
during work.
Protective facilities, such as fire prevention, fire fighting, environmental sanitation, and
protection against typhoons and thunder storms, must be present.
To assure smooth and successful installation, attention must be placed on coordination among
all concerning parties of installation, including owner, supervision, design, and safety control.
Irrelevant persons shall not be allowed to enter the installation area.
Installation must be carried out in accordance with the equipment drawings and the related
technical documents.
During the assembly or installation process, damaged bolts must be replaced with new bolts of
equivalent strength and type. High strength bolts must be tightened in accordance with the
torque stated in the drawings or technical documents.
4.3 Environmental Protection
l
All consumables and materials must be properly disposed, without affecting environment. All
applicable environmental laws and regulations must be abided.
Paint, lubricant, and hydraulic oil shall be stored separately.

Used hydraulic oil, lubricant, protective agent, oil-absorbing agent, and oil cotton shall be
properly disposed in accordance with the environmental regulations.
4.4 Special Danger
l
Attention shall be placed to the installation sequence of structure parts, mechanical parts
Must pay attention in the installation sequence, equipment's center of gravity is the change,
- 7 -
and completes the safety protection measure, prevents danger which the equipment
occurs pours out.
Damaged products shall not be put into use.
5.Goods receiving,handling and storage

5.1 Goods Receiving
After arrival of the equipments at the erection site, the PURCHASER or other designated party shall
organise the unpacking and inspection according to the requirements of the contract.
It is important for the erectors to get involved in unpacking inspections to get acquainted with material
supplied and make better erection working plans for the entire project.
For the unloading and storage of the delivered equipment; see also storage instructions from OEM .
Any damage found is to be reported to the CHEC site representative immediately.
5.2 Goods Handling
The handling work requires lifting and transporting equipments with adequate
carrying capacity.
Accidents, such as, twisting, bending, collision and corrosion, shall be avoided when all parts and
frame of GSU are transported and unloaded to the site. Therefore the following requirements must be
met:
i) When hoisting up the component should tie up two at least, ties up place to have the sark, and ties
up to have the muscle board to strengthen the node place, generally should tie up as far as possible in
component's both sides, is not suitable ties up overhangs in the non-node spot or the component.
ii)
All parts shall be placed on motor carrier or flatbed truck during handling. Rolling or pulling on the
ground is prohibited.
5.3 Goods Storage
Check all goods before warehouse entry and record damages if any. Unload the goods with
adequate care. Cranes or other handling equipments shall be applied if necessary. In general, goods
stroage shall follow the following requirements unless otherwise spedcified:
Steel structure
Steel structure parts may be stored on sleepers without protection except that machined surfaces
shall be protected against corrosion. Fasteners shall be stored under cover, in containers or
equivalent.
- 8 -
Mechanical parts
Large parts may be stored on sleepers and covered by tarpaulins.
Small parts shall be stored under cover, in containers or equivalent.
Inspection for rustiness and corrosion shall be carried out prior to installation for items that have
been stored for long time or placed outdoor. Stains shall be removed. If necessary, recoating and
re-assembly shall be carried out to ensure that all rotating parts are agile and all joining parts are
firmly attached. Periodic maintenance shall be carried out during the storage period, with close
attention to damp-proof, rust-proof, and ventilation.
Paint / Lubricants/
Shall be stored in separate covered containers or equivalent.
Electrical equipment
All electrical parts shall be stored in containers or equivalent.
Cables, conduits etc. may be stored on pallets.
- 9 -
Part II: Erection Documentation
- 10 -
CONTENTS
NO.
Title
Page
General Description of the Equipment
12
Technical Data
15
Erection guide of the Equipment
20
Painting Instruction
83
Welding Instruction
102
Erection Records
104
- 11 -
1.
1.1 General
When the coal ship arrives at the jetty, it is unloaded to the hopper by the grab. The maximum
extension of the shipunloader is 35 meter (the maximum distance from the center of sea side rail to the
trolley at sea side). After being discharged from the coal hopper to the feeder, the coal is then selectively
distributed to the two belt conveyors on the jetty by the diverter hopper. The surrounding of the hopper is
equipped with dust suppression plate and water spray system to suppress dust. The water from the tank
on the jetty is delivered to the water tank on the shipunloader through a pump. The top and bottom outlets
of the hopper and the feeder downspout are all equipped with water pipeline and nozzles. The water will
be pumped in the pipeline, forming a water curtain through the nozzles, to prevent dusting at all
discharging locations
The shipunloader is also equipped with anchor device and wind-proof mooring rope device, which
protects the shipunloader against typhoon during non-working state.
The sea side main girder can pitch 80 to prevent the obstructing of the ships in-shore and off-shore.
The power of this equipment is supplied from ground junction box. The power supply is 10kv, 3
phases, 50Hz. The power is delivered to the main switch cabinet through the ground junction box and the
cable drum of shipunloader, providing output to the main and auxiliary transformers, respectively, which
then enters the main drive and auxiliary switch cabinet located in the machine room.
The control device of shipunloader is actualized by digital speed control drive. The PLC uses
Siemens control system. In addition to the advanced digital control system, it is equipped with automated
auxiliary control system and advanced communication network system, allowing shipunloader to have
high degree of automation during unloading operation.
- 12 -
Picture 1: Grab Shipunloader
1.2
Drawing References
Drawing No.
GSU0702.Erc.00
1.3
Drawing Title
General Arrangement
Functions & Assembly Groups

The Grab Shipunloader consists the following assemblis:
1 Steel Structure (Detail see drawing: GSU0702.Erc.01 Steel Structure)

2 Grab assembly (Detail see drawing: GSU0702.Erc.02 grab assembly)
3 Main-trolley
(Detail see drawing: GSU0702.Erc.03 Main-trolley)
4 Operator Cab (Detail see drawing:GSU0702.Erc.04 Operator Cab)

5 Safety Hook (Detail see drawing:GSU0702.Erc.05 Safety Hook)
6 Boom-Hoist-Cab (Detail see drawing:GSU0702.Erc.06 Boom-Hoist-cab)
7 Boom-Machinery (Detail see drawing:GSU0702.Erc.07 Boom-Machinery)
8Hoist,Close and trolley device (Detail see drawing:GSU0702.Erc.08 Hoist,Close and
trolley device)
- 13 -
9 Machinery G.A (Detail see drawing:GSU0702.Erc.09 Machinery G.A)

10
Name plate (Detail see drawing:GSU0702.Erc.11 Name plate)
11Power cable reel (Detail see drawing:GSU0702.Erc.12 Power cable reel)

12
13
Elevator (Detail see drawing:GSU0702.Erc.13 Elevator)

Stairs & platforms (Detail see drawing:GSU0702.Erc.14 Stairs & platforms)
14
Front cantenary trolley (Detail see drawing:GSU0702.Erc.15 Front cantenary trolley)
15
Gantry (Detail see drawing:GSU0702.Erc.16 Gantry)
16
Hopper System (Detail see drawing:GSU0702.Erc.17 Hopper System)
17Backword cantenary trolley (Detail see drawing:GSU0702.Erc.18 Backword cantenary

trolley)
18
19
Cab Safeguard (Detail see drawing:GSU0702.Erc.19 Cab Safeguard)

Rope system (Detail see drawing:GSU0702.Erc.20 Rope system)
20
Rail-layout (Detail see drawing:GSU0702.Erc.21 Rail-layout)
21
Limits for ship-unloader (Detail see drawing:GSU0702.Erc.22 Limits for ship-unloader)
22
Assistant cab (Detail see drawing:GSU0702.Erc.23 Assistant cab)
23
Dust spray system (Detail see drawing:GSU0702.Erc.24 dust spray system)
24Lubrication Systems General Arrangement (Detail see drawing:GSU0702.Erc.25 Lubrication

Systems General Arrangement)
25
Hydraulic system (Detail see drawing:GSU0702.Erc.26 hydraulic system)
26Control Cable Reel (Detail see drawing:GSU0702.Erc.27 Control Cable Reel)
Shipunloader also includes nameplate, overall limit switch, drivers cab safety protection device,
electric system, and hydraulic system.
1.4
Machine Identification
The two shipunloders mounted on the same rail at TJB site shall be identified as the following:
CHEC GSU150035/22
Denomination:
CHEC GSU
CHEC Grab Shipunloader
1500
t/h
Rated Design Capacity
35
Extension
- 14 -
22
1.5
1.5.1
Span
Design Criteria
Material to be handled
Coal
density = 0.85 t/m3
1.5.2
Ambient Conditions
Environment
Annual Average Temperature
maritime climate and dusty
27 C
Relative Humidity
50%- 92%
Design Wind speeds

In operation
1.5.3
20 m/sec
Tavelling to anchor position
35 m/sec
Max. wind /out of operation
55 m/sec
Rates of Handling
The Grab Shipunloader is designed to service the bulk material handling system and is suitable
for continuous operation for 24 hours a day, 7 days a week in the prevailing dusty and corrosive
environment.
The Grab Shipunloader is designed for an average capacity of 1500 t/hour.
1.5.4
Codes and Standards

The structural steelwork is designed according to the latest editions of FEM and other applicable
standards not listed as per contract.
2. Technical Data
The Grab Shipunloader will be capable of motion speeds as detailed in the Technical
Data Sheets.
2.1 Grab Shipunloader Guaranteed Performance

1500t/h
- 15 -
2.2 Design Data

Max Wind speed in operation
20m/sec
Serviceability wind speed
30m/ sec
Ultimate wind speed
55m/sec
Earthquake
YES, as per contract
2.3 General Dimensions

Outreach distance (centre of of sea travel rails to Max.
travel sea distance of Grab )
Inreach distance (centre of of sea travel rails
to Max. travel land distance of Grab )
Track Gauge (centre to centre of travel rails)

Travel Rail Size
35,000
mm
18,000
mm
22,000
mm
QU100
Travel Rail Standard
Chinese standard
Overall Height (Top of rail to Top of Front

Girder)
approx. 70
2.4 Storm Tie Down Requirements

Grab Shipunloader Service Area Requirements
Storm Tie Down
Yes
2.5 Equipment Weights

Mass of Grab Shipunloader
Complete Machine
1183577 kg
2.6 Electrical Data

Power Supply Cable reel
Power Cable Length in reel
Approx. 150
control Cable Length in reel
Approx. 150
Control Cable reel
- 16 -
2.7 Boom Machinery Operating Data

Maximum Inclination
about 80
degrees
Boom Hoisting Time
About 6
min
Boom Machinery Drive Data

Manufacturer
Motor
Gearbox
Brake
(at hight axis)
CHEC
Manufacturer
Siemens
Power Rating
90
kW
Rated Speed
988
rpm
Power Supply
500/3/50
Type
M4PSF90E
Manufacturer
Sew
Reduction
140.28
Lubrication Method
Splash lubrication
Type (Drum / Disc / Cone)
Disc
Manufacturer
ZPMC
YP21-800-500X30-II.H.RL.HL
Model and Size
Brake
(at low axis)
Volts/Ph/Hz
Release Method
electrical
Disc
Manufacturer
ZPMC
SB250-1700X36
Model and Size

Release Method
hydraumatic
2.8 Hoist, Close and trolley Operating Data

Hoist speed
130/150
m/min
Trolley speed
220
m/min
Hoist, Close and trolley

Manufacturer
CHEC
- 17 -
Hoist
Motor
Close Motor
Trolley
Motor
Gearbox
Brake
(Hoist,Close)
Brake
(Hoist,Close)
Manufacturer
Siemens
Power Rating
500
kW
Rated Speed
992/1100
rpm
Power Supply
500/3/50
Volts/Ph/Hz
Manufacturer
Siemens
Power Rating
500
kW
Rated Speed
992/1100
rpm
Power Supply
500/3/50
Volts/Ph/Hz
Manufacturer
Siemens
Power Rating
315
kW
Rated Speed
993
rpm
Power Supply
500/3/50
Type
PDR40-00
Manufacturer
Jianguin Gear Box Manufacture CO., LTD
Reduction
31.21(Hoist,Close)
Lubrication Method
Splash lubrication
Disc
Manufacturer
ZPMC
Model and Size
YP31-3000-710X30I(II).H.RL.HL
Release Method
electrical
Disc
Manufacturer
ZPMC
Model and Size
YP31-2000-710X30II.H.RL.HL
Release Method
electrical
- 18 -
Volts/Ph/Hz
18.74(Trolley)
2.9 Long Travel Data

Travel Speed
Travel Wheels
Drive Wheel
Idler Wheel
Operation speed
Number of Drive Wheels
Number of Idle Wheels
approx.25
16
16
Tread Diameter
Tread Width
Flange Outside Diameter
Tread Material & Grade
710
135
760
cast
Tread Hardness
320-380 HB at surface
HB320-380
Bearing Type & Size

Bearing Lubrication Method
Spherical roller 53530

- 53530
Automatic lubrication system
Bearing Type & Size
Bearing Type & Size

- 53530
Automatic lub system

Bearing Type & Size
Coefficient of Friction, Wheel to Rail
Dry Rail,
Travel Drive
Motor
Gearbox
mm
mm
mm
mm

0.14
Wet Rail,
Rail Clamper
m/min
0.10
2
Number
Type
Manufacturer
Model and Size
Application Method
Release Method
IP Protection Class
spring loaded
Shanghai Gangan
400KN
Spring
Hydraulic
IP 55
Manufacturer
Model Number
Sew
KH107DV180M4/BM/HF/TH/STH/MIC/C/0S2
Number
Manufacturer
Power Rating
Rated Speed
Frame Size
Power Supply
IP Protection Class
Means of Speed Control
8
Sew
18.5
0-1440
Standard flange type
400/ 3/ 50
55
VVVF Control
- 19 -
off
off
kW
rpm
Brake
Travel Buffers
3.
Number
Type
Manufacturer
Model and Size
Reduction
Lubrication Method
8
off
Helical bevel gearSew
42.33
:1
Splash oil
Number
Manufacturer
IP Protection Class
Disk
Sew
55
Number
Manufacturer
Type
Chinese Manufacturer
hydraumatic buffer
HY100-250
off
Erection guide of the Equipment
3.1 GENERAL
The Erection Works comprise all erction works including finishing works all servicessuch as labour,
heavy equipment, tools, erection consumable materials (like welding rods, sealing materials etc.),
testing equipment, devices, temporary facilities i.e. storage containers, offices, ablutions, utilities,
temporary supports, temporary materials, supplies, electrical distribution at yard, first aid facilities ,
etc. ,for the complete erection and dry commissioning of the structural, mechanical and electrical
portions of the GSU150035/22 Grab Shipunloader complete with travel bogies, steel structure, main
trolley, safety hook, boom machinery, open-close machinery, machine-electric house , operator cab,
boom hoist cab, assistant cab, cable a reelers, drives, front cantenary trolley and backword cantenary
trolley, cab safeguard, dust suppression spray system, lubrication system(s), electric/control system.
all complete.
Goods will be supplied to the site in various shipping dimensions as per the packing lists. The
equipment will be partially pre-assembled so that all major erection parts will fit in reasonable manner.
The delivery consists of wide number of small parts so that the storing of various parts has to be
arranged and co-ordinated well on Job Site. See storage instructions. Mechanical components are to
be stored in a dry lockable storage area. Bolts are to be stored on racks in a secure lockable storage
area.
Goods are equipped with components at factory as far as applicable but the majority of components
shall be installed on Job Site.
- 20 -
Typical components to be installed at site are for example open-close machinery (drum, drive units,
drift shaft, coupling, safty device), power & control cables reel
pipes and distributors, water pipes & fittings, mechanical pins,
power & control cables, lubrication
cover plates etc.
Typical parts to be installed at site are also handrails, platforms, stairs, ladders, supporters, sealing
(inlets, outlets, erection joints), claddings, loading points, rubber parts (skirt boards), wearing plates,
etc.
During these installations drillings as well as some shimming and fittings are necessary to reach the
sufficient accuracy during erection works. Only a small amount of parts as fabricated in different
places and those could not be pre-assembled have to be adjusted and fitted together and the easiest
way is to make on Job Site drilling and fastenings to reach required accuracy, quality and functionality
of the equipment.
Pipe clamps for grease & water services may only be attached to the structure through a fully welded
compensation plate. Site welding of compensation plates and paint touch up is required. Similarly
cable tray, conduit and all electrical field devices must be attached to a fully welded compensation
plate. Welding and touch up painting of compensation plates will be carried out as part of the erection
companies scope.
The Vendors Operation and Maintenance manuals include instructions and information for the
purchased items. It is very important that the Purchaser shall make these manuals available on
Job-Site to Erection companies.
The erection including installation and pre-commissioning work includes, but is not
limited to the following:l Off-loading from arriving transport of all materials and components
l Receipt of goods, of all components and materials necessary for erection and
commissioning
l Storage and protection of such components and materials
l Provision of all labour and supervision for erection and installation of the structural,
mechanical and electrical parts as specified.
l Provision of all cranage and equipment
l Provisions of all consumables and temporary supports
l Erection and pre-commissioning works
l Quality control and maintaining quality records
- 21 -
l Control of documents and preparation of hand marked As Built drawings, data and
specifications
l Maintaining accurate erection records and presentation of all records
l Liaison with construction management representatives and other contractors
l Touch-up painting in accordance with the paint repair procedure of all erection and
transportation damage.
The work under the Contract to be performed also includes:
Progress Reporting (on a bi- weekly basis);
Quality Assurance / Quality Control including survey records, erection data;
Non-destructive Testing for all Site splicing and welding of structural components;
The work shall comply with all rules, Statutory Regulations, and appropriate codes of
practice and standards relevant to such work.
The contractor's attention is drawn to the relevance of the owner Regulation Act
Regulations.
The Grab Shipunload is referred to as "the machine".
3.2
ERECTION PLANNING
3.2.1 General
The competent Erection Company shall prepare detailed scheduling of all erection activities.
CHEC supervisor may be used for review objectives and further advice if needed.
The Erection Company appoints a Site manager for the respective installation / erection work,
who bears the responsibility for:
Timely presentation of overall erection plan including overall scheduling of various erection inputs
like, cranage, labour and major erection sequence of various erection areas.
Timely provision of an adequate number of qualified erection personnel.
The skilful completion of the erection work on schedule in conformity with all application
regulations.
The scheduling shall be prepared in areas of civil engineering and foundation works, mechanical
erection, electrification and instrumentation and finally activities required to put the equipment into
operation.
- 22 -
3.2.2 Scope of Planning

The erection planning shall be developed by the erection company and based on inputs of the
following documentation:
Time schedules as per contract (final Milestone and dates etc.)
Status of equipment to be delivered (level of shop preassembling)
Site Erection
Cranage
Erection Drawings
Installation Instructions of function units/ components (OEMs)
3.2.3 Inspection & Test Plan (I.T.P.)-Erection
For the erection work an ITP is prepared due to the I.T.P.-format as described in QA of CHEC and
The listing up of activities corresponds to the chronological sequence of erection work and forms the
structure for the erection planning.
As per Inspection & Test plan SITE-Erection
3.2.4 Diary of Events
The Erection Contractor, together with CHEC representative shall maintain a diary of all events during
erection and record all test results on inspection/test report forms for compiling to the Data report
(MDR).
3.2.5 Quality Assurance Plan- Installation/ Erection
A summary of the above-mentioned documents such as inputs, outputs and quality records for
erection work is shown on the following chart.
- 23 -
Quality Assurance Plan-Erection
Input/ Reference
activity
INCOMING GOOGS/ STORAGE

INSTRUCTION
CHEC/ Vendors (as per OEM)
MOBILISATION
Erection Contractor
DRAWING
BILL OF MATERIAL
CHEC
output
quality records
INSPECTION RECORD
ERECTION
PERSONNEL
QUALIFICATION
Erection Contractor
PACKING LIST
Shipping/ CHEC
STATUS OF EQUIPMENT
DELIVERED
CHEC
PROGRESS REPORTS
ITP-ERECTION
Erection Contractor
SCHEDULE
TIME/ MAN POWER
Erection Contractor
TOOLS &
EQUIPMENT
Erection Contractor
TEST REPORTS as per ITP-Erection

compiled to MDR
MACHINE
READY FOR
COMMISSIONING
SUPERVISION
CHEC
OEM-INSTALLATION MANUALS
Suppliers/ Vendors
NONCONFORMANCES
CORRECTIVE ACTION
INTERNATIONAL &
LOCAL STANDARDS
PAINTING REPAIR
INSTRUCTIONS
acc. to Contract
SAFETY & HEALTH REGULATIONS
ERECTION CONTRACTOR
S&H PROJECT TEAM

PRE-JOB PLANNING
JSA/ PSST
S&H ASSESSMENT REPORT

S&H Plan; etc.
24
3.3
STANDARDS AND CODES

Unless otherwise specified, design and erction will comply with the rules and provisions of the latest
editions and amendments of the relevant Standards, Rules, Regulations and Codes of practice
where applicable.
In pursuance to the contract, Coal Handling System/145236.61.0401 (Page 28 of 103, Page
B1.3-48), the following standards shall be used for the design of Grab Shipunloader:
a)
ISO 5048 Continuous Mechanical Handling Equipment
b)
ISO 5049 Mobile Equipment for Continuous Handling of Bulk Materials
c)
GB755 Rotating motor, rated value and performance
d)
GB4208 Protective Grade of Outer Cover for Electronics (IP code)
e)
GB12348 Boundary noise standard for industrial enterprises
f)
GB/T 13384-92 General specifications for packaging of mechanical and electrical products
g)
GB12351-90 Environmental technical requirements of rotating motor for tropical use

Under the situation where the aforementioned standards are not applicable, the newest versions
of the following approved standards are used preferentially.

GB
FEM
ISO
German (DIN)
American (US Industries)
Others
The following standards and the standards listed in the Buyer Standards are to be included in this
Installation Manual if there is no restriction of using other related standards
Ref.:
Inspection & Test for Erection Works

Standard of SELLERs countries
Item
Ident - No.
Description
GB3811-1983
Design rules for cranes
GB/T 6067-1985
Safety rules for lifting appliances
GB/T 14405-1993
General objective overhead cranes
JTJ 280-2002
Technical Code for Port Equipment Installation

Construction
25
Remarks
Safety code for the bridge type grab ship

unloader
GB/T 18224-2008
G B/ T 5 9 0 5 - 1 9 8 6
GB/T 985-1988
GB/T 986-1988
Basic forms and sizes of weld grooves for

submerged arc welding
GB/T 5117-1995
Carbon steel covered electrodes
10
GB3323
Radiographv and qualitv grade 0f fusion weld
11
G B/ T 11 3 4 5 - 1 9 8 9
Method for manual ultrasonic testing and

classification of testing results for ferritic steel
welds
12
G B/ T 11 8 4 - 1 9 9 6
Geometrical
tolerancing--Geometrical
tolerance for features without individual
tolerance indications
13
G B/ T 1 8 0 1 - 1 9 9 9
Limits and fits Selection of tolerance zones

and fits
14
G B/ T 1 8 0 4 - 2 0 0 0
General tolerancesTolerances for linear and

angular
dimensions
without
individual
tolerance indications
15
GB1764-1979
Mensuration of paint thickness
16
GB/T 8923-1988
Rust grades and preparation grades of steel

surfaces before application of paints and
related products
17
GB/T 10089-1988
Accuracy of cylindrical worm and wormwheel
18
GB/T 10095-2001
Cylindrical gears-System of accuracy
19
GB11368
Gears drive device cleanliness
20
JB/ZQ4000.7
General specification for forgings
21
GB/T 3766-2001
Hydraulic fluid power-General rules relating to

systems
22
GB/T 7935-2005
Hydraulic fluid power-General requirements

for hydraulic components
23
GB/T 2346-2003
Fluid power systems and componentsNominal

pressures
24
GB/T 15622-2005
Hydraulic cylinder test method
25
GB/T15623
Electrical and liquid servo valves test method
26
GB/T 8104-1987
Hydraulic fluid power--Valves--Testing method

of flow control valves
27
GB/T 8105-1987

of pressure control valves
28
GB/T 8106-1987

of directional control valves
29
GB/T 7936-1987
Hydraulic fluid power--Positive displacement

pumps and motors--Determination of derived
capacity
Cranes--Test code and procedures

Basic forms and sizes of weld grooves for gas
welding
manual
arc
welding
and
gas--Shielded arc welding
26
3.4
30
GB/T 14211-1993
mechanical seals test method
31
JB/T 4127.1-1999
Specification for mechanical seals
32
JB/T 5947-1991
Packaging
general
engineering machine
specification
for
33
GB 7588-2003
Safety rules
installation
manufacture
and
34
G B/ T 1 0 0 5 8 - 1 9 9 7
Specification for lifts
35
G B/ T 1 0 0 5 9 - 1 9 9 7
Lifts--Testing methods
36
GB 10060-1993
Code for acceptance of lifts installation
37
GB4720
No. 1 low-pressure wiring and electric-control

equipment
38
GB7251
low-pressure whole set switch equipment
39
GBJ55
electric power equipment design specification

for industry and civil general equipment
40
GB3859-1993
Semiconductor convertors
41
SDJ 9 - 1 9 8 7
electric-measure and meter equipment design

specification
for
lifts
QUALITY SYSTEM
The Contractor for the installation works will provide quality assurance and quality control in accordance
with ISO9001 / 2000.
The Contractor will appoint a suitably qualified representative who shall have defined authority and
responsibility for implementing and controlling the quality system under the contract.
These requirements will cover all work under the contract, and shall include the activities of all
sub-contractors and suppliers.
An Assembly Data Report (ADR) shall be progressively compiled for the completed works and shall include
but not be limited to:
Signed-off Inspection and Test Plans
Marked-up As-built drawings
Weld maps
Weld Procedure Specifications
Non-Destructive Test Records
Material Certificates or Letters of Conformity
Details of Non-Conforming Items/Correction Actions/Concessions
Dimensional Inspection Reports
3.5 Labour
Erection and installation personnel must have experience and qualifications needed for the works in
question. Understanding of function of system is advantage for the Erection Company to make right
decisions during erection design at site. Instructions and Regulations given by Authorities shall be followed.
3.6 Testing Equipment & Tools
27
The Erection Contractor will provide all test equipment and tools necessary for pre-commissioning tests.
The testing equipment must have current calibration certificates where applicable, including torque
wrenches used for bolted assemblies.
3.7 Crane Works
During erection and finishing work there are several heavy lifts and a lot of other lifts. Therefore it is
important that the Erection Company shall make the erection planning by including the plan of the major
lifts and rigging equipment proposed. Spreader beams or lifting beams required to eliminate horizontal
loading of the structure will be supplied by the erection company. Similarly, temporary erection stands will
be supplied by the erection company.
The lift points and masses for the larger sections of equipment such as bridge,carrier are mostly shown.
Those lift points as recommended should be used. Erection Company shall prepare and design each lift
beforehand to ensure qualifications of crane operator and condition of crane and accessories.
Check the mass given in drawing using the crane load cell on ground level before the lift. Side forces are
not allowed to the lift points, forces and lifting point constructions shall be parallel.
The supporting structure (support legs) must be calculated and manufactured by the erection company,
erected first and after that erection of section in question will be performed with the help of two mobile
cranes.
Some of the sections must be connected to each other on ground level before the erection . Assembly
stands must be supplied by the erection contractor.
The finishing works are always safer and more efficient on ground level and therefore it is important to
carry out such works as ready as possible at that stage.
The rest has to be carried out after the lifting from man cage, like some additional walkways because of
lifting points and touch up painting to those places possible damaged during the lift.
3.9 EQUIPMENT AS DELIVERED TO SITE
3.9.1
STEEL STRUCTURE
The following is a brief description of the condition of the various structures that will be
delivered to site:
3.9.1.1
General
Machining of all structural parts as applicable for fitting of pin-connections, bearings,

slewbearing, mechanical components, etc. has been carried out in the manufacturer's
28
workshops.
Joints for bolted connections are drilled at the workshop.
Field joints to be welded are prepared as required (bevels) at the workshop.
All parts will be shipped with middle paint coat ( except major site weld areas and high
tension bolted joints ).
3.9.1.2
Heavy Steelstructure Components
Frame
Eight wheel bogies
Bogies and Equalizers
Front Girder
Back girder
Pylon
Front tension bar
Back tension bar
Fixed Tie Links
Cab Rail
trolley Rail
machine-electric house
lift
hoppers
3.9.1.3 Secondary Steelstructure Components
Stairs, walkways, ladders, platforms including handrails for

Frame
Front Girder
Back girder
Pylon
hoppers
are generally pre-fabricated and delivered in sections so as to minimize the assembly
work on site.
Ladders
- fabricated
-
Stairs
- fabricated and assembled

29
Handrails
- delivered in pre-fabricated sections
Platforms
- pre-fabricated and delivered in sections
Grating
- loose, parts already cut to platform requirements
Brackets for monitoring electrical field devices will be supplied but are to be mounted
and adapted on site by the erection contractor.
3.9.1.4
Covers and safety guards delivered in sections , fabricated to fit on site.
Temporary Supporting Structure

All temporary supporting structure necessary for the erection and installation, to be supplied
by the erection contractor.
3.9.2
MECHANICAL EQUIPMENT
The following is a brief description of the condition of the various mechanical components that
will be delivered to site:
3.9.2.1
TRAVELING MECHANISM
up to the Four-wheel bogies pre-assembled
Drives
Drive covers
Pins, bushings, distance rings, cover plates, , ,
end buffers
Miscellaneous items as shown on the relevant drawings and listed in the Bill of
Materials (B.O.M.).
3.9.2.2
Main Trolley
Main Trolley
Guiding Roll
Platforms
Materials (B.O.M.).
3.9.2.3
Open-Close Machinery
Reducer
Drift shaft
30
Drum
Motor
Coupling
Break
Materials (B.O.M.).
3.9.2.4
Hoppers
dust-prot-Wall
dust-prot-door
Hopper
Shake -Feeder
Materials (B.O.M.).
3.9.2.5
HYDRAULICS
Hydraulic power pack for Hoppers
Hydraulic power packs for Safety Hook
Hoses, pipes, fittings for hydraulic installation
Hydraulic cylinders
Materials (B.O.M.).
3.9.2.6
LUBRICATION
Lubrication units
Distributors, hoses, pipes for the lubrication system
accessories (valves, gauges, solenoids...) ...
Materials (B.O.M.).
3.9.2.7
DUST SUPPRESSION SYSTEM AND WATER OUTLETS
Booster pump
Water tank
Control box
Piping and hoses for the water system
Spray bars
Valves and fittings

31
Materials (B.O.M.).
3.9.2.8 Boom Machinery
Motor
Braker
Gear Box
Roller Assembly
Anti-ropeskipping
Materials (B.O.M.).
3.9.2.9 Front , Backword Cantenary Trolley
Front , Backword Cantenary Trolley
Protect wheel
Platform
Materials (B.O.M.).
3.9.3
ELECTRICAL EQUIPMENT
Switchroom completely installed as one unit
Air condition units for electrical switch room
Fire protection- halon system-
Transformer
Terminal boxes
Limit switches, field monitoring and control devices
Local control stations
Lighting equipment
Safety signs
Labels
Cable trays and conduits for field installation
Electric and fibre optic cables for field installation
Cable reeler
Cable turn over
Miscellaneous
3.9.4
MISCELLANEOUS
Grab
Operator Cab
32
Safety Hook
Boom Hoist Cab
Lift
Cab Safeguard
Rope System
Assistant Cab
Cable reeler including drive
Bollard and turn over assemblies for cable reelers
Cable saddle
Hand held fire extinguishers
Materials (B.O.M.).
3.10 ERECTION SEQUENCE

3.10.1
General
A detailed erection sequence and programme will be established together with the Construction
Contractor.
Basic installation procedures are not detailed described in this manual since only experienced
crews will carry out the works under supervision of experienced site personnel.
For the required bolt torques for structural and mechanical connections refer to "Required
Torques for Bolted Connections".
In view of a functional and safe erection of the machine, the key-sequence as listed below should
be followed unless otherwise instructed by CHEC or mutually agreed CHEC and the construction
contractor.
Note that the complexity of the Grab Shipunloader erection requires overlapping of several
installation steps so that the sequence especially for secondary components like walkways,
covers, completion works, is not exactly covered in the following list.
Special attention has to be paid to the installation sequence of Frame, Back

girder, Front Girder and all components installed at the Steel Structure installation to keep
the machine balanced and safe during all stages of the erection and to not overload the
temporary support structure.
3.10.2
Pre-Assembling Water Side Frame

33
Water Side Frame is delivered in eight separate parts: W.S.Sill Beam, Underside W.S Legs(2
parts), Upside W.S.Legs (2 parts), Horizontal Beam of W.S, Fixed Tie Links III, Anchor Support.
Lift Underside W.S Legs part 1,part 2 and welded to the W.S.Sill Beam.
Lift Horizontal Beam of W.S part 1 and Horizontal Beam of W.S part 1 to Underside W.S Legs
part 1. Install the high strength bolts to fix the two parts and torque according to the
instructions with the hydraulic bolt tensioner
111,
Lift Horizontal Beam of W.S part 2 and Horizontal Beam of W.S part 2 to Underside W.S Legs
Lift Horizontal Beam of W.S and welded to the Underside W.S Legs part 1,part 2.
Lift Fixed Tie Links III and welded to the Horizontal Beam of W.S and W.S.Sill Beam.
Lift Anchor Support and welded to the W.S.Sill Beam.
3.10.3
Pre-Assembling Land Side Frame

Land Side Frame is delivered in eight separate parts: L.S.Sill Beam, Underside L.S Legs(2
parts), Upside L.S.Legs (2 parts), Horizontal Beam of L.S, Fixed Tie Links III, Anchor Support.
Lift Underside L.S Legs part 1,part 2 and welded to the L.S.Sill Beam.
Lift Horizontal Beam of L.S part 1 and Horizontal Beam of L.S part 1 to Underside L.S Legs
Lift Horizontal Beam of L.S part 2 and Horizontal Beam of L.S part 2 to Underside L.S Legs
Lift Horizontal Beam of L.S and welded to the Underside L.S Legs part 1,part 2.
Lift Fixed Tie Links III and welded to the Horizontal Beam of L.S and L.S.Sill Beam.
Lift Anchor Support and welded to the L.S.Sill Beam.
Install all walkways and access
3.10.4
Long Travel Drive Assembly, Frame

Set the pre-installed 4 wheel wheel bogies which are part of the 8- wheel bogie onto the rails
and support temporarily
34
Lift the 8-
wheel bogie and pin to the 4 wheel bogies
Install the 4-wheel bogie4 Support the installed 4- wheel wheel bogie securily4 Lift Pre-Assembling Water Side Frame onto the 8- wheel bogie and line exactly to the rails.
Install the high strength bolts to fix the two parts and torque according to the instructions with
the hydraulic bolt tensioner
Lift Pre-Assembling Land Side Frame onto the 8- wheel bogie and line exactly to the rails.
Install the high strength bolts to fix the two parts and torque according to the instructions with
the hydraulic bolt tensioner
Lift Horizontal Beam I of Frame, and connect part 1,2 of Horizontal Beam I to Pre-Assembling
Water Side Frame and Pre-Assembling Land Side Frame. Install the high strength bolts to fix
the two parts and torque according to the instructions with the hydraulic bolt tensioner.
,
Lift Fixed Tie Links II, and welded to Pre-Assembling Water Side Frame and
Pre-Assembling Land Side Frame . All components installed at the Steel Structure
installation to keep the machine balanced and safe during all stages of the
erection.
Install Belt system support

Install long travel drives and pin torque arm.
Install covers on drive motors.
Install rail clamps.
3.10.5 Pre-Assembling Upside Frame Part
Lift Horizontal Beam III part 1,2 onto waterside portal and landside portal. Install the high
strength bolts to fix the two parts and torque according to the instructions with the hydraulic
bolt tensioner.
Lift Short Fixed Tie Link 1,2 and welded to Horizontal Beam III part 1,2.
3.10.6 Pre-Assembling Back girder
Lift Back Beam, and welded to Girder part 1,2. ,
Lift Pre-Assembling Upside Frame Part, and welded to Back girde.
,
Lift Pylon onto waterside portal. Install the high strength bolts to fix the two parts and torque
according to the instructions with the hydraulic bolt tensioner.
Lift Back tension bar onto Pylon and Back girder, and Pin to the Pylon, and welded to the Back
girder.
35
Install trolley Rail

Install Cab Rail
For easier installation several components to be mounted at the Pylon and Back girder should be
pre-installed as long as the Pylon and Back girder is still on the ground.
3.10.7 Back girder, Upside Frame Part Assembly ,
Lift Pre-Assembling Back girder onto Underside W.S Legs part 1,2 and Underside L.S Legs
part 1,2 of Frame. Install the high strength bolts to fix the two parts and torque according to the
instructions with the hydraulic bolt tensioner.
3.10.8 Pre-Assembling Front Girder
Lift Front beam, and welded to Girder part 1,2. ,
Lift hoist pulley support, and pin to Girder part 1,2.
Install trolley Rail
Install Cab Rail
For easier installation several components to be mounted at the Front Girder should be
pre-installed as long as the Front Girder is still on the ground.
3.10.9 Front tension bar, Front Girder Assembly
Lift Pre-Assembling Front tension bar, and pin to the Pylon.
Lift Pre-Assembling Front tension bar, and pin to the Pylon.
Lift Pre-Assembling Front Girder, and pin to the back Girder. Lift Pre-Assembling Front Girder
and pin to the Front tension bar.
Lift Front Girder, and hang to the Safety Hook.
3.10.10 Pre-Assembling Machinery House
Pre-Assembling Underframe of the M.R.
Pre-Assembling Water side wall.
Pre-Assembling land side wall.
Pre-Assembling right side wall.
Pre-Assembling Left side wall.
Pre-Assembling Machinery beam.
For easier installation several components should be pre-installed is still on the ground.
36
3.10.11 Machinery House Assembly

Lift Pre-Assembling Underframe of the M.R. and weld to the Horizontal Beam III part 1,2.
Install all components of Boom Machinery driver unit..
Install all components of Hoist, Close and trolley device driver unit.
Install all relevant Electric unit.
Install Water side wallland side wallright side wall and Left side wall.
Install wall indoor, Distance wall, E-house and girder .
Install Electrical maintenance crane .
Install Electrical maintenance crane .
Install Pre-Assembling Machinery beam
3.10.12 Secondary structures
Install all main walkway and stair access
Install walkway in chute area
3.10.13 Hoppers
Pre-install Hopper
Lift the Pre-install Hopper onto the Horizontal Beam of Frame, and weld to the Base support.
Install right dust-prot-Wall, left dust-prot-Wall and Spillage flap.
Install Discharge door, shake-feeder.
Install Chute&support.
Install walkways, stairs, platforms acc. to relevant drawings.
3.10.14 Hydraulics
Lift hydraulic unit into position and bolt to the structure.
Install hydraulic piping and clean.
Install cylinders and fill with hydraulic oil
37
Install cylinder hoses to pipe system.

Fill the hydraulic tanks with oil.
Flush the hydraulic pipe/hose system.
Label the piping system.
Completion works like touch up painting, cleaning, etc.
3.10.15 Lubrication
Refer to the applicable schematic and piping drawings
Install lubrication unit
Fit lubrication pipes and hoses to structure
Install all lub-distributors and connect to line system
Cleaning and Flushing of all lines
Grease filling of all lines, bearings and labyrinths by separate pump
Check the proper function of all grease points (commissioning) and connect to the equipment.
3.10.16 Dust Suppression Systems

Install booster pump and valves on platform
Install suction pipe to water through.
Install water tank.
.
Install piping and water outlets on portal, slewdeck and boom.
Install spray bars.
.
Pressure test for leaks.
Completion works like repairing leaks, labelling, etc.
38
3.10.17 Miscellaneous
Install cable reeler including turn over to tripper car platform.
Install land based bollard and turnover for trail cable.
Install main trolley. .
Install lift. .
Install front cantenary trolley. .
Install backword cantenary trolley. .
Install operator cab.
Install boom hoist cab
Install air condition units for switchroom
Install fire protection system for switchroom
Install brackets for piping and pipework
Install brackets for cable trays and trays
Install strikers for electrical field control devices.
Install signs and labels
Install covers and safety guards
Completion works
Rectification of Punch list items
3.10.18 Electrics
Refer to relevant Electric Installation Manual
The electrical installation has to be done in close conjunction with the structural and mechanical
installation schedule and progress.
The switchroom is completely to assemble
and internally to wire by the installation
contractor.
Installation of brackets (kind, exact location, type of fixing to main structure, etc) for cable trays,
termination boxes, field devices, control station, etc. are subject for approval by CHEC and will
be decided during erection of the Grab Shipunloader unless otherwise specified on the
drawings.
Install cable trays and conduits for field wiring.
For principle routing of cable trays to be installed refer to the relevant drawings
Install flood lights and lighting.
For principle location of lighting refer to the relevant drawings
Installation of junction boxes and field devices like
limit switches
39
chute block probes

I-dent system for long travel
anemometer
encoders
local control stations
etc.
For principle location of field devices, terminal boxes and local control stations refer to the
relevant drawings
Install lightning system from top of rocker to railtracks.
Pull all cable according to the electrical drawings
Terminate all electrical equipment according to the electrical drawings.
Test the electrical installation (refer to relevant document)
Install the PLC program PLC
Relevant electrical drawings:
Single Line Diagrams
Control Schematic Diagrams
Schematic Diagrams
Cable Schedule
Equipment Layout and G.A. DrawingsG.A.
PLC - Block Diagram PLCPLC - Termination Diagrams PLC
Cubicle Termination Diagrams
Junction Box Termination Diagrams
Miscellaneous Termination Diagrams
3.11.
STRUCTURAL ERECTION
3.11.1
GENERAL
All temporary bracing, supports and guys shall be designed and erected to take care of all
loads to which the structure may be subjected during erection, including wind forces, mass of
materials and equipment and stresses due to operation of equipment. Such bracing, supports
and guys shall be left in place as long as may be required for safety.
3.11.1.1
ALIGNMENT AND FITTING
3.11.1.1.1 General
40
Each part of the structure shall be properly aligned before completing field connections.
All members in completed frames shall be true to line and free from bends, twists and open
joints.
Fitting-up bolts and drift pins shall not be used to bring improperly fabricated members and parts
into place, thus causing a strain on bolts in finished work.
Drift pins shall not be driven with
such force as to deform adjacent metal.

No packing, shimming, or wedging will be permitted to correct imperfect work, unless so directed
by CHEC.
All shop errors shall be reported and the proposed method of correction shall be submitted for
review.
Minor miss-fitting may be remedied and corrected by reaming, slight cutting or chipping
as directed.
Damage caused by handling during erection shall be reported.
Corrective measures shall be
completed as directed by the Engineer.
3.11.1.1.2 Erection Tolerances
Erection tolerances shall be in accordance with ISO and 3.14 the main mechanical,
structural components to install the technical requirements of the Erection Manual. Also
refer to the requirements given on the applicable drawings.
Overall dimensions of structural steel frames shall be considered as being within the
limits of these specifications when the cumulative effect of (a), (b) and (c) as follows, are
not exceeded:
(a)
Detailed erection clearances
(b)
Fabrication tolerances for finished parts as specified in ISO

ISO
(c)
Rolling tolerances for profile dimensions permitted under ISO.

ISO
Individual members of structural steel frames shall be considered as being plumb, level
and aligned when the deviation from the dimensions shown does not exceed one in five
hundred.
500
3.11.1.2
WELDING OF STRUCTURAL STEELWORK

Welding procedures for site welding are based on metal arc welding with covered basic
41
electrodes. (Welding supplies like electrodes are not included to delivery.)

The Job Site welding has been minimised as far as transport limitations are the reason for
splitting structural equipment like boom fixed side and portal.
Especially the surface treatment procedure after the Job Site welds shall be carried out with
good care to keep the surface treatment up to the standard.
Only welds shown in the drawings are allowed. In case additional welds are seen practical it is
important to consult with CHEC supervisors for such activities. Even if assembly cleats are attached
to the structure, it will be necessary for the erection company to align structures prior to welding.
All welding will be to the best and most modern practice. Details of methods and procedures
proposed to be used, including details of any pre and post heating of any welds, shall be forwarded
to the CHEC for approval before the commencement of manufacture.
Welding will be in accordance with AWS D1.1 or ISO, Part 1, Class SP or DIN 8563, Part 3, Class
BS, AK, except for equipment such as minor brackets carrying light fittings and cable trays and the
like, which will be a minimum of Class GP (DIN Class CS, BK).
The quality and extent of welds for the works specified herein is shown on the drawings.
The edges of welds shall be held and welding controlled such that the specified gap is
maintained during welding and there is no distortion in the final weldment. This does also apply
for minor welds (brackets) to the main structure.
All contractors will keep records of qualified welders, together with details of the welders
qualifications. The list will be revised on a monthly basis to reflect changes in welders and
qualification.
All welds has to be:
strictly in accordance with the details shown on the approved drawings;
continuous unless otherwise specified
carried out using run-on and run-off tabs.

42
run-onrun-off
Full penetration welds concerning the main structure have to be recorded and the welding
reports have to be submitted as part of the quality system.
Tack welds will be subject to the same standard as the main weld and will not be less than
50mm in length. Welding electrodes will comply with the requirements of AS 1553 or equivalent.
Adequate protection from wind and rain will be given to all field welds. All earth leads will be
attached to the work at a distance no greater than one metre and under no circumstances will
the welding current pass through a bearing or moving part of the assembly.
Lifting lugs, alignment pads and all similar temporary attachments will be taken off the structure
after erection unless otherwise advised by CHEC.
3.11.1.3
INSPECTION AND TESTING OF STRUCTURAL STEELWORK

The erection contractor has to arrange for all non-destructive testing to be performed at a testing
laboratory registered by the National Association of Testing Authorities , or other approved
authority.
The minimum acceptable testing procedures to be used are:

i)
radiographic testing
ii)
ultrasonic testing
iii)
magnetic particle testing
iv)
both ultrasonic and magnetic particle testing.
The extent of testing will be as follows,unless specified otherwise on erection drawings:

All full penetration butt welds test 100% UT or RT
Fillet welds for secondary structures to be visual checked
All welds failing to meet the permissible levels of imperfections allowed in AS1554, Part1, class
SP or DIN 8563, Part 3, Class BK, AK, will be removed or repaired and then re-tested, along
with at least 2 additional samples of either 10% or one in twenty as applicable.
43
Welding will be in accordance with AS1554, Part 1, Class SP or DIN 8563, Part 3, Class BS, AK,
except for equipment such as minor brackets carrying light fittings and cable trays and the like,
which will be a minimum of Class GP (DIN Class CS, BK).
3.11.1.4
SURFACE TREATMENT AND COLOURS

In accordance with compact,facade lacquer of equipment is not part of our duty.The equipment
just has primerbosom lacquer,and completing facade lacquer in locale.
3.11.1.4.1 General
In areas where site welding is required it will be necessary to clean the surfaces prior to welding.
After the assembling all paint damages will be repaired by touch-up.
Repair to painted surfaces will be carried out using the same brand of paint as originally applied
to the steelwork, in accordance with the paint manufacturer's instructions.
Galvanised components will be hot dipped.
Proprietary equipment will be surface coated with the manufacturer's standard paint system,
suitable for the specified service conditions, and colour, except guards and rotating parts of
equipment.
Colour coding shall be in accordance to the main contract colour coding system.
3.11.1.4.2 Surface Preparation
Where practicable, field welded joints and areas of repair to damaged coatings shall also be
cleaned to the above standard. 'Power tool cleaning of steel surfaces' may be approved by
CHEC where the specified surface preparation is not practicable.
Cleaned surfaces shall:
Be kept free of moisture and contaminants, such as dust, spray or perspiration from
hands;
Receive the first application of protective coating within four hours;
Be re-cleaned if they have become contaminated or rusted.
All surfaces immediately before the application of any coating will be clean and dry, free from
44
dust and loose particles and free of soluble salts.

3.11.1.4.3 High Strength Friction Grip Bolted Joint Surfaces
The contact surfaces of high strength friction grip bolted joints will be clean, dry, unpainted and
free of oxidisation immediately prior to jointing. During fabrication these areas will be securely
marked following sandblasting to protect them from moisture and overspray during subsequent
surface treatment and delivery to site. As sand or grit blasting will not be permitted on or in the
vicinity of the machine at the erection site the contact surfaces will be fully protected against
oxidisation prior to delivery to site.
Alternatively the contact surfaces of high strength friction grip bolted joints may be painted
strictly according to the applicable standards. Once painted, these surfaces will be properly
protected, to the satisfaction of CHEC, so that they do not become contaminated by substances
that may be deleterious to the joint, i.e. dirt, grease, other paint etc. prior to jointing.
In either case the bolts, nuts and washers used in the joints shall be clean, dry, unpainted and
free of oxidisation immediately prior to jointing.
3.11.1.4.4 Painting
Painting of all surfaces will be to the appropriate system as specified in this Section.
A.
Climatic Conditions and Surface Conditions
Paint will not be applied when the surface temperature is less than 10C or more than
50C or when the surface temperature is likely to fall below 10C during the curing or
drying period.
Painting will not start or continue if the relative humidity exceeds 85% or the surface
temperature is less than 3C above dewpoint measured with a hygrometer.
B.
Workmanship
All work will be carried out by competent tradesmen using appropriate equipment in
good working order.
There will be supervision by experienced personnel.
C.
Quality of Coatings
Edges, corners, bolts, welds and sharp points in surfaces will be spot primed before
45
general priming to ensure full thickness of cover.
Each coat will be applied in a smooth, even layer, free of sags, runs, holidays and other
faults.
The Contractor will ensure that the paint applied completely covers the surface being
painted and is thoroughly worked into joints, corners and blind areas.
D.
General
All areas internal to plated structures which are not completely seal welded, including
areas to which access may be gained via bolted and sealed manholes, will be painted
according to HI standard specification.
All gauges and nameplates will be masked during painting, any that are defaced by
painting will be cleaned to the satisfaction of CHEC or replaced.
3.11.1.5
CLEAN UP
The work and work area shall be left clean and tidy on completion and all surplus materials and
equipment removed from the site.
3.11.2
GENERAL TORQUE REQUIREMENTS FOR STRUCTURAL BOLT CONNECTIONS

Unless otherwise instructed by CHEC or indicated in the drawings, all structural bolt connections
has to be torqued up to the values given in the following list.
High-strength bolts connections
Metric Thread
3.12
Quality 8.8
Quality 10.9
M 12
70 Nm
92 Nm
M 16
162 Nm
230 Nm
M 20
320 Nm
450 Nm
M 24
550 Nm
775 Nm
M 27
800 Nm
1135 Nm
M 30
1085 Nm
1540Nm
MECHANICAL ASSEMBLY
46
3.12.1
INTRODUCTION
This section specifies the technical requirements for materials, equipment and procedures used
for installation, inspection and testing of mechanical plant and equipment.
3.12.2
GENERAL REQUIREMENTS
3.12.2.1 Installation Procedures

3.12.2.1.1Equipment shall be prepared, installed, aligned, set, lubricated and tested in accordance with the
specifications, drawings and the manufacturer's instruction manuals.
Any conflict in the above
requirements shall be reported immediately and that part of the work shall not proceed until the conflict is
resolved.
3.12.2.1.2All personnel shall be fully instructed in, and familiar with the installation procedures applicable to
the equipment prior to commencement of work.
3.12.2.2 Preparation of Equipment
3.12.2.2.1Equipment shall be thoroughly inspected immediately after unpacking. Any damage or apparent
misalignment shall be reported immediately.
Damaged equipment shall not be installed unless directed
otherwise.
3.12.2.2.2 Installation and assembly instructions shall be read and understood before commencement of
the Work.
3.12.2.2.3Temporary shaft locking devices shall be removed and shafts checked for free rotation in the
appropriate direction by hand only.
3.12.2.2.4Equipment shall be checked for the presence of condensation in oil reservoirs at intervals not
exceeding 30 days. If necessary, remedial action shall be taken in accordance with the requirements of the
manufacturer and/or CHEC. Shafts of relevant equipment shall be rotated at regular intervals in accordance
with the manufacturer's requirements. Bearings shall be protected from ingress of moisture and dust.
3.12.2.2.5Bolted joints shall be checked for tightness.
3.12.2.2.6Rubber and synthetic rubber lined equipment shall be protected from sunlight.
3.12.2.2.7Parts shall be cleaned thoroughly prior to assembly. Protective coatings applied for shipping shall
be removed by use of suitable solvents which shall not be damaging to the equipment or paint system.
Individual equipment components for field assembly shall be internally inspected for foreign materials.
47
Desiccant bags and packing materials shall be removed. After assembly, a film of grease or other approved
coating shall be applied to machined surfaces to prevent corrosion.
3.12.2.2.8Field alterations to steelwork or equipment to facilitate installation shall not be made without prior
approval. In particular, sub-assemblies shall not be dismantled without approval.
3.12.2.2.9Equipment shall be lifted using only those lifting lugs provided by the manufacturer. Where
insufficient lifting lugs and/or bracing have been provided to suit the proposed method of lifting or handling
the approval of CHEC representative to use additional devices shall be sought.
3.12.2.2.10Lifting tackle shall not be fixed to any part of a building or similar structure, other than monorail
beams which may be provided for such objectives without approval. Winches and similar devices shall not
be anchored to girts, handrails, grid mesh flooring or other light structural members.
3.12.2.2.11Temporary bracing and temporary supports may be used for equipment during installation.
However, temporary lugs or attachments for installation objectives shall not be welded to machinery and
other equipment.
Temporary bracing and temporary supports shall be removed after the installation is completed.
3.12.2.2.12Large equipment shall be delivered disassembled, or in parts and sub-assemblies as is
customary or necessary for shipment. The Contractor is responsible for carrying out all assembly or
disassembly work required at site prior to installation.
3.12.2.2.13Unless noted otherwise, all electric motors and drives on furnished equipment will be supplied in
a fully assembled condition.
3.12.2.2.14For equipment mounted on steelwork, the bearing areas will be mechanically cleaned of paint
(topcoats), rust and scale before placing of packers.
3.12.2.3 Shaft Alignment
3.12.2.3.1The permissible amount of shaft misalignment will vary with type of equipment. Misalignment
shall not exceed the manufacturer's recommendations.
When measuring shaft alignment both drive and driven hubs shall be rotated together.
Where manufacturer's data is not available the following criteria shall be used:
Coupling of Criteria
Maximum Allowable
Maximum Allowable
Parallel Offset
Angularity
48
Up to 150kW/3000 RPM
0.100mm (TIR)
0.333 mm/m
Above 150 kW/3000 RPM
0.050mm (TIR)
0.083 mm/m
Rigid Couplings
0.025mm (TIR)
0.083 mm/m
(TIR = Total Indicator Reading)

3.12.2.3.2Potential movements such as thermal expansion or contraction, hydraulic loading, gears with
rising pinions, motor rotors seeking a magnetic centre, and the like shall be allowed for during alignment of
driver and driven equipment.
3.12.2.3.3Electric motors shall be moved rather than the driven equipment. Equipment items with the
largest diameter pipe shall be aligned to the respective pipe. That equipment item shall not be moved
thereafter.
3.12.2.3.4Shims shall not be used under gear cases, without approval. If shims are required, they shall be
non-corrosive and full bearing type.
3.12.2.3.5After the final shaft alignment has been accepted, pipe connections shall be made and shaft
alignment monitored. For pieces of machinery with common pipe such as pairs of pumps, both shaft
alignments shall be monitored during piping-up operations. Shaft alignment shall not change by more than
0.050mm TIR while piping is made up.
3.12.2.3.6Flanges of connecting piping shall not be bolted up under stress.
Flanges shall not be sprung
into position.
3.12.2.3.7Piping shall be supported independently of the equipment casings.
3.12.2.3.8Piping shall be erected in accordance with Specifications, P7ID's, and the drawings.
3.12.2.3.9After bolting up of footings, couplings and pipes, the equipment shall be hand rotated to ensure
that neither binding nor case distortion has occurred.
3.12.2.4Drives and Transmissions
3.12.2.4.1Drive components shall be aligned and installed in accordance with this specification and
manufacturer's recommendations.
3.12.2.4.2Drives shall be turned by hand to check freedom of rotation.
3.12.2.4.3The direction of rotation of motors shall be checked for compliance with the equipment
requirements before drives are tested. The direction of motors shall be rechecked with belts or couplings
disconnected, whenever electrical connections are disturbed.
49
3.12.2.4.4Final alignment of all drives and couplings shall be checked and recorded and may be witnessed
by CHEC. Where applicable, the alignments shall be performed after fitting and hydrostatic testing of the
suction and discharge pipework.
3.12.2.5Coupling Hubs Alignment
3.12.2.5.1When coupling hubs have not been installed by the manufacturer, the shaft extensions shall be
cleaned to parent metal prior to the coupling hub installation.
3.12.2.5.2Before mounting a straight fit coupling, the coupling hub bore and shaft diameter shall be
measured with a micrometer and the results recorded, to determine that the coupling hub will have the
proper installed interference.
3.12.2.5.3Tapered coupling hubs shall be installed with an interference fit of approximately 0.025mm per
25mm of nominal shaft diameter unless otherwise specified.
bath.
Coupling hubs shall be heated in a hot oil
Bath temperature shall be 70C above shaft temperature to ensure proper draw-up on the taper.
3.12.2.6Fasteners
3.12.2.6.1Unless otherwise approved on the drawings, new corrosion resistant and commercial grade
fasteners shall be supplied complying with all applicable standards including the following:
Bolts
GB 5783-86
Nuts
GB6170-86
Flat Washers
GB 97.1-85
Helical Split Washers
GB 93-85
3.12.2.6.2Unless otherwise stated on the drawings, the minimum diameter bolt or screw thread shall be
16mm.
3.12.2.6.3All bolts and stud bolts shall project at least two full thread lengths past the outer
face of each tightened nut.
3.12.2.6.4Masonry anchor bolts shall be galvanised "Dynabolts" or approved equivalent,
having a minimum thread diameter of 12mm.
3.12.2.6.5High strength bolts shall be installed and tightened to GB/T 1231-91 and the
equipment manufacturer's recommendations.
3.12.2.6.6The threaded section of adjusting screws likely to require regular adjustment shall not be painted.
An approved corrosion inhibiting protective coating shall be applied to threaded sections.
3.12.2.6.7Where appropriate, the threads of fasteners shall be lightly greased before assembly.
50
3.12.2.6.8All bolts installed shall be marked after correct installation and tightening.
3.12.2.7Welding and Cutting
3.12.2.7.1Welding shall comply with ISO.
Unless stated otherwise on the drawings, welds shall be 4mm
(minimum effective throat) continuous fillet or full strength butt weld, as appropriate.
3.12.2.7.2The welder's earth connection shall be made as close as possible to the work to be welded.
Welding currents, shall not pass through bearing assemblies.
The Contractor shall be liable for the costs
of replacement of bearings and gears damaged by direct or stray currents.

3.12.2.7.3Welds shall not be placed across the tension flanges of structural beams without approval.
3.12.2.7.4Steel wire ropes shall not be cut with a cutting torch.
3.12.2.7.5All cutting shall comply with the requirements of ISO. A fire watch shall be maintained when
cutting over rubber lined tanks, conveyor belts and the like. Protective mats shall be used to prevent hot
material contacting rubber.
3.12.2.8Guards
Guards shall be installed as shown on the drawings. Where necessary for alignment of couplings, etc, the
Contractor shall remove and replace guards which have been installed prior to delivery.
3.12.2.9Touch up of Damaged Paint Surfaces
Painted surfaces damaged during installation shall be made good. The method and materials used shall be
as detailed in Specifications.
3.13
MECHANICAL INSTALLATION
The following requirements for particular items of equipment shall
be read in conjunction with
the General Requirements of this Specification.

3.13.1
LONG TRAVEL DRIVES

Preparation
Using a suitable solvent, remove the rust inhibitor, containing wax, from the hollow shaft.
Check hollow and machine shaft for any damage to seats and shoulders. If necessary, rework
with a suitable tool and clean again.
51
Protect fitting surfaces by application of a suitable lubricant which prevents fretting corrosion.
Mounting
To install the gear unit, simple tools may be used, like a spindle with nut and cover plate to pull
the gear hollow shaft onto the drive shaft. Care must be taken that the hollow shaft is properly
aligned with the machine shaft in order to prevent any twisting.
3.13.2 Boom Machinery

The installation of Boom Machinery has to done according to the applicable drawings
Drive Motor
Drive Motor Support
Braker
Brake Support
Gear Box
Gear Box Support
Roller Assembly
Cam Limitator
3.13.3 Hoist, Close and trolley device
The installation of Hoist, Close and trolley device has to done according to the applicable
drawings
Drive Motor
Drive Motor Support
Braker
Brake Support
Gear Box
Gear Box Support
Roller Assembly
Cam Limitator
Drift shaft
3.13.4
HYDRAULIC INSTALLATION
3.13.4.1 General Requirements

3.13.4.1.1 Installation Procedures
Equipment shall be prepared, installed, aligned, set, lubricated and tested in accordance with
the specifications, drawings and the manufacturer's instruction manuals.
Any conflict in the
above requirements shall be reported immediately and that part of the work shall not proceed
until the conflict is resolved.
52
All personnel shall be fully instructed in, and conversant with the installation procedures
applicable to the equipment prior to commencement of work.
3.13.4.1.2 Preparation of Equipment
Equipment shall be thoroughly inspected immediately after unpacking.

apparent misalignment shall be reported immediately.
Any damage or
Damaged equipment shall not be
installed unless directed otherwise.
Installation and assembly instructions shall be read and understood before commencement of
the Work.
Temporary shaft locking devices shall be removed and shafts checked for free rotation in the
appropriate direction by hand only.
Equipment shall be checked for the presence of condensation in oil reservoirs at intervals not
exceeding 30 days. If necessary, remedial action shall be taken in accordance with the
requirements of the manufacturer and/or CHEC. Shafts of relevant equipment shall be rotated
at regular intervals in accordance with the manufacturer's requirements. Bearings shall be
protected from ingress of moisture and dust.
Bolted joints shall be checked for tightness.
Rubber and synthetic rubber lined equipment shall be protected from sunlight.
Parts shall be cleaned thoroughly prior to assembly. Protective coatings applied for shipping
shall be removed by use of suitable solvents which shall not be damaging to the equipment or
paint system. Individual equipment components for field assembly shall be internally
inspected for foreign materials. Desiccant bags and packing materials shall be removed. After
assembly, a film of grease or other approved coating shall be applied to machined surfaces to
prevent corrosion.
Field alterations to steelwork or equipment to facilitate installation shall not be made without
prior approval. In particular, sub-assemblies shall not be dismantled without approval.
53
Lifting tackle shall not be fixed to any part of a building or similar structure, other than
monorail beams which may be provided for such objectives without approval. Winches and
similar devices shall not be anchored to girts, handrails, grid mesh flooring or other light
structural members.
Temporary bracing and temporary supports may be used for equipment during installation.
However, temporary lugs or attachments for installation objectives shall not be welded to
machinery and other equipment.
Temporary bracing and temporary supports shall be removed after the installation is
completed.
Large equipment shall be delivered disassembled, or in parts and sub-assemblies as is

customary or necessary for shipment. The Erection Contractor is responsible for carrying out
all assembly or disassembly work required at site prior to installation.
Unless noted otherwise, all electric motors and drives on furnished equipment will be supplied
in a fully assembled condition.
For equipment mounted on steelwork, the bearing areas will be mechanically cleaned of paint
(topcoats), rust and scale before placing of packers.
3.13.4.2 Hydraulic power packs

The Hydraulic power packs will be delivered as complete shop assembled and shop tested units.
The installation work on site therefore is reduced to lifting of the units to the designated locations
and bolting down to the supporting structure. Cabling will be installed by the erection company.
Further checks and starting of the unit are part of pre-commissioning and commissioning. Refer to
the relevant manuals as well as to the maintenance manual for further information.
3.13.4.3 Cylinders
The cylinder is complete shop assembled and shop tested including the valves built-on.
The installation of the hoisting cylinder is reduced to
lifting the cylinder to the designated locations and connecting the bearing of the cylinder pipe
side to the support structure with the pin foreseen.
Fix the position of cylinder against tilting by temporary supports.
To bring the bearing hole of the piston rod into the connecting position an auxiliary pump unit
is be used.
Attention: Use already the hydraulic oil in the auxiliary pump unit foreseen for the normal operation.
3.13.4.4 Piping
54
3.13.4.4.1General
The general routing of the lines has to be according to the relevant drawings. The detailed routing
has to be measured and fabricated according to the actual situation on the machine in close
conjunction with lubrication, water and electric installation to avoid any interference between all
pipes, cable trays, conduits and other installed equipment.
Hoses has to be provided at all points of movement.
Hoses piping and fittings as per the specification.
For further instructions for field piping installation refer also to section below.
3.13.4.4.2Piping Fabrication, Installation & Testing
3.13.4.4.2.1Flanged Construction
All flanges, bolting and gaskets shall be furnished and installed in accordance with applicable
Piping Code.
Steel flanges to be mated with cast iron flanges shall be flat faced to accommodate full face
gaskets.
3.13.4.4.2.2 Screwed Piping
Where equipment is fitted with N.P.T. or B.S.P. or other screwed connection, the Erection
Contractor shall ensure that interconnecting piping/fittings have matching thread form.
3.13.4.4.2.3Pipe Fabrication
Unless otherwise shown, flange bolt holes shall straddle principle centre lines of equipment
and piping.
Unless otherwise shown, the radius of all bends shall be at least five times the pipe diameter.
All threaded connections shall be gauge checked or chased after welding or heat treating.
Fabricated pipe spools shall be cleaned free of weld splatter, scale, grease and dirt.
3.13.4.4.2.4 Installation
Field routed piping shall be located in such a manner as to facilitate the safe installation of
hangers and supports and consideration shall be given to the appearance of the installation.
Special care shall be taken when connecting piping to pumps and equipment to see that
excessive stress are not transmitted to such connections. In the case of welded nozzle
connections, the Erection Contractor shall allow for shrinkage of the line during welding and
ensure that the pipework is supported so that accurate matching of bolt holes and uniform
contact is obtained over the entire flange surface before installing the bolts.
Wherever galvanized pipe is used with screwed fittings, the exposed threaded portion shall
be coated with a galvanizing compound after the screwed joints are made up.
55
Any galvanized pipe that is bent or welded shall have the galvanized surface made good with
galvanizing compound after erection.
3.13.4.4.2.5 Pipe Support

All piping shall be field supported by the Erection Contractor.
Every hydraulic joint shall have a pipe support within a limit of 1 metre linear distance from the
joints.
Hydraulic pipe end spans and spans adjacent to tees and elbows shall have two supports between
joints.
Allowable pipe span between supports:
Tube diameter
spacing
up to 10 mm
1.0 m
> 10 mm to 25 mm
1.5 m
Pipe diameter > 25 mm 2.0 m
Pipe clamps has to be welded either to the main structure or to secondary steel brackets.
Clamps as well as brackets has to be welded with a continuous weld around all four corners when
welded to the main structure. Welding of brackets to secondary structures may be intermittent.
Location and type of brackets are subject for approval by VAMH in any case prior to fixing.
3.13.4.4.2.6 Pipe Painting and Colour Code
Field priming, painting and piping service colours shall be in accordance with Clients Standard
code.
3.13.4.4.2.7 Inspection of welding
CHEC may inspect the welding of all piping to the extent deemed necessary to establish the
quality of welds.
The number of welds to be radiographed shall be decided by CHEC but will be a
minimum of 10% of all welds.

3.13.4.4.3Chemical Cleaning of Carbon Steel Pipe
3.13.4.4.3.1 General
All fuel oil, lube oil, hydraulic oil and kerosene piping shall be chemically cleaned.
3.13.4.4.3.2 Pre-Cleaning Preparation
Install high point vents, low point drains and blind end bleed-off connections.
Remove or isolate from the system to be cleaned, all parts constructed from materials which
are subject to corrosion attack by the cleaning medium. Materials to be removed will depend
on the cleaning chemicals used. Extreme care shall be exercised to prevent the entry of any
cleaning chemical or vapours into any part of the machinery.
Remove all control valves, pressure gauges, filters, flow orifices, transmitters, or other
instruments that may be damaged by the cleaning procedure.
56
Install temporary piping as required, to control flow through the system, and hydrostatically
test joints for leaks at sufficient pressure to ensure tightness during cleaning.
3.13.4.4.4 Cleaning and Flushing Procedures
Subsequent to fabrication and prior to flushing, all pipework and fittings shall be dismantled
and mechanically cleaned (i.e. weld spatter and slag removed).
The pipes shall then be pickled by immersion in an acid solution, followed by a degreasing in
trichlorethylene.
After pickling, the pipes shall be rinsed in cold water, then immersed in a neutralising solution
mixed with water (potassium dichromate at a concentration of 50g/100 litres of bath solution).
The pipework shall then be dried , sealed and sent to site for installation, followed by
hydrostatic testing and flushing.
Flushing shall be carried out using a flushing fluid compatible with the final working fluid,
heated to a temperature of 60 C and circulated at twice the normal flow rate for a minimum of
12 hours.
The system pumps, and valve blocks shall be bypassed during flushing.
The flushing system shall incorporate its own filtration system with a filter element mesh size
of 30 m.
Filter elements shall be inspected and cleaned or replaced at 30 minute intervals.
Flushing shall continue until two separate samples taken 30 minutes apart show that the
flushing fluid contamination levels are below ISO DIS 4406 18/15 or the system component
manufacturer's recommendation, which ever is the more stringent.
Confirmation of the cleanliness level shall be provided by independent laboratory test prior to
disassembly of the flushing equipment.
3.13.4.4.5 Cleanliness-Guarantee
Erection Contractor shall give written guarantee of the effectiveness of removal of mill scale and
other oxides, together with statement of maximum amount of base metal which will be removed
during the cleaning operations.
3.13.5
LUBRICATION SYSTEM
3.13.5.1 General
Automatic lubrication systems has to be installed on the machine. For the installation refer to the
applicable schematic and piping drawings.
57
Lubrication units
The lubrication units will be delivered as complete shop assembled and shop tested units. The
installation work on site therefore is reduced to lifting of the to the designated locations and
bolting down to the supporting structure.
Further checks and starting of the unit are part of pre-commissioning and commissioning. Refer
to the relevant manuals as well as to the maintenance manual for further information.
PIPING
The general routing of the lubrication lines has to be according to the relevant drawing. The
detailed routing has to be measured and fabricated according to the actual situation on the
machine in close conjunction with hydraulic, water and electric installation to avoid any
interference between all pipes, cable trays, conduits and other installed equipment.
Hoses has to be provided at all points of movement and at the line connections to the lubrication
units. Hoses piping and fittings as per the specification.
For further instructions for field piping installation refer.
3.13.5.2 LUBRICATION SCHEDULE
Time of Use
Pitching
Drive
Gear Box
List of Oil (Grease) Used by the Shipunloader

Recommended
Quantity of
Type of Oil
Oil (Grease) Replenishing
Replacement Cycle
(Grease)
Added
Time
According to
Product Operation
Instructions
Four-Drum
Drive Gear Box
N220(ISOVG220)
Traveling
Mechanism
Gear Box
According to
Product Operation
Instructions
Rolling Bearing
Sliding Bearing
Lithium-base
Grease
Centralized
Lubrication
Lithium-base
Grease
To the Oil
Line
Take the
Circumstance
into
Consideration
To the Oil
Line
To the Oil
Line
Initial
Phase:
Month
Take the
Circumstance
into
Consideration
Initial
Phase:
Month
Afterwards:
6 Months
Take the
Circumstance
into
Consideration
Initial
Phase:
Month
Afterwards:
6 Months
Daily
58
Afterwards:
6 Months
Motor Bearing
Lithium-base
Grease
Annually or
During Major
Overhaul
Rail
Clamper
Hydraulic
Device
46# Anti-wear
Hydraulic oil
Oil Line
Take the
Circumstance
into
Consideration
Initial
Phase: 1
Month
Afterwards:
6 Months
Oil Line
Take the
Circumstance
into
Consideration
Initial
Phase: 3
Months
Afterwards:
12 Months
Hydraulic
System
According to
Product Operation
Instructions
Note: a. 46# anti-wear hydraulic oil shall meet the requirements of GB2512-81
b. Extreme-pressure lithium-base grease shall meet the requirements of SYB/408-59
3.13.6
REQUIRED TORQUES FOR BOLTED CONNECTIONS
Unless otherwise instructed by CHEC or indicated at the drawings, all bolt connections has to be
torqued up to the values given in 3.11.2.
The erection contractor has to make tests of the high strength bolts connection according to
Chinese regulations.
3.13.7 INSPECTION AND TESTING
Inspection and testing of the installed equipment generally is part of pre-commissioning , no load
commissioning and load commissioning.
3.14 The main mechanical, structural components to install the technical requirements
3.14.1 Installation of Traveling Mechanism
3.14.1.1 The precision of rails of installation must meet the requirements of the relevant standards. Prior to
installation, the installation quality of rails of long travel must be inspected strictly. The installation shall only
be carried out after meeting the requirements, with inspection report. The quality requirements are:
i) Every component of the machine shall only be assembled after qualifying inspection.
ii) The slope of rails of the machine shall be less than 1/1000, with the two rail tracks parallel, at equal
height, and straight.
3.14.1.2 Prior to installation, the location and dimension of embedded parts and reserved holes for cable
leading device, anchor block, cable inlet box and car bumper must be verified according to the on-site track
layout.
59
3.14.1.3 Precision of track layout of shipunloader at the installation location

A, A, B, and B are positions of legs. Every position is the center point of the width of the track surface.
:
Tension and corrected value for measuring span:
The Tension Value and Corrected Value Used for Measuring Span
A1 Tension Value and Corrected Value Used for Measuring Span
Tension
Span
Sectional Dimension of Steel Measuring Tape mm

100.25
130.2
150.2
150.25
m
Corrected Value mm
100
0.5
0.5
1.5
1.5
10
11
1.5
14
1.5
60
A.2 The temperature of steel tape and the machine frame must be consistent during measuring. They shall
not be moved by wind, and the steel tape shall naturally sag.
A.3 Reading of the steel tape plus the corrected value shall be the actual span (or length of diagonal line)
of the shipunloader during measurement.
3.14.1.4 Parallelism of Track
a. Position of Inspection
Every position of A, B, A, and B. Draw a straight line from the center point of the track surface width of A
and B and A and B and measure every position.
b. 3mm of deviation is permitted.
3.14.1.5 Diagonal Line Deviation
a. Position of inspection is AB-AB
b. 2mm of deviation is permitted.
3.14.1.6 Parallelism of Railhead
a. Position of inspection includes every position of A, A, B, and B
b. Deviation of 1mm is permitted.
3.14.1.7 Draw the center line of track gauge from the foundation plane and mark the line.
There are 4 sets of bogie of long travel. The water side rail has two sets of 8-wheel bogie. The land
side rail has two sets of 8-wheel bogie. All bogies are all pre-installed in the factory. The driving
components have all undergone no load test run.
The traveling bogies shall be assembled according to drawings, including active wheel groups, driven
wheel groups, spreader beam, ream base, buffer, rail sweeper, and grounding device.
The traveling bogies shall be firmly stationed and supported after they are put in position and then
undergo inspection according to technical requirements.
3.14.1.2 Wheel Iso-Positioning Difference
The center of the rolling circle of all wheels on the same side of track shall be on the same plane
(same position), with the deviation meeting the requirements of Table 3 and Figure 1 (inspection on the
reference end surface of wheel is permitted)
Table 3
Measuring Position
Deviation
1mm
The two wheels of the same bogie frame
3mm
More than three wheels under one leg
61
All wheels under same frame on the same side of rail
5mm
Figure 1
3.14.1.3 Vertical Deviation of Wheels

The vertical deviation value ay (See Figure 2of wheels cannot exceed 1/400 of the measured length L,
and the deviation direction of a set of wheels on the same axis has to be in the opposite direction. The top
of the wheels shall deviate to the outside of the rail.
Figure 2
3.14.1.4 Horizontal Deviation of Wheels
The horizontal deviation value ax (See Figure 3of wheels cannot exceed 1/1000 of the measured
length L, and the deviation direction of a set of wheels on the same axis has to be in the opposite direction.
62
Figure 3
3.14.1.5 Precision of Spreader Beam Installation
The precision of spreader beam installation shall meet the requirements of Figure 4 and Table 4.
Table 4
mm
Inspection Items
A-B
Measuring Method
C-D
Wheelbase
A-C B-D
Span
Use steel tape for measurement

Use steel tape, optical level, and plumb
Deviation
5
bob for measurement
A-D B-C
Diagonal Difference (Difference of A-D
and B-C)
Use steel tape for measurement
Horizontal Difference (Height
Use steel tape, optical level, and plumb
Difference of Main Hinge Shaft)
bob for measurement
15
Inspection on the height of main hinge base is carried out. When low deviation of the main hinge base
exceeds the permitted value stated in the table, base plate is used to adjust the height
63
Figure 4
3.14.2 Installation of Steel Structure
3.14.2.1 Prior to installation, the factory-made steel structures shall undergo repetition measurement in
accordance with the requirements of Table 5, Table 6, and Table 7. The on-site assembly of steel structures
shall be carried out in accordance with the factory labeling, and the permitted deviation shall meet the
requirements of Table 5, Table 6, and Table 7.
Permitted Deviation of Door Frame and Upper Frame
Table 5
mm
Item
Description
Permitted Deviation
L/1000
Exterior dimension of structure
B/2000
Basal Distance of land and sea side door frame
8
Left and right side door frame span
D1-D2
Two geometric axis diagonal difference
10
Warping degree of door frame or upper frame
plane
64
Meeting the requirements stated in Table

6
3.3.1 of JTJ280-2002 Port Equipment
Axiality of pin hole
Note:
Installation Technical Rules
L is the measured length, and B is the basal distance with mm as unit;

See Figure 5 Door Frame and Upper Frame Assembly Schematic Diagram for assembling of
door frame and upper frame.
Left and right side door frame
Figure 5
Land and sea side door frame
Door Frame and Upper Frame Assembly Schematic Diagram
B-Basal Distance; S-Span; H-Height; D1 and D2-Diagnoal Length

Permitted Deviation of Main Girder and Cantilever Girder
Table 6
mm
Item
Description
Permitted Deviation
8
Horizontal distance of center of supporting point of
main girder
8
Vertical distance of center of supporting point of main
girder
65
10
Supporting point diagonal difference
Meeting the requirements stated in
Axiality of Pitching axis main pin hole
Table 3.3.1 of JTJ280-2002 Port

Equipment Installation Technical Rules
h/2000
Verticality of upper structure of door frame
3
Track gauge of trolley
Height Difference of same
Track
sectional rail surface
gauge
Rail straightness
2.5m
3.0
2.5m
5.0
Every 2m
=<1.0
Every 10m
=<2.5
Position difference between center line of trolley rail
and center line of bearing rail beam web plate

Note: h is the upper structural height of door frame, with mm as unit.
Permitted Deviation of Diagonal Brace and Tension Bar
Table 7
mm
Item
Description
Permitted Deviation
6
Axial Length
3.14.2.2 The permitted deviation of installation of leg, door frame, upper frame, main girder, and cantilever
girder shall meet the requirements of Table 8, Table 9, and Table 10.
Permitted Deviation of Installation of Leg and Door Frame
Table 8
mm
Item
Description
Permitted Deviation
1
Verticality
H/1000 and 20
8
Span
8
Basal Distance
66
8
Diagonal Difference of Leg
Note: H is height of leg or door frame with mm as unit.
Permitted Deviation of Installation of Upper Frame
Table 9
mm
Item
Description
Permitted Deviation
h/2000
Verticality
Note: h is the height of upper frame with mm as unit
Permitted Deviation of Installation of Main Girder and Cantilever Girder
Table 10
mm
Item
1
2
Description
Permitted Deviation
+0.3F
Camber on Main Girder
-0.1F
+0.3F0
Warping of Cantilever
-0.3F0
L1/2000
Side-Deflection of Main Girder
L2/2000
Side-Deflection of Cantilever Girder
Note: F will be the camber of design of main girder. F0 is the design warping of cantilever girder. L1 is
the length of main girder. L2 is the length of cantilever girder. All units are mm.
3.14.2.3 For the joining of main girder and cantilever girder, the installation of the hinge joining buffering
device shall meet the design requirements. The height difference of the rail girder face plate at two sides of
rail installation location shall be less than 0.5mm.
3.14.2.4 The laying and welding of rails of trolley shall comply with the requirements of the drawings and
Rail Welding General Technique.
3.14.2.5 The diagonal brace and tension bar shall meet the design requirements. The direction of upper
and lower wing plates shall not be reversely installed.
3.14.3 Installation of Main Trolley and Cantenary Trolley
67
3.14.3.1 The tolerance limit of wheel span of trolley shall not exceed 2mm.
3.14.3.2 Degree of Vertical Deviation of Trolley Wheels
The vertical deviation value ay of wheels (see Figure 6) shall not be greater than 1/1000 of the
measured length L and shall deviate in the opposite direction for the same set of wheels on the same axis.
The upper part of the wheel shall deviate to the outside of the rail.
Figure 6
3.14.3.3 Horizontal Deviation of Wheels
The horizontal deviation value ax (see Figure 7) shall not be greater than 1/1000 of the measured
length L and shall deviate in the opposite direction for the same set of wheels on the same axis.
Figure 7
68
3.14.3.4 The wheels of trolley shall all come in contact with the rail.
3.14.3.5 After the trolley is positioned on-site, make sure that the horizontal wheels are adjusted. The gap
between the horizontal wheel and the rail is 2.5mm at the narrowest place of the rail center distance.
3.14.4 Installation of Hoisting and Opening/Closing Mechanism
3.14.4.1 Installation of the hoisting and opening/closing mechanism shall meet the design requirements.
Positioning shall be carried out in accordance to the positioning label of assembling in factory.
3.14.4.2 The permitted deviation of drum Installation (Figure 8) shall meet the requirements of Table 11.
Figure 8
Table:11
item
permitted deviation (mm)
Center line
3.0
D E
2.5
3.14.5 Installation of Trolley Traveling Mechanism

3.14.5.1 Installation of trolley traveling mechanism shall meet the design requirements. The positioning
shall be carried out in accordance with the positioning label of assembling in factory.
3.14.5.2 Installation of drum of trolley travelling mechanism shall meet the relevant terms stipulated under
3.14.5.3 Installation of trolley rope tension device shall meet the design requirements.
3.14.5.4 Installation of rope tray shall meet the design requirements
3.14.6 Installation of Pitching Mechanism
3.14.6.1 Installation of pitching mechanism shall meet the design requirements and shall be carried out in
69
accordance with the positioning label of assembling in factory.

3.14.6.2 Installation of pitching mechanism drum shall meet the relevant requirements of Article 3.14.4.2.
3.14.6.3 Installation of safety hook shall be carried out under non-working state. The support of safety hook
and support of stick pusher shall be fixed after proper positioning of the safety hook.
3.14.6.4 The rope of the machine room shall not collide against the rim of channel after tension. The
vertical center line of support base of the machine room shall overlap with the vertical center line of jib. The
permitted deviation is 8mm.
3.14.7 Installation of hopper device shall meet the following requirements.
3.14.7.1 The bolts of hopper base plate shall be tightened, and the hopper shall open and close agilely.
3.14.7.2 Installation of force sensor of hopper weighing device shall meet the requirements of design and
equipment technical documents.
3.14.7.3 The permitted deviation for installation of hopper shall meet the requirements of Table 12.
Permitted Deviation for Installation of Hopper
Table 12
mm
Item
Description
Permitted Deviation
5
Deviation from center line of hopper to center line of rail
5
Deviation from center line of hopper to center line of door frame
2
Relative height difference of support surface
10
Diagonal difference of support
10
5
The deviation between the center line of mobile hopper and the
theoretical center line
3.14.8 The permitted deviation for installation of lift inside the machine shall meet the requirements of Table
13.
Permitted Deviation for Installation of Lift inside the Machine
Table 13
mm
Item
Description
Deviation
2
Gap between the Inner Side of the two Guide Rails
Entire Length
Every 5m
Guide Rail Verticality
L/2000 and 10
70
H/1000 and 20
Pylon Verticality
Entire Length
Every 5m
Rack Verticality
Note: L is the length of guide rail. H is the measuring length of pylon. All units are mm.
3.14.9 Installation of belt conveyor of the machine shall meet the relevant requirements of Section 5.10 of
JTJ280-2002 Port Equipment Installation Technical Rules.
3.14.10 After cable drum is installed, cable shall move freely, and cable jamming is prohibited.
The permitted deviation for installation shall meet the requirements of Table 14.
Permitted Deviation for Installation of Cable Device
Table 14
mm
Item
Description
Permitted Deviation
1
Parallelism between cable drum and rail
2.5
.
3.14.11 Installation of cable chock shall be aligned with position of cable drum, and the rollers on cable
chock shall be able to rotate freely and agilely.
3.14.12 The permitted deviation for installation of repair carriage shall meet the requirements of drawings
and Table 15.
Permitted Deviation of Installation of Repair Carriage
Table 15
mm
Item
Description
Permitted Deviation
5
Track gauge
5
Height difference of same sectional rail surface
5
Rail straightness
Full length
3~5
The gape between inner side of wheel edge and the flange of I rail
3.14.13 Pulley Block

3.14.13.1 The permitted deviation of center line of every pulley block to its theoretical center line position is
5mm.
71
3.14.14 Drivers Cab

Drivers cab is hanging under the jib on one side of rail. Its installation shall meet the dimension
requirements of the drawings.
3.15.15 Towing of Drivers Cab
The rope trolley of drivers cab is installed on the traveling rail of drivers cab, which is pulled by the drivers
cab. The gap between the wheel edge of rope trolley and rail shall be adjusted by spacer.
3.14.16 Hydraulic, Lubrication, and Dust Suppression Installation
3.14.16.1 Installation of hydraulic, lubrication and dust suppression shall meet the requirements of their
respective drawings and installation instruction documents.
3.14.16.2 Prior to installation, pipeline must undergo acid wash or other rust-proof cleaning treatment,
making the internal pipe to show shinny metallic luster (including acid wash, cleaning, and rust-proof
treatment after the on-site heated construction).
3.14.16.3 Prior to installation of centralized lubrication, the base plate and the pipe clip shall be welded first,
and then the lubrication fitting and pipeline are installed.
3.14.16.4 When installing breaks, protective plugs shall be used to block the openings of pipeline to
prevent entry of debris.
3.14.16.5 During commissioning of centralized lubrication, all oil inlet connectors of distributor or terminal
plugs of distributor must be opened. The pipeline shall be flushed with thin oil, and it is fully filled with
grease to eliminate air in the pipeline. The pipeline is then connected accordingly.
3.14.16.6 Various automatic control instruments shall undergo verification, adjustment and calibration prior
to installation.
3.14.16.7 Component must be washed prior to installation with pressure and seal testing. No contamination,
deformity, or leakage shall be present.
3.14.16.8 The joining between pump (or motor) and its prime mover (or working unit) must have sufficient
rigidity to assure that centering is sufficient during operation.
3.14.16.9 Sealed parts or sealed components shall be easily replaced.
3.14.16.10 Installation of valve pieces must avoid heavy force, impact, and shaking, which may affect the
main components of valve.
3.14.16.11 The action direction of operating handle and the action direction of mechanism shall be
coordinated.
3.14.16.12 Curving of pipe shall meet the requirements of Figure 9, Table 16, and Table 17.
Table 16
72
(R)
Curving
16
Radius of
20
25
30
40
50
60
80
10
12
16
20
25
30
40
50
60
Steel Pipe
(R) Series
2
Deviation
10
15
Table 17
Minimum Curving
External
Diameter of
Radius R min
Steel Pipe
620
4d
2035
5d
3560
60114
Lmin
Lomin
of Pipe
3d
4d
5d
Roundness of Curving
70
3d
15
1.0
20
1.5
30
2.0
45
3.5
Note:
(1) After calculating curving radius R min according to Table 17, choose the nearest radius dimension
R (after rounding off) according to Table 16, with as the wall thickness of steel pipe.
(2) Lmin refers to the minimum length of steel pipe that is required to bend into the necessary
minimum radius.
(3) Lomin refers to the possible thread grinding condition.
Figure 9
73
3.14.16.13 Pipes must be firmly fixed and nicely arranged. The distance between supports of pipe shall be
carried out in accordance with Table 18.
3.14.16.14 Lubricant pipeline shall be free of obstruction. Lubricant must be filtered first before adding it to
the oil tank.
Table 18
mm
External Diameter of
10
1025
2550
50
1.5
2.0
2.5
Pipe
m
Distance between
0.9
1.0
Supports of Pipe
3.14.17 Joining of ladder, walkway, and handrails of the entire unit.
3.14.18 Installation of other parts, such as anchor device and rail clamper.
3.14.19 Installation of Electrical Equipment
3.14.19.1 Electrical Equipment Installation Notes
a. Installation of electrical equipment shall be carried out by skilled electricians under guidance of
engineer.
b. Installation location, fixation method, and cable run and fixation of electrical equipment shall be
carried out in accordance with the electrical installation technical documents accompanied with the
machine.
c. Prior to installation, construction personnel must thoroughly familiarize the technical documents,
understanding electrical principles and effects and the mutual relation principle of electrical components.
3.14.19.2 Fixation of Electrical Equipment
In addition to the operator console and control cabinet, other control cabinets, local operation cabinets,
and travel switches shall be positioned and fixed on-site.
Electric cabinets are generally fixed with bolts, but the electric cabinets inside the electrical room shall
be welded to a fixed base.
The verticality of all positioned electric cabinets shall be 1/300 of their respective heights.
Travel switches are fixed with bolts, but their positions shall be determined after adjustments.
3.14.19.3 Cable Layout
The cable of this machine uses the following laying method: cable tray, steel hose, and plastic flexible
hose. Cables shall not be exposed openly.
The curved radius of cable shall not be less than five folds of the diameter of cable
Generally, cables shall not be joined in the middle. If joining exists, sealed junction box must be
74
present.
All cable terminals shall have routing sign, with the programming matching the design drawings.
3.14.19.4 Wiring
Wiring is carried out according to electric schematic diagram and electric diagram
Copper pig tail with hook treatment shall be used at the wiring end of cable.
The bolts, nuts, and washers used in wiring shall all be copper-made. When they are made of steel,
bolts, nuts, and washers must be galvanized.
3.14.19.5 Grounding
The steel structure of the entire machine is used as grounding conductor, connecting to the grounding
wire of the cables of the machine, which forms the grounding system.
3.14.19.6 Voltage Endurance
a. Voltage endurance testing shall be carried out for rectifier devices, such as single slide wire,
conductor, and slip-ring current collector.
b. The switch cabinet shall be able to withstand the voltage endurance testing with the data listed in
Table 19. Neither electric breakdown nor flashover shall occur with 1 min of testing time;
Table 19
Rated Voltage
Testing Voltage
kV
10
24
32
42
c. High voltage cable shall undergo water immersion voltage endurance inspection. Neither electric
breakdown nor flashover shall be present under 6h of water immersion with voltage endurance (testing
voltage) of 15 kV for 5 min;
d. Voltage endurance testing for transformer shall meet the requirements of Table 20.
Table 20
kV
Insulated 1min Testing
Rated Voltage
Maximal Working Voltage
3.5
10
6.9
16
10
11.5
24
3.14.19.7 Insulation
75
Voltage
3.14.19.7.1 Low Voltage Insulation

a. Under the cold state with the surrounding medium temperature of 205 and air relative humidity
of 50~70%, the insulation resistance of circuit to ground shall not be less than 10 M(use 500Vmegameter
for measurement);
b. Under the heated working temperature state with the surrounding medium temperature of 205
and air relative humidity of 50~70%, the insulation resistance from the electric conductive part of the switch
to the button shall not be less than 5M.
c. Voltage endurance testing shall be carried out in a constant temperature and humidity environment
with surrounding medium temperature of 205 and air relative humidity of (953)%. The insulation resistance
shall not be less than 0.5Mafter 72h.
3.14.19.7.2 High Voltage Insulation
In pursuance to the clearance requirement, the distance of high voltage electronics, such as between
primary circuit charged bodies and between charged body and structural frame, shall meet the requirement
of Table 21.
Table 21
Position
kV
Between different phases of conductors and
10
75
90
100
105
130
155
175
200
225
live parts and grounding frame

Between live parts and metal plates or
mm
transmission pieces
Between live parts and metal valves or/and
metal net
3.14.19.8 Installation of Illumination and Beacons
a. Appropriate illumination shall be installed in places, such as machine room, walkways, and
operation positions.
b. The power voltage of fixed illumination devices shall be 220V. Use of metal structure as circuit of
illumination wiring is prohibited;
c. The power voltage of portable illumination devices (safety lamp) shall not exceed 24V and shall use
isolation transformer. Use of auto-transformer for direct power supply is prohibited. Safety lamp shall come
with protective support, 10 m of flexible cable, and plug (2P+b).
d. Illumination devices in outdoor or humid environment (such as mercury lamp or spotlight) shall be
tightly sealed and able to sustain shaking.
3.14.20 Installation of Cable Drum
The precision of installation of cable drum shall meet the requirements of Figure 17 and Table 4.
76
Table 4 Unit: mm
Inspection Item
Measuring Method
Parallelism between drum

and rail
Use plumb bob and steel tape to

measure distance of every point of
A ~ H to rail
Deviation
5
Figure 17
3.15 REPORTING
During the whole process of erection and installation the mechanical and electrical installation
contractors are responsible to keep records about all activities during their work on site. Where
test or record sheets are provided by CHEC, the contractors has to use the issued forms.
Following reporting as a minimum is required:
Daily reports
Weekly progress reports
Torque reports for high strength bolt connections
Welding repords for field welding
Welding test records as specified in the manual
3.16 Brackets for different applications
For brackets of field devices refer to the applicable drawings.
General brackets, type and welding to the structure for piping, cable trays and the like.
The different types of pre-fabricated brackets have to be chosen during installation according to the
requirements of the application.
77
3.17 SPECIAL TOOLS for erection / installation and maintenance/

noets: Special tools are not included to delivery. Erection companies provide for
oneself. CHEC does not provide.
Heavy Machine Equipment

300 ton pedrail crane
quantity 1
500 ton sea float crane
quantity 1
100 ton camion crane
quantity 1
150 ton camion crane
quantity 1
Hydraulic bolt tensioner system, containing:

3 pcs. hydraulic bolt tensioner for bolt size M30
2 pcs. high pressure hand pumps with pressure gauge
6 pcs. high pressure hoses, each 8 m long with quick coupling connector
2 pcs high pressure coupling distributor ( 3-way )
Hydraulic jack system ( for slew bearing removal ), containing:

3 pcs. 200 tons hydraulic maintenace cylinder
3 pcs. high pressure hoses, each 8 m long with quick coupling connector
1 pc. High pressure electric pump aggregat with pressure gauge
1 pc. High pressure coupling distributor ( 3 way )
Hydraulic testing set, containing:

1 set different rated pressure gauges
1 set check hoses for testing objectives
78
Hydraulic flushing set, containing:

1 pcs pump
1 set filters, connectors and hoses
Lubrication cleaning and
flushing set, containing:
1 pcs pump
1 set filters, connectors and hoses
1 set air compressor
Electric testing set, containing:
1 pc. Amperemeter
1 pc. ohmmeter
1 set minor electrical tools
Torque wrench, containing:

3 pcs. torque adjustable torque wrenches
3 sets sockets of different sizes up to M30
Hydraulic pipe bender

2 sets hydraulic pipe bender, suitable for different pipe sizes up to an outside
diameter of 38 mm.
Terminal punch
two sets of hydraulic terminal punch ( crimp type ) for hose fittings
Optic cable connector
1 pc. Cable connector for the fibre optic cable complete set
3.18
PROPOSAL OF GENERAL TOOLS & FITTINS LIST

79
noets: Special tools are not included to delivery.Erection companies provide for
oneselfCHEC doest provide
Special tools
1
Hydraulic draw up and puller
4
Extractor 2-arm, 3-arm (medium and large construction)
Measuring instruments and marking tools:
2
2
2
2
6
20
5
2
2
4
2
4
3
3
2
2
2
2
5
2
5
5
2
1
1
leveling instlrument with stand

machine water balance (prismatic water balance)
frame water balance
strightedge of steel 1 m, 1.5 m and 2 m
water balance 0.5 m with magnetic base
measuring taps 3 m
measuring taps 30 m
dial gauge with magnetic-stand
knife-edge-strightedge 200 lg, 300 lg
sliding caliper 250 lg each
depth gauge 300 lg
thickness gauge (2 short, 2 long)
front lay gauge 150, 250, 400 lg each
solid steel squares 250 lg
Goniometer 150 lg, 300 lg
adjustable square 150 lg, 300 lg
outside calipers medium, large
inside calipers medium, large
plumb bob
2 divider
center punch
gauge point
miter square 300 lg 45 grad
measuring-gauges for hydraulics
straightedge for machine 3 m
Lifting and presure tools :

4+4
chain-lift-pull 1.5 to 3 to each
5
gripp pulls 1.5 to and 3 to each
6
rope-ratchet-pull (Lug-All) 1.7 to --5 p. rest 0.75 to each
4 +4
hydraulic lever 10 to, 20 to, wkth pumps each
3+3
stick winch 2 to, 5 to each
4
stick winch 10 to
4
stick winch 20 to
Expedient for lifting applicance :
1 +1
pulley 3to 2- and 3-rollig
4+4+4+4
shackle 2 to, 5 to, 12 to 25 to each
4+4
perlon-rope 3 to, 5 to each 4 m
4+4+4+4
steel rope 1 to, 2, 3 and 8 to each; rope-metal-clip 3/4", 1/2", 5/8", 3/8", 3/16"; anchor-rope
a 25 m
1+1
chains 2-strang, 4-strang (5 to/10 to)
4
steel rope 20 o a 8 and 10 m long
Welding-tools :
8
e-welding-machine 380 V
2
e-welding-transformer 220 V
80
Acetylene-cutting-and welding tools :

4
pressure-regulating for gas and oxygen each
4
hose for gas and oxygen a 25 m + champs each
2
heating torch
5
cutting torch (div. sizes)
2
propane-gas.torch with armature and tube a 10 m + champs
Welding fittings :
20
welding cable a 25 m lg, impregnated cable a 25 m lg, electrode holders with 3 m cable
each
8
electrode holders
8
welding couplings
4
oxygen- and acetyle nspanner
5
sets of jet drills
20
nozzels for cutting torches (dif. size)
2
eelctrode hearth furnace
Tools - Machine :
6
electric grinding machine
2
electric drilling machine with magnetic base
4
handdrilling machine
4
handoperated driling machine
8
electric grinding machine small size
1
impact wrench 1/2", 3/4",1" each
1
sockets for impact wrench 1/2", 3/3", 1" W 24--46 each
Hand Tools :
4
3
2
5
5
3
3
3
10
4
10
3
2
4
4
4
2
2
3
3
3
1 set
4 sets
4 sets
4 sets
4 sets
1 set
4 sets
4 sets
2
2
2
1
3
hammer 0.5 kg 1 kg each

hammer 1.5 kg
hammer 10 kg
chisel
cross chisel
hand saw (metall)
plastic hammer with spare
cu-hammer with spare
mandrels
crow bars big
crow bars small
pipe pliers 1"
pipe pliers 2", 3" each
tongs for water pumps
cutting pliers
combinations pliers
longnose plies medium, big
seegerring pliers medium, big, crankeg inside and outside each
wood clamps 300 lg, 500 lg, 1000 lg
half clamps
oilcan
letter stamps 5 mm
ring-spanner SW 8 - 24 each
ring-spanner SW 27 - 50 each
open-spanner 8 - 24 each
open-spanner 27 - 50 each
ringhammer ringspanner SW 36 - 50
wrench for socket head cap screws SW 4 - 21 each
gedorre set (socketwrench) 1/2", 3/4" for size 10 - 32 and 22 - 55 each
drill sleeve
boring head shank
hydr. ring-sapnner SW 17 - 36 each
reamer 0 8 - 27
drill w. conus 0 2 - 13 (zyl.), 0 13.4 - 21 each
81
2
4 sets
2 sets
1
1
2
2
2
1set
drills 0 22 - 31each
threading die and threading drill M 6 - M 12
threading die and threading drill M 16 - M 24
file smooth-cut file rough file
scraper
pipe cutter for pipe 8 mm 0 - 16 mm 0
tergre wrench 100 Nm with sockets for SW 24, 30, 36
bending machine for pipes 6 0 - 16 0 mm
warting file
Makeshift Tools :
30
wood beam 4 m lg
4
ladde 3 m and 6 m
4
box opener big and small each
1
blade cutting
5
wooden box (wood or blade) medium size
5
wooden box (wood or blade) small size
2
plateform truck for 250 kg
2
distribution box for 5 welding machiens and 10 grinding machines
10
halogenlamps and handlamps each
5
workbench with vise
2
tool container
2
material container or field office
8
extension wire 380 V a 25 m
20
extension wire 220 V a 25 m
2
canras hood 6 x 8 m
1 band
rope 0 14 ca. 200 lfm
100 lfm
steel wire 0.5 mm - 1 mm
3
pail 10 l
10
brush dif. size each
Safety device :
150
(safety belts)
( safety lases with bright and dark)
( safety helm for all fitters)
( waterproof clothing dif. Size)
( gloves short)
( welding gloves long)
( safety coats for welder)
( welding helmet)
( first aid out fit)
( hand barrow)
Expendable - stock :
0.5 kg
chalk
10
steel brush
10
igniter for gas
4 kg
rustproofing groase
5 kg
gease
10 kg
oil
30
abrasive paper or cloth dif. grain
4 rolls
cleaning paper
40 kg
cleaning rag
50 l
solvent benzol
100 pcs.
grinding disk, cutting disk 0 178, 50 0 125 each
15
spareplate for handsaw
100 lfm
plumb bob
20
wood and metall wedge gib dif. size each
5
cu-mandrels 0 30, 200 lg, grinding stone for handdrilling machine
10 pcs.
anti-corrosive spray
82
Emergency Material :
rolling wheel products:
100 lfm
structural steel 50 x 50 x 5
50 lfm
structural steel 70 x 70 x 7
100 lfm
structural steel U 100
50 lfm
structural steel U 120
3 lfm
pipe 1/2", 3/4", 1", 2", 3" each
30 pcs.
steel plates 0.2 mm, 0.5 mm, 1 mm, 2 mm strong, 100 x 150 each
welding materials:
4 cartons
welding electrode 2.5 0
20 cartons
welding electrode 3.25 0
4 cartons
welding electrode 4 0
+ oxyeen-, acetylen- and propangas
+ NO2
Electrical Tools:
2
Chrimbing tools (0,5mm until 16mm)
1
handdrilling machine
1
hammer small
1
hand saw
10
saw plates
5
Screw driver (5 different sizes)
2
side cutter (2 different sizes)
3
long nose pliers (3 different sizes)
1
adjustable wrench (0 - M20)
1
spanner set (M2 until M36)
1
gedorre set (M2 until M36)
1
combination pliers set (2 different sizes)
2
measuring tapes
1
soldering tool
1
water pipe plier
1
hand lamp
1
insulation tape set
2
knifes
4.
Painting Instruction
4.1 Painting
4.1.1 Scope of Application
4.1.1.1 This Standard has stipulated the general technical conditions for rust removal and painting of metal
structure surfaces of CHEC. In the event that the owner has special need, then the relevant contract and
the technical agreement shall be executed.
4.1.1.2 This Standard is applicable to the painting of steel structure surface for products without special
coating needs, such as stacker, reclaimer, and shipunloader. The length of anti-corrosion of the coating is 3
to 5 years.
4.1.2 Referenced Standards
4.1.2.1 GT/T3181-1995 Color Standard for Paint Film
4.1.2.2 GB/T8923-88 Rust and corrosion class and class of rust removal of steel structure surface prior to
painting
4.1.3 Technical Requirements
4.1.3.1 Pre-treatment prior to coating: the surface of forging, casting, and welding structures shall be
smooth, and riser and runner, joint flash, fins, and veining shall be removed.
83
4.1.3.2 Surface treatment prior to coating: Rust removal class shall be Sa2.5 class. Sa2.5 is rust removal
with very thorough injection or casting. The surface of steel structures shall have no adhesives, such as
visible grease, dirt, iron scale, rust, spatter, and painting coat. Any trace of residues shall only be spotted or
lined slight pigmentation.
4.1.3.3 Parts such as metal structures and auxiliary structures of shipunloader, stacker, and reclaimer that
can enter shot blasting room shall all undergo shot blasting. In the event that the structural pieces are too
long, two rounds of shot blasting shall be carried out to assure the quality of rust removal. The diameter of
projectiles shall not exceed 1.2mm. To enhance the effect of rust removal, appropriate amount of steel wire
sections can be added. Compressed air shall be used to blow clean the surface of structure pieces after
shot blasting treatment.
4.1.3.4 Steel Plate Pre-Treatment: The metal structure pieces, including gantry, rotating platform, and jib of
stacker and reclaimer and the girder and gantry of shipunloader, shall all undergo steel plate pre-treatment.
In the Summary Table of Techniques and Materials and Accessories, the pre-treatment paint is 704
inorganic zinc silicate workshop primer with dry film thickness of 20m. The outdoor anti-corrosive period is
3 months. Therefore the pre-treatment of plates must be completed within 3 months, and the pre-treatment
is ineffective after expiration.
4.1.3.5 Selection of paint: See Table 1~3 Paint Selection Table.
4.1.3.6. In case that the paint manufacturer has special requirements, the standard of the paint
manufacturer shall be executed.
1
Table 1 Selection of Surface Paint for Steel Structures of Stacker/Reclaimer and Shipunloader
Construction Steps and Paint Brand
Number and Name
Pretreatment
Sa2.5
704
Surface treatment: Class
of rust removal quality is
Sa2.5
Workshop primer: 704
Color
Gray
(m)
Dry
Film
Thickness
Thinner
20
106
Recoating
Time
Interval
High
Airless
Rules
Pressure
Spraying
Size of
Nozzle
Output
Pressure
Remark
Pretreatment
and
inspection
shall
be
carried out.
Next
step
shall only be
proceeded
with
after
qualification.
Sa2.57028
Surface treatment: No matter whether pre-treatment has been carried out, the surface of pieces must undergo surface
treatment, allowing them to reach or re-achieve Sa2.5 standard. Then proceed to first coat of primer (702 epoxy
zinc-rich) procedure with interval time < 8 hours
702
40
103
> 8 hours
First Time
702
Gray
0.0190 100
Recoating
epoxy
interval: no
.023 kg/c
Undercoat
zinc-rich
limitation
primer
84
Second
Time
Third
Time
Intermediate
Coat
Finish Coat
(On site)
702
702
epoxy
zinc-rich
primer
842
842
epoxy
mica
iron
primer
Polyurethane
finish
coat
Yellow
Gray
According
to the
need of
user
40
103
> 8 hours
80
103
24~48
hours
50
101
0.0190
.023
150
kg/c
0.017
150
kg/c
75
If it exceeds
7 days, the
sand paper
is used to
rough up the
surface, so
the
finish
coat can be
applied.
The
construction
temperature
cannot
be
lower
than
5
On site painting make-up: the damaged paint film occurring during the transportation and installation process
must be repaired according to the aforementioned procedures. Use cloth to rub other surfaces before
re-painting
101
0.017 150
Polyure- According 30
to the
thane
kg/c
need of
finish
user
coat
Overall thickness of dry paint film: 240m
In case that 842 epoxy mica iron primer uses paint for winter use, then painting can be carried out at 0 and
above. When the relative humidity is greater than 85%, no painting work can be carried out. Shot blasting shall also
be suspended.
Finish Coat
(On site)
1.
2.
3.
Steel structures refer to gantry, rotating platform, jib, column, counterweight frame, girder, tension bar, tail car,
traveling mechanism, slewing mechanism, center hopper, and bucket-wheel.
4.
Only undercoat is applied to the inner surface of sealed steel structure.
Table 2 Selection of Surface Paint for Mechanical Parts and Auxiliary Structures of Stacker/Reclaimer and
Shipunloader
Construction Steps and Paint Brand
Number and Name
Color
(m)
Dry
Film
Thickness
Thinner
Recoating
Time
Interval
High
Airless
Rules
Pressure
Spraying
Size of
Nozzle
Output
Pressure
Remark
Surface treatment: Class of rust removal quality is Sa2.5

The surface shall have no grease and iron scale. The surface of steel plate shall be gray (original color). Then proceed to
first coat of primer (702 epoxy zinc-rich) procedure with interval time < 8 hours
85
First Time
Undercoat
Second
Time
Third
Time
Intermediate
Coat
Finish Coat
(On site)
702
epoxy
zinc-rich
primer
702
epoxy
zinc-rich
primer
842
842
epoxy
mica
iron
primer
Chloride
rubber
Gray
Yellow
Gray
According
to
the
need of
user
30
103
30
103
40
103
30
101
> 8 hours
> 8 hours
0.0190
.023
24~48
hours
100
kg/c
150
kg/c
0.017
150
kg/c
Recoating
interval:
limitation
no
If it exceeds 7
days, the sand
paper is used to
rough up the
surface, so the
finish coat can
be
applied.
The
construction
temperature
cannot be lower
than 5
On site painting make-up: the damaged paint film occurring during the transportation and installation process
must be repaired according to the aforementioned procedures. Use cloth to rub other surfaces clean before
re-painting
Finish Coat
(On site)
Chloride
rubber
According
to
the
need of
user
30
101
0.017
150
kg/c
Note:
1.
2.
In case that 842 epoxy mica iron primer uses paint for winter use, then painting can be carried out at 0 and above
When the relative humidity is greater than 85%, no painting work can be carried out. Shot blasting shall also be
suspended.
3.
Brush painting is permitted for small area, and roller painting is prohibited.
4.
Mechanical parts and auxiliary structures refer to traveling wheel block, belt conveyor, machine room, cable drum unit,
hoister, ladder, walkway, and guard rail.
5.
Alkyd oil resistance paint in various colors is applied to the inner wall of oil tank.
Due to the fact that Sa2.5 rust removal standard is hard to achieve for thin-wall cover with thickness under 2.5mm, epoxy
iron red rust proof paint can be applied as undercoat, and then polyurethane finish paint with the same color as the
machine can be applied. The overall thickness of the dry film is 160m
Table 3 Stacker/Reclaimer and Shipunloader with Inlet and Outlet Box Girder Inner Surface Paint
Selection
Construction Steps and Paint Brand,
Number and Name
Color
(m)
Dry
Film
Thinner
86
Recoating
Time
Interval
High
Airless
Rules
Pressure
Spraying
Remark
Thickness
Size of
Nozzle
Output
Pressure
Surface treatment: Class of rust removal quality is Sa2.5

The surface shall have no grease and iron scale. The surface of steel plate shall be gray (original color). Then proceed t
primer procedure with interval time < 8 hours
702
100
First Time
epoxy
60
103
> 8 hours
kg/c
zinc-rich
Gray
Under Coat
primer
0.0190
.023
Intermediate
Coat
Second
Time
842
epoxy
mica iron
primer
Gray
60
103
2
24~48
hours
150
kg/c
Note:
1.
2.
3.
4.
Brush painting is permitted.

In case that 842 epoxy mica iron primer uses paint for winter use, then painting can be carried out at 0 and above.
When the relative humidity is greater than 85%, no painting work can be carried out. Shot blasting shall also be
suspended.
4.1.3.6 Outer Coating Color
4.1.3.6.1 Selection of outer coating colors uses GB/T3181
4.1.3.6.2 For product drawings without specifying outer coating color, one color of orange, light gray or light
blue can be selected. The Summary Table of Techniques and Accessories has noted that accessories, such
as motor, pump, electrical control cabinets, generator, and gear box, generally maintain their original colors
without re-painting.
4.1.3.6.3 Parts requiring attention shall be painted according to the colors listed in Table 4.
Table 4
Item
1
2
Position
Color
Loading bucket, hook, drum, counterweight iron, wheel, wheel axle, and inner wall of
coal hopper
Black
Foundation base, lower plate, step plate, and walkway
Exposed rotating parts, such as spokes from flywheel, belt wheel, and gear; nozzle,
oil cup, oil plug, and lubricator of lubrication system; handle and switch of risk
prevention device; fire protection facilities; and reading of limit position on the
indicators
Black
or
same color
as
the
machine
Red
4.1.3.6.4 All pipelines shall be color painted. Painting according to the colors listed in Table 5 is
recommended.
Table 5
87
Item
1
2
3
Name of Pipeline
Color
Hydraulic and lubricant pipelines
Red
General water piping
Silver gray or original color of zinc coating
Air conduits
Light blue
Electrical lines
Black or original color of the machine
4.1.3.6.5 Eye-catching safety warning shall be painted on the parts of the machine that are easily collided
when working or moving, which is labeled on the design drawings. For example, the outrigger of mobile
machines, the two ends of loading bridge mobile trolley, lifting hook, pulley support side plate, external
surface of slewing counterweight, spreader beam of traveling mechanism, drive bogie frame, driven bogie
frame, and traveling trolley frame, consisting alternating diagonal yellow and black stripes. The width of
yellow and black stripes is identical, which is generally 100mm120mm (depending on the size of the
machine and the safety location, different widths can be appropriately used). More than two stripes per
color shall be used on smaller surface. The angle of stripes is generally 45 to the horizontal plane. The
direction of yellow and black stripes shall use the center line of the machine as symmetrical axis, forming
symmetrical shape as shown in Figure 11. For some machines if yellow and black stripes are not
eye-catching enough, red and white stripes may be used.
Y=Yellow, B=Black
Figure 11
4.1.3.7 Painting requirements for inner wall of oil tank, drivers cab, interior of machinery house, and
thin-wall of covers:
4.1.3.7.1 Interior of gear box, surface of parts without processing, and interior of mechanical oil tank are
coated with two layers of yellow oil resistance paint (excluding stainless oil tank).
4.1.3.7.2 Interior of drivers cab and machinery house are generally coated with white top and sky blue walls
(coating is not applied to decorating plates)
4.1.3.7.3 Thin-wall pieces, such as covers, that have steel plate with thickness under 2.5mm, cannot
achieve Sa2.5 rust removal standard after rust removal treatment, epoxy iron red rust-proof paint can be
applied as undercoat, and then polyurethane finish paint with the same color as the machine can be
applied.
4.1.3.8 Requirements for coating environment conditions: coating environment has great impact on the
coating quality. To assure the quality of painting, the following requirements regarding coating environment
conditions are introduced:
88
4.1.3.8.1 Coating is generally carried out under the weather conditions of above 5 and relative humidity
below 85%, with clean, dry, and nicely ventilated environment. Coating of polyurethane finish paint can be
carried with temperature above 0 and relative humidity below 75%.
4.1.3.8.2 Double metal surface contact thermometer or contact surface thermometer is used to measure
the temperature of steel plate. Hydrometer is used to measure the relative humidity. Then dew point is
calculated. When the surface temperature of steel plate is close to or below dew point, condensation will
occur, leading to the result of large area of peeling. Therefore, coating must be carried out when the
surface temperature of steel plate is at least 2 above the dew point. Please see Table 6 for calculation of
dew point.
Table 6
Environment
Temperature
Relative
Humidity
95
85
80
75
70
65
60
55
50
45
40
35
30
-5
10
15
20
25
30
35
40
-6.5
-7.2
-7.7
-8.4
-9.2
-10.
-10.8
-11.5
-12.8
-14.3
-15.9
-17.5
-19.9
-1.3
-2.0
-2.8
-3.6
-4.5
-5.4
-6.5
-7.4
-8.4
-9.6
-10.3
-12.1
-14.3
3.5
2.6
1.9
0.9
-0.2
-1.0
-2.1
-3.2
-4.4
-5.7
-7.3
-8.6
-10.2
8.2
7.3
6.5
5.6
4.59
3.3
2.3
1.0
-0.3
-1.5
-3.1
-4.7
-6.9
13.3
12.5
11.5
10.4
9.1
8.0
6.7
5.6
4.1
2.6
0.9
-0.8
-2.9
18.3
17.4
16.5
15.4
14.2
13.0
11.9
10.4
8.6
7.0
5.4
3.4
1.3
23.2
22.1
21.0
19.9
18.5
17.4
16.2
14.8
13.3
11.7
9.5
7.4
5.2
28.0
27.0
25.9
24.7
23.3
22.0
20.6
19.1
17.5
16.0
14.9
12.0
9.2
33.0
32.0
31.0
29.6
28.1
26.8
25.3
23.0
22.2
20.2
18.2
16.1
13.7
38.2
37.1
36.2
35
33.5
32.0
30.5
28.0
27.1
25.2
23.0
20.6
18.0
Example: Environment temperature is 10, and the measured relative humidity is 80%. From the
table, the dew point is 6.5. Then, the surface temperature of the steel plate has to be higher than 8.5for
the construction to proceed.
4.1.3.8.3 Outdoor construction is prohibited under conditions, such as snow, rain, fog, early morning dew,
strong wind, or under extreme sunlight.
4.1.3.9 Preparation of Paint
4.1.3.9.1 Prior to preparation of paint, the type and name of the paint shall be verified to determine whether
it meets the requirements.
4.1.3.9.2 Paint must be qualified product. Bad quality and deteriorated products cannot be used. Mixer
must be used to evenly mix the paint before use to prevent layering.
4.1.3.9.3 Prior to its use, the two-component paint type must be evenly mixed according to the specified
weight ratio. If the mixing ratio is incorrect, it will affect the drying property and anti-rust property.
4.1.3.9.4 Preparation of 702 Epoxy Zinc-Rich Primer. Preparation ratio: Epoxy zinc-rich paint:Curing agent
= 10:1 (weight ratio).
Method: Place the curing agent into the large can of epoxy zinc-rich primer and mix them evenly. Set aside
89
for 30 minutes and is used after curing.

4.1.3.9.5 Preparation of 842 Epoxy Mica Iron Intermediate Coat. Preparation ratio: Paint:Curing agent = 6:1
(weight ratio).
Preparation of 842-2 Epoxy Mica Iron Intermediate Coat. Preparation ratio: Paint:Curing agent = 7.22:1
(weight ratio).
Method: Place the curing agent into the paint and mix them evenly. Set aside for 30 minutes, and is used
after curing
4.1.3.9.6 Preparation of Chlorinated Rubber Paint. Chlorinated rubber paint can be used immediately upon
opening of the can and after even mixing.
4.1.3.9.7 Preparation of 704 Inorganic Zinc Silicate Primer. Preparation ratio of anti-corrosion paint:
Paint:Curing Agent = 4:1 (weight ratio)
Attention: Paint in can 20kg, Curing agent 10 kg (plastic bottle) one bottle. Make sure that two bottles of
paint are mixed with one bottle of curing agent.
4.1.3.9.8 Preparation of Aliphatic Polyurethane Recoatable Finish Paint. Preparation Ratio: Group A: Group
B = 8:1 (weight ratio)
Method: Add Group B (curing agent) into Group A. Mix them evenly and set aside for 30 minutes, which
can then be used after curing.
4.1.3.9.9 Thinner
Thinner shall not be arbitrarily added for preparation of paint. In the event that dry environment and
high temperature are present, thinner of not exceeding 5% of the weight of paint can be added. The
preparation shall be fully and evenly mixed.
4.1.3.10 Painting Method
4.1.3.10.1 The surface treatment shall achieve Sa2.5. Coating shall only be carried out with the
environment temperature and relative humidity meeting the requirements (coating on welded parts can only
proceed after 72 hours of welding). Solvent must be used to clean the surface with oil contamination.
4.1.3.10.2 Coating shall primarily be achieved with use of high pressure airless spraying. Small areas may
use brushing or air spraying method. Roller coating is strictly prohibited. The parts of structure pieces
requiring welding after coating must be taped with paper to avoid coating with paint.
4.1.3.10.3 High pressure airless spraying gun produced by Changjiang Mechanical Factory may be
selected: 6C and 9C. The pressure ratio of 6C is 64:1, which can spray undercoat and finish coat and is
capable of spraying high build coatings, with broad range of application. The pressure ratio of 9C is 32:1,
which is especially suitable for spraying of epoxy zinc-rich primer.
4.1.3.10.4 Selection of high pressure airless spraying nozzles (see Table 7).
Table 7
Item
1
2
3
4
5
6
Number
011-20
011-25
011-30
011-35
014-20
014-25
Item
7
8
9
10
11
12
Number
014-30
014-35
017-20
017-25
017-30
017-35
Item
13
14
15
16
17
18
Number
017-40
020-20
020-25
020-30
020-35
020-40
90
Item
19
20
21
22
23
24
Number
023-25
023-30
023-35
023-40
026-25
026-30
Item
25
26
27
28
29
30
Number
026-35
026-40
030-25
030-30
030-35
030-40
Note: (1) The first three digits of the number is the flow under 100kgf/c of pressure. For example, 014 is
1.4l/min, and 030 is 3.0l/min;
(2) The latter two digits of the number is the width of mist at 30cm from the mouth of high spray
nozzle.
20 refers to 20cm
(3) Testing medium: water.

The nozzle models are divided to Z, P, and C models. Z model is tungsten steel head nozzle with
good resistance to wear. P model is regular nozzle, which is suitable for spraying epoxy zinc-rich undercoat
and epoxy mica iron intermediate coat. The specific model numbers that may be selected for use are:
016017Z2025 or 016017P2025. C model is finish coat nozzle, which is more flat and is able to
spray chloride rubber and polyurethane finish coat. The specific model number is 014017C2030.
4.1.3.10.5 Compressed air pressure is calculated according to the recommended output pressure divided
by the pressure ratio 64 of the spraying gun. The spraying gun and the object being painted shall be
perpendicular with each other and shall maintain an unchanged distance (see Figure 12). For places, such
as side, angle, welding seam, and insection mark, a coat of paint shall be brushed prior to the spraying.
Then large area of coating can be carried out to assure the painting film thickness of the protruded parts.
Figure 12
4.1.3.10.6 When construction is carried out under severe condition with temperature over 30, the solvent
volatilizes very fast, readily leading to dry spraying when undergoing high pressure airless spraying. To
avoid dry spraying, the spraying gun is brought in as close to the object as possible and perpendicular
spraying shall be used concurrently. If dry spraying is still present, no grater than 5% of the painting weight
of solvent can be added to thin the paint.
4.1.3.10.7 Painting shall be completed prior to assembly for the surfaces of structural pieces that cannot be
painted after assembly.
4.1.3.10.8 Painting cannot be applied to the followings: on-site welding joined parts of steel structures,
faying face of high strength bolt, and combined surface of connecting plates
4.1.3.10.9 Second Rust Removal
Refers to the process of partial rust removal for steel structures with damage to the paint film as result of
gas cutting, welding or fire work correction, despite pre-treatment with coating of primer or finish paint. The
scope of rust removal includes: 50mm around heat affected zone, such as welding seam, left and right
sides of cutting slot, and the surrounding area of fire work correction. Power rust removal tools are used for
polishing to reach St2 standard, and then painting make-up is performed.
91
4.1.4 Safety Measures for Painting Construction

4.1.4.1 Welding cutting, smoking, and ignition are strictly prohibited at the painting site. Metal friction or
electrical sparks shall also be avoided to avoid occurrence of explosion or burning. The construction site
shall be equipped with sufficient amount of fire-fighting instruments.
4.1.4.2 Paintings shall be stored in the warehouse of dangerous goods and shall only be taken out for
immediate use to minimize the accumulation of paints and solvents on the construction site.
4.1.4.3 Construction site must have good ventilation to reduce the gas concentration from volatilization of
solvent, decreasing the influence of harmful gases
4.1.4.4 Various protective gears, such as work clothes, gloves, masks, and protective goggles, shall be
worn during construction. In the event that the construction conditions are very bad, air supplying head
cover or mask shall be worn. Otherwise, construction cannot be carried out.
4.1.4.5 When the skin of construction personnel is stained with paint, no benzene class solvent can be
used for cleaning. A mixture of detergent powder, soap, and small amount of rosin water can be used for
scrubbing and cleaning, and then rinse under clean water.
4.1.4.6 Paint film combustion produces harmful gases, causing danger to the on-site personnel. For pieces
after shot blasting with parts requiring welding and cutting, paper shall be taped to the positions, isolating
the paint or a grinder can be used to remove the paint prior to gas cutting and welding.
4.1.5 Quality Control of Painting
4.1.5.1 The submission for inspection of products or parts shall include painting as well (including
purchased pieces).
4.1.5.2 The surface treatment of pieces and every coating process require submission for inspection. The
next step of work can only be proceeded with after qualification of inspection. Inspection shall include outer
appearance inspection and dry film thickness inspection. Quality inspection card system shall be
implemented with recording of inspection data.
4.1.5.3 Requirement of Dry Film Thickness
Dry film thickness gauge is used for measurement of dry film thickness. Every measuring value is
derived from an average value of three to four points around the measuring point. More than 90% of the
measured points cannot be lower than the required value. The remaining measuring points cannot be lower
than the 90% of the required value. Otherwise, rework of painting shall be carried out. The measuring
points shall be appropriately selected, with one point in every 6 for large structures. Small structures
shall have less measuring points correspondingly but no less than 6 points. The dry film thickness cannot
92
be too thick, which is not to exceed 20~30% of the required thickness.

4.1.5.4 Adhesion Inspection
Due to the fact that during painting work, any oversight or omission of the process, such as improper
rust removal, failed removal of grease, high air humidity, inappropriate coating interval, faulty use of paint
type, will cause the pieces to have large area of peeling. Hence, adhesion testing is necessary.
Inspection personnel may use blunt object to scrape the coating surface to test for any peeling
phenomenon. Moreover, cross cut test can be used as an auxiliary measure to macroscopically control the
coating quality. On the coating surface, reasonably select testing points (no less than 2 points). Use a blade
to carve 6 horizontal lines and 6 vertical lines, forming grid lines with 1mm of grid spacing. The carving shall
penetrate the painting film thickness, reaching the steel plate. Then brush back and forth several times
along the diagonal line of the grid. It shall be deemed qualified if the overall peeling area is no more than
15% of the grid area. See Figure 3.
Figure 3
4.1.5.5 In addition to the product name, part name, drawing number, and date, the Painting Inspection List
(Verification List) shall include the following content:
(a) Requirement and measurement for surface treatment of steel structures;
(b) Requirement and measurement for paint type for every coat of paint and dry film thickness and
color;
(c) Recoating timer interval requirement and measurement for every coat of paint;
(d) Measurement of adhesion;
(e) Fill out the environment temperature and the relative humidity.
4.1.5.6 Protection of Coating
The finished coating must be carefully protected. Therefore, in addition to the personnel carrying out the
painting job, on-site lifting and handling personnel shall all be responsible for the protection. Design
personnel shall try to protect the coating in the design, avoiding as much damage as possible.
4.1.5.6.1 When designing long pieces, sectioned transportation must be considered to avoid temporary
cutting.
4.1.5.6.2 When designing large structure pieces, lifting positions shall be considered to avoid temporary
hole opening or lap welding for lifting.
4.1.5.6.3 Pieces that can be assembled and welded in the factory shall be carried out in factory if possible
93
to reduce the welding workload after painting job.

4.1.3.6.4 During lifting, scratch readily occurs at the location of rope or the bundled objects. Therefore, old
cotton cloth or wooden board shall be used as underlay to protect the coating.
4.1.5.7 Treatment of Coating Quality Problems: See Table 8
Table 8
Problem
Bubbling
Dry Spray
Runs
Condition
Coating of paint is
mixed with air,
forming bubbles
during formation of
coating film
During high
pressure airless
spraying, the paint
has already dried
and became
powder when
reaching the
painting surface
Some of the paint

has flowed
downward during
vertical painting,
forming uneven
surface with partial
over-thickness
Cause
Prevention and Treatment Methods
Paint is immediately
applied after vigorous
mixing
Vigorous mixing
shall be avoided,
and the paint shall
be set aside for a
while before
coating.
The solvent in the paint

has volatilized too fast
and the surface
temperature of the
painted object is too
high
Thinner is adjusted
appropriately. Thin
coating shall be
used for one-time
painting and
coating shall be
avoided during high
temperature
The viscosity of paint is

too high
Thinner is added
appropriately to
decrease the
viscosity of the
paint
Temperature is too high
Coating shall take

place under
suitable
temperature
The solvent in the paint

has volatilized too fast
The type and

quantity of thinner
shall be adjusted
The spraying distance is

too large.
Adjust the spraying

distance
Uneven spraying,
causing partial or
complete over-thickness
In pursuance to the
requirements,
painting shall be
carried out carefully
Excessive use of thinner
In pursuance to the
requirements,
thinner shall not be
used excessively
The temperature of the

high or too low when
undergoing painting
Painting shall be
carried out under
suitable
temperature
94
Re-work must
be done for
coating with
severe
condition of
bubbling
Coating surface
with severe
case of dry
spray shall
undergo
re-work
Re-work
Removal of
runs
Bleeding
Lifting
Wrinkling and
Orange Skin
Pin-Holes
The darker color of

the lower coat
paint has infiltrated
the lighter color of
the finish coat
The undercoat
paint has been
softened by the
finish coat solvent,
leading to
wrinkling, even
peeling.
The paint surface

is wrinkled or
orange skin like
The paint surface

has small holes,
like needle
punctures
Blushing
Coating surface is
whitish and fuzzy
Finish coat paint is

applied before the
undercoat paint is dried,
leading to mixing of
paints from the two
coats
The finish paint

shall be applied
after the undercoat
paint has dried
Use of the thinners for

two coats of paint are
faulty
Change the thinner
The solvent of finish

coat paint is too strong,
and the undercoat paint
does not match well.
Matching of
heterogeneous
paint types shall be
avoided
The undercoat paint is

insufficiently dried
Finish coat paint

shall be applied
after the undercoat
paint is dried
Finish coat is applied

before the undercoat
paint is dried or the
coating is too thick
Pay attention to
coating time
interval and
recommended film
thickness
The temperature of the

high or under extreme
heat after painting
Pay attention to
suitable
temperature
condition and avoid
high temperature
Water or oil is present

during painting
Remove the water

and oil
The surface temperature

is too high
Painting is carried
out under suitable
temperature
condition
The coating is too thick
Coating shall be
carried out
according to the
recommended film
thickness
Coating during high

temperature or the
temperature of coating
object is too low,
causing surface
moisture, which leads to
blushing of coating
Strengthen control
of temperature and
humidity or
implement dew
point management
95
Re-coating of
the finish coat
after the
bleeding coat is
dried
Re-work
Re-painting
after polishing
Use sand paper

to polish the
surface with
mild and small
pin-holes, and
then a thin coat
is applied. For
severe case of
pin-holes,
re-work must
be performed
Rubbing with
thinner for mild
blushing.
Severe
Cracking
Peeling
Coating surface
shows cracking.
Fine cracking is
referred as hair
crack. Large
cracking is referred
as cobweb
cracking
6m6m
Coating starts to
peel off from the
surface of base
material. Peeling
with less than 6
2
mm is known as
flaking. Peeling
2
greater than 6 mm
is known as
scaling. Large area
of peeling is known
as molting
The night temperature

decreases after painting,
causing condensation
on the surface or raining
after painting
Use of paint with

long drying time
shall be avoided
after evening
Paint solvent volatilizes

rapidly, making the paint
surface to produce
condensation
Thinner shall be
adjusted to slow
down volatilization
Finish coat is applied

before the undercoat is
fully dried or the
undercoat is too thick
Finish coat is
applied after the
undercoat is dried,
and coating is
carried out
according to the
recommended film
thickness
Coatings are not

properly matched. For
example, the undercoat
is relatively soft, and the
finish coat is relatively
hard.
Pay attention to the

correctness of the
matching system of
coatings
Sharp decline in
temperature
Take necessary
measures when
sharp decline in
temperature is
expected
Sa2.5
The quality of
surface treatment
must achieve Sa2.5
The painted surface was

contaminated with
impurities, such as
grease, water, rust, and
dust
Inappropriate
combination of base
paint and surface paint
Note the
correctness of
coating accessory
system
The time applying the

surface coat has
exceeded the required
painting interval
Coating shall be
applied according
to the coating
interval
Coated surface is too

smooth
Note the roughness

of coating surface
blushing
requiring
rubbing off the
area and
re-coating
Re-coating after
removing the
cracking part
New coat of
paint shall be
re-applied after
polishing the
peeling area.
With severe
molting
condition,
complete
re-work shall be
done
4.2 Protective Painting on Site

4.2.1 Objective
This Specification based on the
Project Specification and defines the general technical requirements for protective coatings
and the
96
special requirements for protective measures on site for high friction type bolted
connection.
4.2.2 General Application

This Specification is applicable to the surface preparation and application of protective coatings to
steel surfaces which have not been sufficiently protected in the manufacturers workshop on areas
to be only pre-painted due to still open assembly activities such as site welding for main steel
structures or minor brackets and friction type bolted connection.
Any damage to protective coatings shall be made good after erection.
carried out in accordance with this project specification.
Coating repairs shall be
4.2.3 Friction Type Connection

Steel surfaces around assembled friction type connections, that have received a prime coat only,
shall be completed as for coating repairs in accordance with this specification for protective
coatings.
NOTE: To prevent the water inflow into the connection all gaps between the plates and
structural steelwork around bolt, washers and nuts shall be sealed by permanently elastic
sealant.
4.2.4 Scope
All surfaces of structural steelwork, plant, equipment, pipework and platework including floor plate
shall be painted or otherwise protected against corrosion in accordance with this Specification
unless otherwise specified or approved. The technical requirements of this Specification define
minimum acceptable standards.
The following items are exempt from the requirements of this Specification:
Non-corrodible materials (e.g. Grade 304 Stainless Steels or better) unless required to be painted
for appearance or identification objectives.
Machined surfaces, which must be unpainted for proper performance but shall have a temporary
coating of an approved corrosion inhibitor.
Proprietary equipment for which the standard preparation and painting may be deemed satisfactory,
subject to approval.
Non-ferrous metals such as brass and bronze, plastic, glass and rubber.
Hoses and cables.
Instruments, gauges, valve stems and grease nipples and flexible hoses fittings.
4.2.5 General Requirements
4.2.5.1 Standards
97
All equipment, workmanship and materials of construction shall comply with the requirements of all
relevant Chinese Standards, regulations, codes and statutory requirements and with the relevant
Chinese, Acts and Regulations
4.2.5.2 Materials
All paints, thinners, and the like, shall be delivered to the point of use in unopened containers
bearing the manufacturers label and instructions and shall be supplied in the ready mixed condition
and stirred, handled, applied and cured strictly in accordance with the manufacturers directions.
Where necessary, the addition of thinners to any coating shall be as recommended by the
manufacturer and shall only be of the type and quantity recommended.
The Manufacturer's serialised batch reference number shall confirm the age of all coating materials
to be twelve (12) months or less.
All materials, after delivery to the shop or site, shall be stored in a cool dry place, out of direct
sunlight.
Unless specified otherwise, finish coats shall be full gloss coats.
sufficiently different colour to distinguish from the previous coat.
Individual coats shall be of
4.2.6 Technical Requirements - Protective Coatings

4.2.6.1 Surface Preparation
All surfaces shall be properly prepared prior to application of protective coatings in accordance with
the coating manufacturers written instructions. The coating manufacturers instructions
notwithstanding, the following provisions shall also apply as minimum acceptable standards:
a) Surfaces to be coated shall be free of welding slag, spatter or imperfections such as slithers
etc.
All sharp edges and irregularities including weld spatter etc., shall be removed. All edges shall be
deburred and rounded to a 2mm minimum radius.
.
Deposits of oil and grease shall be removed, prior to abrasive blasting, by solvent cleaning in
accordance with AS1627.1.
All fabricated steelwork, pipework and platework to be coated shall be abrasively blasted in
accordance with the standards Unless approved otherwise, a minimum of Class2.5 shall be
provided. Profile height shall be between 25 and 65 micron. Abrasive cleaned surfaces shall
be primed within 4 hours of blasting and on the same day. Any contamination of the blast will
result in the entire surface being re-blasted. No night blasting is permitted.
Steel shall be brushed or blown to remove dust and similar contamination.
All sheet steel used for electrical cubicles and panels shall be acid de-scaled and phosphate
passivated prior to fabrication.
Items which are to be hot-dip galvanised shall be either blast cleaned or acid pickled and fluxed
before coating in accordance with the requirements of the standards. All items shall be
dimensionally correct after hot-dip galvanising.
Cleaned surfaces shall be kept free of contamination and not be touched by bare hands. Any oil,
grease or other surface contamination of bare steel, or previous coatings, shall be solvent
cleaned in accordance with the Standards before applying the next coat. Particular care shall
be exercised with steel primed off site and erected and painted on site.
98
Motors, gearboxes and similar proprietary items supplied ready painted shall have any surface
damage such as chipping repaired and then solvent cleaned and repainted to the required
colour. All breathers, seals, terminal box glands, and the like shall be adequately masked or
sealed to prevent contamination by blasting or painting materials.
All surfaces adjacent to areas to be painted shall be protected with drop cloths, masking or other
suitable means.
Hardware, gratings, accessories or equipment shall be removed before any
materials are applied. These items shall be replaced upon completion of work in each area.
Unless approved otherwise, abrasive blasting is to be conducted in fully enclosed blast chambers.
4.2.6.2 Application of Coats
All coatings shall be applied strictly in accordance with the Manufacturers written instructions by
approved specialist applicators.
Unless otherwise approved, no coating shall be applied under the following conditions:
When the temperature of the surfaces are less than 3C above dew point so as to prevent
moisture condensation.
When the relative humidity of the air is greater than 85%.
When the air temperature is below 10C or above 40C.

When atmospheric conditions are windy and dusty, foggy or wet.
When there is a likelihood of a detrimental change in weather conditions within 2 hours

after application, so as to create conditions outside the ranges allowed above.
When the surface temperature of the item to be painted is below 10C or above 50C.
Unless approved otherwise, protective coatings shall be applied under cover.
Protective coatings
shall not be applied in the field without approval.
4.2.6.3 Transport and Handling

Particular care shall be taken to avoid damage to coatings in handling and transport. Coated items
shall not be handled until the coating has cured in accordance with the manufacturers instructions.
Coated items shall be handled and transported in a manner that will not chip, scratch, abrade, or
otherwise damage the finished coatings.
All slings, lifting devices, dunnage, packing, tie-downs,
and the like, shall be of a type that is designed to achieve this end.
99
No sign writing, stencilling or marking shall be applied to painted surfaces of plant, machinery and
equipment unless specifically approved and compatible with the specified coating system.
4.2.6.4 Rectification and Touch-up Painting
Surfaces where the paint coating has been damaged or marked in any way shall be touched up or
repainted in accordance the coating manufacturers instructions, the Specification, and as approved.
Blast cleaning in situ shall not be carried out without approval. Spray painting at the site will only
be allowed in approved areas and conditions.
Precautions shall be taken to avoid over spray
hazards to personnel or other plant. Brush or roller application shall be used where necessary.
All faults in the preparation or application of paint systems shall be rectified. Areas of paint that
are found to be deficient shall be removed and touched up.
Such deficiencies include, but are not
limited to:
Sags and over-runs

Mud cracks
Lack of adhesion
Incomplete curing/hardening/
Film thickness out of range
Inclusions of foreign materials
Mechanical damage
Bubbles
Dry over-spray
Incorrect colour
Dust inclusions
Coatings not to thickness or not of a high standard free from defects likely to result in inferior
protective shall be made good in an approved manner. The finished coating of paint shall be
continuous over each surface to be painted.
4.2.6.5 Quality Assurance
Appropriate quality assurance procedures shall be implemented to ensure that surface preparation
and the application of protective coatings are carried out in accordance with the coating
manufacturers instructions and the requirements of this Specification. The quality assurance plan
shall include adequately descriptive procedures and documentation to illustrate the preparation and
application processes have been completed correctly and checked.
4.2.6.6 Application Records
Written records shall be maintained so that complete traceability of all work and materials provided
under this Specification is maintained. These reports shall be maintained on a daily basis.
As a
minimum, these reports shall include, as a minimum, appropriate information concerning the
following:
100
Job identification (work area)

Surface preparation performed and equipment used
Coating applied and equipment used
Material used, batch number, colour and thinner
Application details including which coat was applied, wet film thickness and dry film thickness
Weather conditions, including temperature of air and surface during application; relative
humidity; wind conditions and general weather conditions.
4.2.6.7 Inspection
The following inspection requirements shall apply:
:
Five (5) working days notice is to be given prior to the commencement of work.
Two (2) working days notice is to be given prior to abrasively blasting each item.
Surface profiles outside the specified range will not be accepted.
Dry film thickness ranges as specified are absolute minimum or maximums. Measurements
shall not be averaged. Areas found to be outside the range of the Specification shall be
rectified to an approved procedure.
The dry film thickness shall be checked with an electric dry film thickness gauge Elcometer 245 or
similar instrument. Calibration of the gauge shall be done weekly or as required using standard
thickness plates of Electrophysik brand or similar.
4.2.7 Safety
All equipment used in the surface preparation and application of protective coatings including, but
not necessarily limited to, ladders, scaffold, compressors, electrical and pneumatic equipment shall
conform to the requirements in force by the appropriate statutory authority and shall be properly
maintained and used strictly in accordance with any additional safety regulations which may apply.
All caution notices on the manufacturers coating and material labels shall be strictly observed and
every necessary precaution taken to prevent accidents.
Transport, storage and handling of coating products shall be strictly in accordance with the
requirements of the relevant statutory authority and recognised trade practices.
When working in enclosed spaces, a documented safety procedure is to be prepared and
submitted for approval. Adequate ventilation shall be provided to remove and disperse solvent
vapours, avoid explosion, ensure safety of personnel and safe working conditions.
101
Where air operated equipment is used, the operators hood or headgear shall be ventilated by clean,
cool, oil free air served through a regulator filter to prevent blasting residue from being inhaled by
the operator.
Breathing masks shall be worn when painting inside enclosed spaces.
Forced ventilation sufficient to keep fume concentration at a safe level shall be provided for all
enclosed spaces.
Safety data sheets shall be produced for all brands of paints, solvents or cleaning agents intended
for use on site. Only approved products shall be used on site.
On site storage of paints and painting materials shall be restricted to approved locations. The
mixing of paint components shall be carried out only in these locations. Empty paint and paint
material containers, paint-soaked rags and other debris shall not be allowed to accumulate and
shall be promptly removed. Drop cloths shall be spread out to dry.
Precautions to prevent fires shall be continually exercised.
Persons performing spray painting shall abide by all the necessary Statutory Regulations.
5.
Welding Instructions
5.1 General
5.1.1 Introduction
Due to delivery conditions and size of main structures, site welding is required before assembly of the
Stacker/Reclaimer.
Site welding has to be carried out close to the mounting area which will be under outdoor conditions.
5.1.2 General Site Welding Requirements
All welding shall be in accordance with the requirements of AWS D1.1and the following,unless specified
otherwise on erection drawings:
Pre-qualified weld procedures shall be used unless approved otherwise.
All welds to be category SP unless noted otherwise on the design drawings
All butt welds to be full penetration
All fillet welds to be 6mm minimum continuous unless noted otherwise on the design drawings
Electrodes to be classification E48XX or equivalent
If intermittent welding of fillet welds larger than 6mm is used, the space between welds shall be
seal welded.
All welding shall be supervised by a welding supervisor qualified in accordance with AWS
Weld procedures shall be submitted to the Principals Representative for review prior to commencement of
welding.
Welder qualification certificates shall be made available upon request.
5.1.3 Inspection and Testing of Site Welds
All non-destructive testing associated with welding structure shall be carried out in accordance with the
following.
102
Unless specified on drawings, the extent of testing and inspection of welds shall be as follows:
Visual Inspection (XP, SP & GP Welds) (XP, SP & GP )
To be as per AWS, except the scanning and examination to be 100%.
Non-Destructive Testing (SP Welds Only) (SP)

Groove Welds (Full and Partial Penetration Welds)
100% of the length of each group of site welds shall be 100% tested using Ultrasonic Testing
(UT) and Magnetic Particle Inspection method (MPI).
All welds annotated with B.G shall be 100% tested using UT and MPI methods.
Fillet Welds
10% of the length of all site welds longer than 1000mm or One in Five joints of all other joints
shall be 100% tested using Magnetic Particle Inspection method (MPI).
All welds failing to meet the permissible levels of imperfections allowed in AS1554
Part1 shall be removed or repaired and then 100% re-tested using the previously
nominated method.
Where weld examination at less than 100% is specified and the testing identifies a weld
to be rejected, removed or repaired, additional examination shall be undertaken on
other welds of the same type and size. The additional examination shall continue until
the original percentage of defect free welds has been examined.
Inspection acceptance criteria as EN 25
5.2 Base material Steel Structure
All primary material for the Steel structure to be site welded is Q345B. All second material for the Steel
structure to be site welded is Q235B OR Q235A.
Material:
Grade
Chemical Composition:
Carbon
Manganese
Vitriol
Mechanical Properties:
UTS (N/mm2)
2
Y.S. (N/mm )
Impact Test:
At +20
At 0
At -20
Elongation
Q345B
max. 0.20%
1.50%1.60%
0.02%1.50%
For all thickness

For Thk. 16 mm
For 16 mm Thk. 35 mm
Min. 34J
NA
NA
A 21%
103
R 470 N/mm
Rs 345 N/mm
Rs 325 N/mm2
Rs 295 N/mm2
Rs 275 N/mm2
Grade
Q235A Chemical Composition:
Carbon
Manganese
Silicon
Sulphur
Phosphorus
0.14%0.22%
0.30%0.60%
Max. 0.30%
max. 0.050%
max. 0.045%
Q235B Chemical Composition:

Carbon
Manganese
Silicon
Sulphur
Phosphorus
0.12%0.20%
0.30%0.60%
Max. 0.30%
max. 0.045%
max. 0.045%
Mechanical Properties:
UTS (N/mm2)
2
Y.S. (N/mm )
Impact Test:
Q235A
At +20
At 0
At -20
Q235B
At +20
At 0
At -20
Elongation
6.
Q235A
For all thickness
Q235B
375500 N/mm2
For Thk. 16 mm
Rs 235 N/mm2
Rs 225 N/mm2
For 40 mm Thk. 60mm
Rs 215 N/mm2
For 50 mm Thk. 100 mm Rs 275 N/mm2
For 100 mm Thk. 150 mm Rs 195 N/mm2
For Thk. 150 mm
Rs 185 N/mm2
NA
NA
NA
Min. 27J
NA
NA
For Thk. 16 mm
A 26%
A 25%
For 40 mm Thk. 60mm
A 24%
For 50 mm Thk. 100 mm A 23%
A 22%
For Thk. 150 mm
A 21%
Erection Records
6.1 General
The competent Erection Company shall prepare detailed scheduling of all erection activities.
CHEC supervisor may be used for review objectives and further advice if needed.
The Erection Company appoints a Site manager for the respective installation / erection work,
who bears the responsibility for:
timely presentation of overall erection plan including overall scheduling of various erection
inputs like, cranage, labour and major erection sequence of various erection areas.
104
timely provision of an adequate number of qualified erection personnel.

the skilful completion of the erection work on schedule in conformity with all application
regulations.
The scheduling shall be prepared in areas of civil engineering and foundation works,
mechanical erection, electrification and instrumentation and finally activities required to put the
equipment into operation.
6.2 Diary of Events
The Erection Contractor, together with CHEC representative shall maintain a diary of all events
during erection and record all test results on inspection/test report forms for compiling to the Data
report (MDR).
6.3 Data report sheet
6.3.1 Rail fixing requirement for Moblie Major Equipmen
105
106
6.3.2 Dimensional Report
Machine: ______________________________
Item: _________________________________
Description: _____________________________
Drawing No.: __________________________

Sketch:
Measure
(according
sketch):
A
B
C
D
E
F
G
H
I
J
K
L
M
N
taken
to
designed
actual
______________________________
______________________________
CHEC
Customer
6.3.3 NON-CONFORMANCE REPORT
- 107 -
PROJECT SPECIFIC
NON-CONFORMANCE REPORT (NCR)
Stacker / Reclaimer
NCR No.: ST
CATEGORY:
Safety
Mechanical
Design
DATE:
Sheet
of 1
Non-Conformance Reported by:

Location:
Drawing No: SR0707.
Photo Reference:
Drawing No :SR0707.
Attachment(s):
Drawing Nos:
Item Nos:
Item No:
Item No:
Description of Non-Conformance:
(Detail reasons and consequence of non-conformance)
Verification of Non-Conformance:
Manager)
(QA / Project / Construction / Dept / General
Further Investigation Required: No
Estimated
Drawing Revision Required:
Hours
Costs
Yes
&
$ Value
Hours
Recommended Corrective Action:
Labour
manhours
Supply
Painting
Transport
Total Cost:
Signature:
Position:
Site Manager
Date:
Corrective Action Approval:
Signature:
(QA Manager)
Date:
Signature:
Date:
(Project / Construction / Dept / General Manager)
- 108 -
Corrective Action Taken and Verification:
QA Representative
Project / Construction / Dept / General Manger
Name:
Name:
Signature:
Signature:
Date:
Date:
6.3.4Torque Report Form

Unit:
_____________________________
Drawing No: _____________________________
PART
No.
DESCRIPTION
Bolt
Size
Grade
M16
10.9
M20
10.9
M24
10.9
M27
10.9
M30
10.9
M16
8.8
M20
8.8
M24
8.8
M27
8.8
No. of
Bolts
TORQUE
No.
checked
[Nm] *
required
As per table 1
below
[Nm]
measured
CARRIED
OUT ON
[Date]
*Legend: Torque for lightly lubricated (add a little oil or molybdenum dioxide at screw thread and
washer)K = 0.12; no-added oil K = 0.145
Carried out by:
_____________________________
Checked by:
_____________________________
Reviewed by:
_____________________________
- 109 -
6.3.5 Primary & Key Parts Installation Dimentional Inspection Table Form
CHEC Division of Material Handling Shanghai R&D Center
Primary & Key Parts Installation Dimentional Inspection Table
Project
Drawing
Number

GSU1500.35/22 type Grab Shipunloader
1
Name
General Description
Construction
unit
page 1 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Foreword
1. The Primary & Key Parts Installation Dimentional Inspection Table workship documents aim at
the department of engineering equipment for on-site installation ,which monitor,test,record,
supervise and verify the key points of quality for the primary & key parts of production.
2. The erection & construction unit carry out the inspection and record that the ducuments
regulate,who bear the main responsibility. The rest of the parties are concerned to assist the
parties,who bear responsibility for assistance and supervision.
3. This documents are provided for all test items and test records, in addition to the installation
of construction units (mainly the implementation of side), which must have a (not less than
two parties), the three members of the co-signature to be effective.
4. When the test data of test items which the ducuments provide is not consitence with the
relevant regulation ,implement high standards.Or contact with Shanghai R&D Center,then
implement the conclusion after contacting. It will not be permitted to amend the testing data.
5. Products on-site installation is implemented in addition to the test items provided by the
documents,the rest of which is implemented according to the productions installation
instructions and other relevant documental regulation.
6. After products on-site installation finished,the documents must be integrally submitted to

Shanghai R&D Center in order to keep for future reference.
7. The interpretation right belongs to Shanghai R&D Center.
TPSC supervisor:
BVI
supervisor:
- 110 -
CHEC supervisor:

Project
page 2 of 20
Document
Number
GSU0702-ZZ
Drawing
Number
Equipment
Number
GSU0702.21
Name
Construction
unit
Gantry Rail Measure
GSU0702-0
Manufacturing
units
Rail Distance(S)
B
Rail Distance(S)
A
tance
Base Dis
H2
H1
TPSC supervisor:
BVI
supervisor:
- 111 -
CHEC supervisor:

Project
page 3 of 20
Document
Number
GSU0702-ZZ
Drawing
Number
Equipment
Number
GSU0702.21
Name
Construction
unit
Check Item
Allow
Tolerance
Rail Distance(S)
10
TPSC supervisor:
GSU0702-0
Manufacturing
units
N0.
At the same
section, both rails
top distance
H1
At the same side,
the rail top distance
of high to low
H2
Gantry Rail Measure
(mm)
Drawing
Dimension
(mm)
Remark
(mm)
In the same
erection area
In the same
erection area
H1
S/1000
In the same
erection area
H2
10mm
BVI
Measure Dimension
supervisor:
- 112 -
CHEC supervisor:

Name
GSU0702.16
GSU0702-0
Sea Side
Base Distance
(Lj)
Rail Distance
(S1)
Land Side
BVI
A
L2
L1
supervisor:
- 113 -
(H2)
Sea Side Gantry height
Base Distance
(Lj)
Land Side Gantry height

(H1)
TPSC supervisor:
Equipment
Number
Manufacturing
units
Sea Side Gantry height

(H1)
Construction
unit
Gantry Orientation
GSU0702-ZZ
Land Side Gantry height

(H2)
Drawing
Number
Document
Number
Rail Distance
(S2)
Project
page 4 of 20
CHEC supervisor:

Tanjung Jati B Units 3 & 4 600 MW Coal-Fired
Project
Name
Project
Drawing
Number
Gantry Orientation
GSU0702.16
Construction
unit
N0.
Check Item
Allow
Tolerance
Rail Distance
(S1)
Rail Distance
(S2)
Sea Side
Base Distance
(Lj)
Land Side
Base Distance
(Lj)
Sea Side Gantry
height
Sea Side Gantry

height
Land Side Gantry

height
Land Side Gantry

height
2
3
4
(H1)
(H2)
(H1)
(H2)
Diagonal Distance
A-D(L1)B-C(L2)
TPSC supervisor:
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
(mm)
page 5 of 20
Drawing
Dimension
(mm)
Measure Dimension
(mm)
5
5
5
5
3
10
BVI
supervisor:
- 114 -
CHEC supervisor:
Remark

Project
Drawing
Number

Name
Waterside Portal
GSU0702.01.09.01
Construction
unit
page 6 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
M3
M4
M1
N0.
Check Item
1
2
3
4
M1
M2
M3
M4
TPSC supervisor:
Allow
Tolerance
(mm)
1.5
1.5
2.5
2.5
BVI
Drawing
Dimension
(mm)
supervisor:
- 115 -
M2
Measure Dimension
(mm)
CHEC supervisor:
Remark

Project
Drawing
Number

Name
Landside Portal
GSU0702.01.09-19
Construction
unit
GSU0702-ZZ
Equipment
Number
GSU0702-0
M4
M1
Check Item
Allow
Tolerance
(mm)
1
2
3
4
Document
Number
Manufacturing
units
M3
N0.
page 7 of 20
M1
M2
M3
M4
TPSC supervisor:
1.5
1.5
2.5
2.5
BVI
Drawing
Dimension
(mm)
supervisor:
- 116 -
M2
Measure Dimension
Remark
(mm)
CHEC supervisor:

Project

Drawing
Number
Name
GSU0702.01.09
Construction
unit
Gantry,Sea and Land

Frame Assembly
Check Item
S1(left side)
S2(right side)
Uprightness tolerance
(AB plumb to level )
(CD plumb to level )
TPSC supervisor:
Equipment
Number
GSU0702-0
H
Land Side
Rail Distance S1 (Rail Distance S2)
Drawing
Dimension
Allow
Tolerance
(mm)
GSU0702-ZZ
H
Sea Side
1
2
Document
Number
Manufacturing
units
N0.
page 8 of 20
(mm)
8
8
Measure Dimension
Remark
(mm)
Face to sea side
Face to sea side
H/1000 20
H/1000 20
BVI
supervisor:
- 117 -
CHEC supervisor:

Project

Drawing
Number
Name
Pylon
GSU0702.01.04
Construction
unit
page 9 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
L1
L2
N0.
Check Item
Allow
Tolerance
(mm)
1
2
L1
L2
TPSC supervisor:
3
3
BVI
Drawing
Dimension
(mm)
supervisor:
- 118 -
Measure Dimension
(mm)
CHEC supervisor:
Remark

Drawing
Number
Name
GSU0702.01.01
Construction
unit
N0.
Check Item
2
3
4
5
Bearing-hole
1 dia.
Bearing-hole
2 dia.
Bearing-hole
3 dia.
Bearing-hole
4 dia.
Rail Distance
TPSC supervisor:
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Allow
Tolerance
(mm)
Front girder
Document
Number
+0.016
-0.036
+0.016
-0.036
+0.016
-0.036
+0.016
-0.036
3
BVI
Drawing
Dimension
(mm)
supervisor:
- 119 -
Bearing-hole
Bearing-hole
Bearing-hole
Bearing-hole
Measure Dimension
(mm)
CHEC supervisor:
Remark
Rail Distance
Project
page 10 of 20

Project
Name
Drawing
Number
End Grider
GSU0702.01.08
Bearing-hole
5
Bearing-hole
3
Bearing-hole
6
Bearing-hole
4
Bearing-hole
1
Bearing-hole
2
Check Item
center distance L2
L1 L2
Rail Distance
Bearing-hole Bearing-hole
7
8
N0.
center distance L1
Allow
Tolerance
(mm)
1
2
3
4
Bearing-hole
1 dia.
Bearing-hole
2 dia.
Bearing-hole
3 dia.
Bearing-hole
4 dia.
TPSC supervisor:
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
connect stand-mast center distance

M1
Construction
unit
Document
Number
connect stand-mast center distance

M2
Project
page 11 of 20
+0.052
0
+0.052
0
+0.052
0
+0.052
0
BVI
Drawing
Dimension
(mm)
supervisor:
- 120 -
Measure Dimension
(mm)
CHEC supervisor:
Remark

Project
Name
Project
Drawing
Number
End Grider
GSU0702.01.08
Construction
unit
N0.
Check Item
Allow
Tolerance
(mm)
+0.052
0
+0.052
0
+0.052
0
+0.052
0
3
1.5
1.5
9
10
11
12
L1
13
L2
14
L1,L2 diagonal
tolerance
10
6
7
8
TPSC supervisor
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Bearing-hole
5 dia.
Bearing-hole
6 dia.
Bearing-hole
7 dia.
Bearing-hole
8 dia.
Rail Distance
M1
M2
page 12 of 20
BVI
Drawing
Dimension
(mm)
Measure Dimension
(mm)
Remark
the same
direction
the same
direction
supervisor:
- 121 -
CHEC supervisor:

Project
Name
Project
Drawing
Number
Main-trolley
GSU0702.01.03
Construction
unit
page 13 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
benchmark Line
sea side
Rail Distance 1
Notes:
1.Put the Main-trolley on the
level to measure
2.the distance of the two

measure-point on the
wheel is L.
Rail Distance 2
land side
N0.
1
2
3
Check Item
Rail Distance 1
(Sea side)
Rail Distance 2
(Land side)
Wheel-surface
center line to
rail center line
tolerance A
TPSC supervisor:
Allow
Tolerance
(mm)
Drawing
Dimension
(mm)
Measure Dimension
(mm)
3
3
|A1-A2|
L/1200
BVI
supervisor:
- 122 -
CHEC supervisor:
Remark

Project
Name
Project
Drawing
Number
Main-trolley
GSU0702.01.03
Construction
unit
N0.
Check Item
Wheel-surface
center line to
rail center line
tolerance B
Wheel-surface
center line to
rail center line
tolerance C
Wheel-surface
center line to
rail center line
tolerance D
TPSC supervisor:
page 14 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Allow
Tolerance
(mm)
Drawing
Dimension
(mm)
Measure Dimension
(mm)
|B1-B2|
L/1200
|C1-C2|
L/1200
|D1-D2|
L/1200
BVI
supervisor:
- 123 -
CHEC supervisor:
Remark

Project
Upside structure of
Name
Project
Drawing
Number
End Grider and Frame

assembly
GSU0702.01
Construction
unit
page 15 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
A
h
B
N0.
1
2
Check Item
Left side
right side
TPSC supervisor:
Allow
Tolerance
(mm)
Drawing
Dimension
(mm)
Measure Dimension
Remark
(mm)
h/2000
Face to sea side
h/2000
Face to sea side
BVI
supervisor:
- 124 -
CHEC supervisor:

Project

Drawing Number
Name
GSU0702.01
Construction unit
N0.
1
2
3
4
5
page 16 of 20
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing units
Check Item
rail distance 1
high-low tolerance
rail top
rail distance 2
high-low tolerance
rail top
rail distance 3
high-low tolerance
rail top
rail distance 4
high-low tolerance
rail top
rail distance 5
high-low tolerance
rail top
Upside structure of End Grider and

Frame assembly
Document
Number
Allow Tolerance
(mm)
Drawing Dimension
Measure Dimension
(mm)
(mm)
3
at the same section
3
3
at the same section
3
3
at the same section
3
3
at the same section
3
3
at the same section
- 125 -
Remark
N0.
6
Check Item
Allow Tolerance
(mm)
Drawing Dimension
Measure Dimension
(mm)
(mm)
rail distance 6
3
high-low tolerance at the same
3
section rail top
Hopper center line to
Main-trolley rail center line and frame
5
center line
- 126 -
Remark
6
1-6rail distance
Notes:
From Main Hinge Center to front,to back ,
every other 10M as one measure-point,measure
Main-trolley rail distance and high-low tolerance at
the same section rail top.
TPSC supervisor:
BVI
supervisor:
CHEC supervisor:
- 127 -

Project
Name
Project
Drawing
Number
Gantry measure
GSU0702.16-1
Construction
unit
page 17 of 20
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
A1a A1b A2a A2b A3a A3b A4a A4b
A5a A5b A6a A6b A7a A7b A8a A8b
Check Request
N0.
Check Item
Wheel-face
line to rail top
line tolerance
A1
Wheel-face
line to rail top
line tolerance
A2
TPSC supervisor:
center
center
center
center
1.Gantry is divided by four groups

A,B,C,Deach group havs 8 wheels.
2.two groups of the same rail is as
one measure group,and record
measure data.
Allow Tolerance
(mm)
Drawing
Dimension
Measure
Dimension
(mm)
(mm)
|A1a-A1b|L/1000
Remark
measure
length
L-
|A2a-A2b|L/1000
BVI
supervisor:
- 128 -
CHEC supervisor:

Project
Name
Project
Drawing
Number
Gantry measure
GSU0702.16-1
Construction
unit
N0.
10
11
TPSC supervisor:
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Check Item
Wheel-face
line to rail top
line tolerance
A3
Wheel-face
line to rail top
line tolerance
A4
Wheel-face
line to rail top
line tolerance
A5
Wheel-face
line to rail top
line tolerance
A6
Wheel-face
line to rail top
line tolerance
A7
Wheel-face
line to rail top
line tolerance
A8
Wheel-face
line to rail top
line tolerance
B1
Wheel-face
line to rail top
line tolerance
B2
Wheel-face
line to rail top
line tolerance
B3
page 18 of 20
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
Drawing
Dimension
(mm)
Allow Tolerance
(mm)
Measure
Dimension
(mm)
|A3a-A3b|L/1000
|A4a-A4b|L/1000
|A5a-A5b|L/1000
|A6a-A6b|L/1000
|A7a-A7b|L/1000
|A8a-A8b|L/1000
|B1a-B1b|L/1000
|B2a-B2b|L/1000
|B3a-B3b|L/1000
BVI
supervisor:
- 129 -
CHEC supervisor:
Remark

Project
Name
Project
Drawing
Number
Gantry measure
GSU0702.16-1
Construction
unit
N0.
12
13
14
15
16
17
18
19
20
TPSC supervisor:
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Check Item
Wheel-face
line to rail top
line tolerance
B4
Wheel-face
line to rail top
line tolerance
B5
Wheel-face
line to rail top
line tolerance
B6
Wheel-face
line to rail top
line tolerance
B7
Wheel-face
line to rail top
line tolerance
B8
Wheel-face
line to rail top
line tolerance
C1
Wheel-face
line to rail top
line tolerance
C2
Wheel-face
line to rail top
line tolerance
C3
Wheel-face
line to rail top
line tolerance
C4
page 19 of 20
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
Drawing
Dimension
(mm)
Allow Tolerance
(mm)
Measure
Dimension
(mm)
|B4a-B4b|L/1000
|B5a-B5b|L/1000
|B6a-B6b|L/1000
|B7a-B7b|L/1000
|B8a-B8b|L/1000
|C1a-C1b|L/1000
|C2a-C2b|L/1000
|C3a-C3b|L/1000
|C4a-C4b|L/1000
BVI
supervisor:
- 130 -
CHEC supervisor:
Remark

Project
Name
Project
Drawing
Number
Gantry measure
GSU0702.16-1
Construction
unit
N0.
21
22
23
24
25
26
27
28
29
TPSC supervisor:
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Check Item
Wheel-face
line to rail top
line tolerance
C5
Wheel-face
line to rail top
line tolerance
C6
Wheel-face
line to rail top
line tolerance
C7
Wheel-face
line to rail top
line tolerance
C8
Wheel-face
line to rail top
line tolerance
D1
Wheel-face
line to rail top
line tolerance
D2
Wheel-face
line to rail top
line tolerance
D3
Wheel-face
line to rail top
line tolerance
D4
Wheel-face
line to rail top
line tolerance
D5
page 19 of 20
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
center
Allow Tolerance
(mm)
Drawing
Dimension
Measure
Dimension
(mm)
(mm)
|C5a-C5b|L/1000
|C6a-C6b|L/1000
|C7a-C7b|L/1000
|C8a-C8b|L/1000
|D1a-D1b|L/1000
|D2a-D2b|L/1000
|D3a-D3b|L/1000
|D4a-D4b|L/1000
|D5a-D5b|L/1000
BVI
supervisor:
- 131 -
CHEC supervisor:
Remark

Project
Name
Project
Drawing
Number
Gantry measure
GSU0702.16-1
Construction
unit
N0.
30
31
32
TPSC supervisor:
Document
Number
GSU0702-ZZ
Equipment
Number
GSU0702-0
Manufacturing
units
Check Item
Wheel-face
line to rail top
line tolerance
D6
Wheel-face
line to rail top
line tolerance
D7
Wheel-face
line to rail top
line tolerance
D8
page 20 of 20
center
center
center
center
center
center
Drawing
Dimension
(mm)
Allow Tolerance
(mm)
Measure
Dimension
(mm)
|D6a-D6b|L/1000
|D7a-D7b|L/1000
|D8a-D8b|L/1000
BVI
supervisor:
- 132 -
CHEC supervisor:
Remark
Part III: Commissioning Documentation
- 133 -
CONTENTS
NO.
Title
Page
1.
General Provision
1.1
Objective and Requirement
1.2
Safety Matters
1.3
Preparation prior to Commissioning
1.4
Inspection prior to Commissioning
2.
No Load Test Run
2.1
Objective of No Load Test Run
2.2
Commissioning of Lift
2.3
No Load Commissioning for Hoisting and Opening/Closing Mechanisms
2.4
No Load Commissioning for Trolley Travelling
2.5
No Load Commissioning for Pitching Mechanism
2.6
Commissioning for Drivers Cab Travelling Mechanism
2.7
No load Commissioning for Hoppers
2.8
2.9
Commissioning for Travelling Mechanism of Long Travel

/
Commissioning for Electric and Water Cable Drum
2.10
Commissioning for Water Spraying Dust Suppression System
2.11
Commissioning for Hydraulic System
2.12
Commissioning for Centralized Lubrication System
2.13
Commissioning for Belt Conveyor
Commissioning for Safety Interlocking Operation
4.
Static Load Test Run
4.1
Assembly Loading Preparation
4.2
4.2.1
Trial Operation Prior to Static Load Testing
4.2.2
Full Load Static Load Testing: (100% Load)
- 134 -
4.2.3
Overload Static Load Testing: (125% Load)
Dynamic Load Test Run
5.1
Hoisting and Opening/Closing Mechanisms Single Test Run: (100% Load)
5.2
Trolley Traveling Single Test Run: (100% Load)
5.3
Linked Operation of Hoisting and Opening/Closing and Trolley Travelling:

(100% Load)
5.4
110% Overload Dynamic Testing
5.5
Two-Hour Continuous Operation Testing
5.6
Cyclic Working Time Determination
5.7
Continuous Shipunloading Testing
Shipunloader Inspection Acceptance Evaluation
Test Run and Inspection Acceptance Handbook Attachments
- 135 -
1. General Provision
1.1 Objective and Requirement:
This handbook is a guiding document for the commissioning of shipunloader. The
Commissioning personnel shall carefully read this handbook prior to the commissioning.
This handbook is a guiding document used after completion of installation of all mechanical and
electrical control equipment of the shipunloader, guiding the commissioning personnel to undergo
commissioning.
Its objective is adjusting the newly installed shipunloader to a normal working state, inspecting the
technical performances and parameters of the shipunloader, determining the conditions for inspection
acceptance of the shipunloader, and assuring the safe and reliable operation after delivery of the
shipunloader.
The commissioning of the shipunloader is divided into three stages: no load commissioning, static
load test run, and dynamic load test run. The tasks in the previous stage must be completed before
proceeding to the tasks of the next phase of test run for completion of tasks of all three stages.
This handbook may be used as a reference for completion of commissioning and inspection
acceptance of the shipunloader after a major overhaul of the shipunloader.
1.2 Safety Matters
1.2.1 The area for the commissioning shall be defined, and eye-catching signs shall be hung. Unrelated
personnel or other vehicles are prohibited to enter the commissioning area. A specific person shall be
appointed to be responsible for the safety inspection during the entire period of the commissioning.
1.2.2 The site shall be cleaned, achieving the requirements of civilized construction and safe
commissioning.
1.2.3 All commissioning personnel entering the site must have the necessary protective measures (e.g.
safety helmet, working clothes, and insulated shoes)
1.2.4 The commissioning site must be equipped with the corresponding fire protection instruments. All
personnel must be familiar with the locations and operations of fire extinguishers.
1.2.5 Fuse with rated current class shall be used. In case that malfunction occurs in the power system,
power supply can be immediately cut off to protect equipment.
1.2.6 No miscellaneous items and wastes shall be left in places, such as stairs and walkway.
1.2.7 Prior to welding, flame cutting, and grinding, the surrounding environment must be cleaned to
remove dusts and other flammables. Sufficient ventilation in the working environment must be assured
(avoidance of danger of explosion)
- 136 -
1.2.8 Professional personnel must carry out the operation when lifting heavy goods, and no one should
be standing below the lifting.
1.2.9 The relevant professional personnel must carry out the commissioning of electrical and hydraulic
system.
1.2.10 Second person must be present when working on live parts and components for emergent
shutdown of the main power switch in the event that danger situation emerges. Red-white safety tape,
acting as a warning of danger, shall be used to isolate the working area. Only insulated tools can be used
during working.
1.2.11 Safety operation rules of the owner must be complied with.
1.3 Preparation prior to Commissioning
1.3.1 A commissioning team shall be formed prior to the commissioning, whose members, in general,
shall primarily be from the installation institution with participation of the user and the design and
manufacturing institution sending engineer for guidance. The commissioning team shall be familiar with
equipment technical performance, operation manual, and commissioning items and shall master the
related commissioning safety knowledge, with formulation of safety assurance measures for the
commissioning. In pursuance to the requirements of every phase of the commissioning, all types of
technical data are measured and recorded. A commissioning report shall be submitted after completion of
the commissioning. In the event that equipment defect is discovered during the course of commissioning,
a list can be prepared for the installation institution to fix it if the defect has no impact on the product
performance, and no new commissioning is necessary. However, if the defect affects the product
performance, the commissioning shall be performed again, and inspection acceptance is signed only after
the design performance is reached.
1.3.2 Various necessary tools, lifting gears, communication equipment, and testing instruments shall be
prepared.
1.4 Inspection prior to Commissioning
1.4.1 The shipunloader is moved to the designated location. The commissioning area is defined with
eye-catching signs hung. A designated person shall guard the area, restricting unrelated persons to enter
the commissioning area.
1.4.2 Anchor pin of the shipunloader shall be properly anchored or the stop block for the wheels of long
travel is properly used to prevent movement of the shipunloader during the course of the commissioning.
1.4.3 To protect against sudden occurrence of cyclone, wind-proof mooring rope of the shipunloader shall
be tied.
1.4.4 Inspect and confirm that no defect, such as fracture, damage, and deformation, is present on the
outer appearance of metal structures and that all welding seam meets the design requirements.
1.4.5 Inspect and confirm that the nameplate and parameters of each driving mechanism meet the design
requirements.
1.4.6 Inspect and confirm that the installation of all transmission mechanism is correct and that all parts
are free of damage and are not left out of installation
- 137 -
1.4.7 Inspect and confirm that no interference, jamming, or obstruction is present for all mechanisms.
1.4.8 Inspect that the installation and nameplate of the outsourcing components meet the design
requirements.
1.4.9 Inspect and confirm that all fastening pieces have been fastened according to the requirements.
1.4.10 Inspect and confirm that all external protective devices, such as limit switch, deviation switch,
pulling wire switch, emergent switch, and photoelectric encoder, are all correctly and fully installed
1.4.11 Inspect and confirm that the ladder platform is in a safe and reliable state.
1.4.12 Inspect and confirm that the main parameters, models of every nameplate of shipunloader are
complete and correct.
1.4.13 Inspect and confirm that appropriate draining holes are present at structures where water
accumulation is possible.
1.4.14 Inspect and confirm that the painting of shipunloader is in good state and meets the requirements
of technical specification.
1.4.15 Inspect and confirm that every pulley and pulley shaft and support are in good condition.
1.4.16 Inspect and confirm that every wheel shaft and hinge point pins are in good conditions.
1.4.17 Inspect and adjust the straightness of drivers cab and trolley rails.
1.4.18 Inspection of lubrication system: (according to lubrication system layout diagram)
l
Inspect and confirm that each lubrication point is equipped with nozzle and that grease has
been added according to the corresponding requirements of the operation manual
Inspect and confirm that the connection of pipelines of every centralized lubrication system is
correct and reliable
Inspect and confirm that the oil charging quantity and the model of gear box oil tank meet the
requirements of the operation manual
Inspect and confirm that the oil charging quantity and model for all brakers and hydraulic
couplers meet the requirements of the operation manual.
1.4.19 Inspection of Hydraulic System: (according to the hydraulic system schematic drawing)
l
Inspect and confirm that the pipeline installation and joining of every hydraulic component meet
the design requirements.
Inspect and confirm that no impurity has entered the entire hydraulic system and that no oil
leakage occurs at every joining of flange and pipe fitting.
Inspect and confirm that air has been eliminated from the entire hydraulic system.
Inspect and confirm that the oil position in the oil tank of every hydraulic system has met the
requirements.
1.4.20 Inspection of Water Spraying Dust Suppression: (according to the system diagram for water
- 138 -
spraying dust suppression system)

l
Inspect and confirm that every water spraying component, pipeline installation, and connections
all meet the design requirements.
Inspect and confirm that no impurity enters the entire water spraying pipeline system, with no
blockage at every point of water spraying.
Inspect and confirm that water cable drum has been correctly installed in accordance with the
requirements
1.4.21 Inspection of Electrical Equipment (according to electrical system schematic drawing)

l
Inspect and confirm that testing of every high voltage electrical equipment has been completed
according to the requirements
Inspect and confirm the grounding resistance of shipunloader: to rail, not greater than 4; to the
entire machine, not greater than 10.
Inspect and confirm that the grounding for direct and alternate current drive control system is
correct and that the equipment operating handles are agile and reliable.
Inspect and confirm that the electrical layout has been correctly installed according to the
requirements of drawings.
Inspect and confirm that cable drum has been correctly installed according to the requirements.
Inspect and confirm that no short circuit has occurred for every phase sequence to ground and
interphase of main power supply, and that the voltage of main power supply and control power
supply is normal
Inspect and confirm that the insulation of ground cable junction box, high voltage slip-ring box,
high voltage transformer, and all related cables (including interphase insulation and every phase
to ground insulation) has met the design requirements
Inspect and confirm that the optical fiber connection device is in good condition.
Inspect and confirm that the electrical wiring is free of omission and error and that all switches,
instruments, and indicators have been calibrated.
Inspect and confirm that the nameplate for every electrical component meets the design
requirements.
Inspect and confirm whether the insulation of every motor is good
Inspection of wiring and insulation of frequency converter.
Inspect whether the resistance value and power of braking resistance meet the design
requirements and whether the wiring is correct.
1.4.22 Illumination and Fire Protection

l
Inspect and confirm that the indoor illumination for platform walkway, drivers cab, machine room,
electrical control room has met the design requirements, and that the illumination for work area
is outdoor spotlight
Inspect and confirm that the fire protection measures inside the drivers cab, machine room,
pitching operation room, and electrical control room have all met the requirements of the
technical agreement.
Inspect and confirm that the illumination of the shipunloader meets the requirements of the
technical agreement.
- 139 -
2.
No Load Commissioning
No load commissioning is carried out after that the inspections prior to commissioning have been
completed, and the shipunloader is assured to be in normal state. During the commissioning process of
this stage, every mechanism of the shipunloader is required to undergo independent action.
Commissioning at rated speed is carried out after slow speed action has been carried out for 3~5 times
according to Article 4.1.3 and no abnormality is found after inspection.
The recommended main commissioning procedure is as follows: supplying power to the entire
unitcommissioning of liftno load commissioning of hoisting and opening/closing mechanisms
(executed before and after the rope has passed through the drum)no load commissioning of trolley
no load commissioning of pitching mechanism (executed before and after the rope has passed through
the drum)commissioning of drivers cabno load commissioning of hopper systemno load
commissioning of drive mechanism of long travelcommissioning of cable drumcommissioning of
water spraying dust suppression system.
In order to speed up the process of commissioning, the order of every independent test run process
can be mutually adjusted. However, commissioning of trolley must be carried out after completion of
commissioning of hoisting and closing mechanisms. When undergoing commissioning of long travel, the
commissioning of electric and water cable drum shall be carried out concurrently.
2.1 Objective of No Load Commissioning
2.1.1 Inspect and eliminate the existing problems after assembly of shipunloader to be fully prepared for
the static load test run.
2.1.2 No load commissioning requires to be carried out at wind speed of 8.3m/s (clear wind under class
5).
2.1.3 No load commissioning for every mechanism shall be carried out with independent slow action for
3~5 times according to Article 4.1.3, which is followed by commissioning at rated speed if there is no
abnormality.
2.1.4 No Load Commissioning Items and Requirements:
l
Inspect and adjust the installation situation and action of every transmission mechanism.
Inspect and adjust the consistency of every operating handle and the corresponding action, with
inspection and adjustment of consistency of every operating button and the corresponding
action.
Inspect and adjust the installation position and action of every type of limit switches and
interlocking devices.
Undergo no load testing on every mechanism and part and measure and record the relevant
technical data.
2.2 Commissioning of Lift
- 140 -
The objective of commissioning of lift is to undergo commissioning according to the testing general
outline of the lift and obtaining the operation permit issued by the local technical supervision bureau.
The specific steps are as follows:
2.2.1 Commissioning of lift can only be carried out after completion of inspections and confirmations
specified under Article 1.2, 1.3 and 1.4.
2.2.2 Inspect and confirm that electrical wiring and buttons are correctly installed according to the
requirements.
2.2.3 Inspect and confirm that the lift guiding rail and installation support are correctly installed according
to the design requirements thus safe and reliable for use.
2.2.4 Inspect and confirm that the lift door and limiters are all properly installed and reliable with proper
functioning of lift door.
2.2.5 Inspect and confirm that escape door is present inside the life and that escape ladders are present
along the travelling course of lift without any obstruction.
2.2.6 Inspect and confirm that protection safety nets are setup at the platforms and walkways along the
travelling course of the lift.
2.2.7 Initiate the main power supply of the lift and initiate the control power supply.
2.2.8 Inspect and confirm that the buttons at every level of lift and inside the car are safe and effective.
2.2.9 Inspect and confirm that the lift car operates stably during the travelling course of lift.
2.2.10 Inspect and confirm that the load and speed of lift meet the requirements of the technical
specification.
2.2.11 Commissioning is carried out according to the testing general outline provided by the lift supplier.
2.2.12 Obtain the operation permit issued by the local technical supervision bureau.
2.3 No Load Commissioning for Hoisting and Opening/Closing Mechanisms
Commissioning for hoisting and opening/closing mechanisms is divided into 2 phases:
l
Commissioning before the rope has been passed through
Commissioning after the rope has been passed through
During commissioning of this stage, particular attention should be paid to the step by step
commissioning of the hoisting and opening/closing mechanisms, and the synchronization of the four
ropes (opening/closing action should be tested before the synchronized action of hoisting and opening/
closing action).
2.3.1 No load commissioning of hoisting and closing mechanisms can only be carried out after completion
of inspections and confirmations specified under Article 1.2, 1.3 and 1.4
- 141 -
2.3.2 Move the trolley to a position between the legs and immobilize it (no obstacle is present between
trolley and ground).
2.3.3 Move the grab to a position underneath the trolley (no obstacle is present between trolley and grab)
2.3.4 Inspect whether the opening of grab meets the design requirements.
2.3.5 Inspect whether every part of grab is fastened and connected normally and reliably.
2.3.6 Inspect whether the joining ring and the pyriform head device are in good condition without
abnormality.
2.3.7 Inspect and confirm the weigh sensor model and installation meet the design requirements.
2.3.8 Initiate the main power supply of hoisting and opening/closing and initiate the control power supply.
2.3.9 Separate motor and gear box, allowing the frequency converter to complete self-learning.
2.3.10 Configure frequency converter parameters and set the thermal relay and over-current relay at 1 ~
1.2 folds of the rated current.
2.3.11 Electrify to undergo commissioning of hoisting and opening/closing mechanisms. Repeat test runs
at low speed operation for 10~20min according to Article 4.1.3 first. Then after inspection and adjustment
of driving mechanism and brakers are completed, test run is carried out at the rated speed according to
Article 4.1.3.
2.3.12 Initiate hoisting and opening/closing mechanisms to undergo no load operation before the rope
has been passed through.
2.3.13 Inspect and confirm that the hoisting and opening/closing mechanism operates stably without
abnormal shaking and heating phenomena.
2.3.14 Inspect and confirm the rotating direction and synchronization of hoisting and opening/closing
motors to be in good state.
2.3.15 Inspect and adjust the braking and synchronization of every braker to be in good state and
adjusting the braking torque of brakers.
2.3.16 Inspect and confirm that the operation of driving motor, gear box, and bearing is sound
2.3.17 Inspect and confirm the consistency of operating handle and hoisting action.
2.3.18 Initiate hoisting and opening/closing mechanisms to undergo no load operation after the rope has
been passed through with joining of the grab.
2.3.19 Inspect and confirm that the rope operation is in good condition.
2.3.20 Inspect that the tightness of closed grab meets the design requirements.
2.3.21 Inspect and confirm that the joining of every transmission component support is in good condition
before and after operation.
2.3.22 Inspect and adjust limiting switch with confirmation of hoisting height, and maximal lowering depth.
- 142 -
2.3.23 Measure motor rotating speed and record motor current and rotating speed separately.
2.3.24 Inspect and confirm that the joining of hoisting and opening/closing ropes is in good condition after
operation.
2.3.25 Operate the handle on the operation platform in the drivers cab to lift the grab to a position 1m
above ground and undergo grab opening/closing action for 3~5 times. Then lower the grab to ground.
Repeat the aforementioned actions 3~5 times and undergo inspection and confirmation regarding Article
2.3.26 Inspect and confirm that the handle direction is consistent with the direction of hoisting/lowering
and opening/closing of the grab.
2.3.27 Inspect and confirm whether the compensation travel of opening/closing rope and hoisting is
synchronized.
2.3.28 Inspect and confirm that the opening/closing action of grab is agile and whether the positioning
block is good and reliable after the grab is opened for inspection.
2.3.29 Inspect and confirm whether the hoisting chain, C ring, taper clamming sleeve, and pulley are
reliable and whether large impact and abnormality are present during the hoisting process.
2.3.30 Inspect and adjust the length of hoisting ropes to maintain the balance of the grab.
2.4 No Load Commissioning for Trolley Travelling
The trolley traveling mechanism of shipunloader is divided into three types of trolleys, including main
and auxiliary trolleys, mechanical/electrical differential driven four-drum, and self-traveling trolley, which
shall be discussed separately after overview.
Please note that this test run is only limited to round-trip traveling of trolleys, i.e. independent test
run.
2.4.1 No load commissioning of trolley mechanism can only be carried out after completion of inspections
and confirmations specified under Article 1.2, 1.3 and 1.4
2.4.2 Prior to traveling of trolley, inspect and confirm that the installation of trolley rail meets the design
requirements.
2.4.3 Inspect and confirm that no obstacle is present on the total length of trolley rail, interfering traveling
of trolley.
2.4.4 Prior to traveling of trolley, inspect and confirm the gap between wheels and rail with adjustment of
eccentricity of horizontal wheels, allowing the center to be consistent with the center of rail.
2.4.5 Inspect and confirm that the model and installation of trolley buffers meet the design requirements.
2.4.6 Inspect and confirm that the stop block on the end of trolley traveling rail is safe and reliable.
2.4.7 Initiate the main power supply of trolley mechanism and initiate the control power supply.
- 143 -
2.4.10 Electrify to undergo commissioning of trolley traveling mechanism.
2.4.11 Repeat test runs at low speed operation for 10~20min according to Article 4.1.3 first. Then after
inspection and adjustment of driving mechanism and brakes are completed, test run is carried out at the
rated speed according to Article 4.1.3.
2.4.12 Initiate trolley traveling mechanism to undergo no load operation before the rope has been passed
through.
2.4.13 Inspect and confirm that the traveling mechanism of trolley operates stably without abnormal
shaking or heating phenomena.
2.4.14 Inspect and adjust the working condition of braker and adjusting the braking torque of brake.
2.4.15 Inspect and confirm the consistency of operating handle and motor rotating direction.
2.4.16 Initiate trolley traveling mechanism to undergo no load operation after rope has been passed
through.
2.4.17 Inspect and confirm the reliability of joining of ropes.
2.4.18 Inspect and confirm the consistency of traveling direction of trolley and action of operating handle.
2.4.19 Inspect the operation of driving device, pulley bearing, and wheel bearing.
2.4.20 Inspect and adjust increase and decrease time and acceleration and deceleration of trolley to meet
the design requirements.
2.4.21 Adjust maximal limit switch, end-point limit switch, deceleration limit switch, and sea and land side
differentiation limit switch (parking position limit switch) to allow proper function.
2.4.22 Inspect the locomotion of rail joint of trolley when it arrives at the hinge point of front and back
girders.
2.4.23 Inspect and adjust the working condition of the interlocking switch, allowing trolley to operate only
when the level of front girder is at 0 position.
2.4.24 Inspect whether the grab will produce abnormal swing during trolley operation process.
2.4.25 Inspect trolley traveling speed and motor voltage, current, and rotating speed;
2.4.26 Main and auxiliary trolley type: (undergo the following inspections)
l
Inspect and confirm main and auxiliary trolleys rope reeling and rope lubrication condition.
Inspect and confirm trolley rope fixation and trolley operating situation.
Inspect and confirm installation state of main and auxiliary trolleys reverse roller/hook and adjust
gap of the entire traveling distance.
Inspect and confirm whether trolley tension system meets the design requirements.
Inspect and adjust the balance between the left and right ropes of trolley.
- 144 -
Inspect and adjust the relative position of main and auxiliary trolleys.
2.4.27 Four-Drum Type: (undergo the following inspections)

l
Inspect rope reeling condition of front and backward cantenary trolley.
Inspect rope fixation and rope lubrication condition of cantenary trolley.
Inspect the relative positions of front and backward cantenary trolleys and main trolley.
Inspect installation of main/cantenary trolley reverse rollers and adjust the gap of the entire
traveling distance.
Inspect and confirm the tension system of cantenary trolley meets the design requirements.
Inspect and adjust the balance between the left and right ropes of cantenary trolley.
Inspect and adjust the rope and roller height of cantenary trolley, allowing rope to deflect
downwardly to optimal condition.
2.4.28 Self-Traveling Trolley Type: (undergo the following inspections)

l
Inspect and confirm that the power supply method meets the design requirements.
Inspect whether the travel of trolley meets the design requirements.
Inspect and confirm that the wheels of trolley do not slip.
2.5 No Load Commissioning for Pitching Mechanism

Commissioning for pitching mechanism is divided into 2 phases:
l
Commissioning before the rope has been passed through
Commissioning after the rope has been passed throug

2.5.1 No load commissioning for pitching mechanism can only be carried out after completion of
inspections and confirmations specified under Article 1.2, 1.3 and 1.4
2.5.2 Inspect and confirm that every drift pin position of the front tension bar is in sound condition with
good lubrication.
2.5.3 Inspect and confirm pulley and its support base are in sound condition with good lubrication of
pulley.
2.5.4 Inspect and confirm that pitching can only be executed when trolley and pitching interlocking switch
are activated.
2.5.5 Initiate the main power supply of trolley mechanism and initiate the control power supply.
2.5.8 Electrify to undergo commissioning of pitching mechanism.
2.5.9 Initiate pitching mechanism to undergo no load operation before the rope has been passed through.
2.5.10 Inspect and confirm that the pitching mechanism can operate stably without abnormal shaking and
heating phenomena
- 145 -
2.5.11 Inspect and confirm the action situation of every braker (when working normally, high-speed shaft
braker is activated first. Then the safety braker is activated. Under speeding condition, safety braker shall
brake immediately). Adjust the braking torque of braker.
2.5.12 Inspect and confirm that the direction of operating handle and motor rotating direction are
consistent.
2.5.13 Initiate pitching mechanism to undergo no load operation after the rope has been passed through.
2.5.14 Lift the front girder approximately 10 degrees at low speed operation for 3~5 times according to
Article 4.1.3 first. Then after inspection and adjustment of driving mechanism and brakers are completed,
test run is carried out at the rated speed according to Article 4.1.3 for 3~5 times.
2.5.15 Inspect and confirm the reliability of action of operating the girder inside the drivers cab and the
pitching operation room
2.5.16 Inspect the running condition of motor, gear box, and bearing support of the pitching mechanism.
2.5.17 Inspect and confirm the joining of support of each transmission part.
2.5.18 During the course of pitching, inspect and confirm that no interference exists between the hoisting
and opening/closing and trolley rope.
2.5.19 During the course of pitching, inspect and confirm the synchronization of two pitching ropes.
2.5.20 During the course of pitching, inspect the motion of drivers cab and trolley rail joint.
2.5.21 When the front girder is slowly hoisted to the hook position, reaching the pitching angle, inspect
the automatic hooking of safety hook with centering of the two left and right hooks and locking to the pin
of the front girder.
2.5.22 Inspect the working condition of limit switch for hooking and unhooking of safety hook and all the
related signal lights.
2.5.23 Measure and record derricking time and driving motor current, voltage, and rotating speed.
2.5.24 Inspect working condition of pitching emergent mechanism.
2.6 Commissioning for Drivers Cab Travelling Mechanism
The specific steps are as follows
2.6.1 No load commissioning can only be carried out after completion of inspections and confirmations
specified under Article 1.2, 1.3 and 1.4
2.6.2 Inspect and confirm that the installation of buffers meets the design requirement.
2.6.3 Inspect and confirm cable pulleys are properly arranged on the rails without drag and are firmly and
reliably joined. Confirm that the pulley blocks are fully lubricated accordingly and that they are tightly
joined to the base with anti-loosening device. Confirm that the horizontal wheels of pulley blocks are agile
and reliable.
2.6.4 Inspection of the entire traveling course of the drivers cab is free of obstacle. Drivers cab and the
- 146 -
upper hanger are tightly joined. The active and driven wheels have good contact with rails. Motor and
electrical wiring are correct and firmly attached. Confirm that the motor and gear box flange are tightly
and reliably joined.
2.6.5 Inspect and confirm that brake of drivers cab is installed and adjust the braker to operate normally.
2.6.6 Inspect and confirm that anchor device and limiter switches are setup according to the design
requirements and are safe and effective.
2.6.7 Inspect and confirm that every function button, indicator, instrument, communication equipment, air
conditioning, illumination, and fire protection equipment are fully equipped.
2.6.8 Inspect and confirm that the escape platform of drivers cab is safe and reliable for the drivers cab to
be at any position.
2.6.9 Initiate the main power supply of drivers cab and initiate control power supply.
2.6.11 Electrify to undergo commissioning of traveling mechanism of drivers cab.
2.6.12 Inspect and confirm that the drivers cab can only undergo pitching after stopping at the designated
position of the back girder.
2.6.1 Inspect the effectiveness and proper function of every interlocking and limiter throughout the entire
traveling course at rated speed and repeat the process three times.
2.6.1 Inspect whether it is possible for the drivers cab and cable tray to interfere with the platform or
guardrail throughout the entire traveling course.
2.6.15 Inspection of stable operation of drivers cab.
2.6.16 Inspect and record traveling speed of drivers cab and motor working current, voltage, and rotating
speed;
2.7 No load Commissioning for Hoppers System
2.7.1 No load commissioning for hoppers system can only be carried out after completion of inspections
and confirmations specified under Article 1.2, 1.3 and 1.4
2.7.2 Inspect and confirm that no obstacle is present within the operating boundary of hoppers system.
2.7.3 Inspect and confirm the joining condition between hoppers system and dock belt conveyor system.
2.7.4 Inspect and adjust the interlocking function and working reliability of each limiter switch of hoppers
system.
2.7.5 Inspect and confirm whether installation of all parts of hoppers system meets the design
requirements.
2.7.6 Initiate the main power supply of hoppers system and initiate control power supply.
- 147 -
2.7.8 Electrify to undergo commissioning of hoppers system
2.7.9 Inspect working condition of grab opening/closing mechanism.
2.7.10 Inspect working condition of shake-feeder (if present).
2.7.11 Inspect working condition of receiving plate.
2.7.12 Inspect working condition of wind damper (if present).
2.7.13 Inspect working condition and protection device of belt conveyor system (if present).
2.7.14 Inspect operating condition of motor and gear box of all mechanisms (if present).
2.7.15 Inspect joining of rope, pulley block, and transmission shaft (if present).
2.7.16 Inspect working condition of hydraulic component and hydraulic system (if present).
2.7.17 Inspect and adjust display of weight sensor.
2.8 Commissioning for Travelling Mechanism of Long Travel
The commissioning of traveling of long travel is carried out in two steps with the commissioning of
local operation cabinet of long travel first and followed by the commissioning of operation in the drivers
cab.
Prior to the traveling of long travel, the wind-proof mooring rope shall be un-tied, and the anchor pin
is raised.
2.8.1 No load commissioning for traveling mechanism of long travel can only be carried out after
completion of inspections and confirmations specified under Article 1.2, 1.3 and 1.4
2.8.2 Inspect and confirm that the installation of long travel driving mechanism meets the design
requirements.
2.8.3 Inspect whether there are obstacles on or around the travelling rails of long travel.
2.8.4 Inspect and confirm that the installation of anchor device, windproof mooring rope, and rail clamper/
trochus meets the design requirements.
2.8.5 Confirm that the nameplate and installation of long travel buffers meet the design requirements
2.8.6 Inspect all the limit switch wirings of the mechanism are correct and confirm the voltage grade of
limit switch meet the design requirements. Manually move the limit switch three times to assure reliable
functioning.
2.8.7 Initiate the main power supply of long travel mechanism and initiate control power supply.
- 148 -
2.8.9 Electrify to undergo commissioning of traveling mechanism of long travel

2.8.10 Adjust the encoder of traveling of long travel.
2.8.11 Adjust end-point travel limiting switch of traveling of long travel.
2.8.12 Inspect and confirm that every interlocking of drive mechanism of long travel meets the design
requirements.
2.8.13 Inspect and adjust the direction of motor rotating direction to be consistent with the driving
direction of long travel.
2.8.14 Measure every phase sequence of inlet and outlet of frequency converter and its grounding
insulation performance and inspect whether the control board wiring of sensor is correct
2.8.15 Inspect and confirm that the interlocking of electric and water cable drum and traveling of long
travel is normal and reliable.
2.8.16 Inspect and confirm that the operating handle is consistent with the driving direction of long travel.
2.8.17 Inspect and confirm the normal operation of every motor, gear box, wheel bearing.
2.8.18 Inspect and adjust brake with adjustment of braking torque.
2.8.19 Inspect working condition of anchor device after inching the long travel to the anchor position.
2.8.20 Inspect the contact situation between wheels and rail.
2.8.21 Inspect the working condition of lighting and warning sound signals of traveling of long travel.
2.8.22 Inspect reliability of emergent button of long travel drive
2.8.23 Measure the driving speed of long travel after driving 50m round-trip twice.
2.9 Commissioning for Electric and Water Cable Drum
2.9.1 Inspect and confirm that electric and water cable drum has been installed and tightly joined
according to the requirements of the drawing.
2.9.2 Inspect and confirm that gear box and bearing shaft are fully lubricated and that the turning part is
installed with protection cover.
2.9.3 Inspect and confirm that the endings are firmly and reliably connected and that the sealing and
insulation meet the requirements.
2.9.4 Inspect and confirm that every motor, gear box, nameplate parameter meets the design
requirements.
2.9.5 Electrify to undergo commissioning of cable drum.
2.9.6 Inspect the position of cable on top of supporting bracket.
2.9.7 Inspect and confirm whether cable drum has sufficient amount of safety strap.
- 149 -
2.9.8 Inspect and adjust over-midpoint testing switch of cable drum.

2.9.9 Inspect, confirm, and adjust the normal working condition of over-tension and anti-relation protection
of drum
2.9.10 Inspect and adjust over-end-point protection of cable drum.
2.9.11 Inspect and adjust the interlocking protection of traveling of long travel
2.10 Commissioning for Water Spraying Dust Suppression System
2.10.1 Inspect and confirm that the water tank, valve block, and pipeline of water spraying dust
suppression system have been correctly installed.
2.10.2 Inspect and confirm that the nameplate and parameters of water pump motor meet the design
requirements, that the joining of motor support is reliable with anti-loosening measures, and that the
electrical wiring is correct with grounding of outer cover and insulation resistance value meeting the
requirements.
2.10.3 Inspect whether the fluid level gauge of the water tank and the wiring of electromagnetic valve are
correct. Confirm whether the voltage grade meets the design requirements.
2.10.4 Measure whether there is any presence of short-circuits between the phase sequence and
grounding of the main power source of the mechanism and control power supply.
2.10.5 Set the parameters of the thermal relay of the motor of this mechanism, and the set value is 1 ~
2.10.6 Inspect and confirm that every water spraying point is positioned according to the design
requirements and is firmly fixed to the hopper and centralized dusting positions of materials.
2.10.7 Electrify to initiate water spraying dust suppression system.
2.10.8 Confirm that valve pieces and valve block system are reliable without leakage from pipeline and
adjust pressure to meet the design requirements
2.10.9 Adjust motor turning direction and initiate the mechanism motor, which operates for 5 minutes to
assure the normal working condition of motor.
2.10.10 Inspect and confirm that the electromagnetic valve action meets the interlocking design
requirements.
2.10.11 Adjust system outfall pressure. Water spraying is in the form of mist and is displayed at every
point of water spraying.
2.10.12 Test and record the initiation and operating current of motor.
2.11 Commissioning for Hydraulic System
2.11.1 Inspect switch of every valve of hydraulic system.
2.11.2 When user is adding oil, 20 of filtering carriage must be used, and hydraulic oil is infused into the
- 150 -
oil tank from the oil filler on the oil tank (see hydraulic system operation manual) until reaching the upper
limit of the oil leveler. During the process of commissioning, pay close attention to the oil level in the oil
tank. Oil shall be timely added to the oil tank, after the hydraulic oil enters the system pipeline and
cylinder (or hydraulic motor). The oil level shall be maintained at the position above the middle of the oil
level gauge in the oil tank.
2.11.3 See hydraulic system operation manual for use and replacement of hydraulic oil and the
replacement of filter in the system.
2.11.4 Inspect and determine all nameplate parameters meet the design requirements.
2.11.6 Set the protection parameters of the thermal relay of the motor and fan of this mechanism, and the
set value is 1 ~ 1.2 folds of the rated current of its nameplate.
2.11.7 Use megameter to inspect every phase sequence to ground insulation performance of motor and
fan of this mechanism with insulation resistance 2M.
2.11.8 Confirm motor rotating direction. When initiating the machine for the first time, inching of motor
shall be carried out. Confirm that the rotating direction of motor is consistent with the direction of the red
arrow on the motor. Prior to electrify test run, hydraulic oil circulating testing shall be carried out, with
cleanness grade of hydraulic oil reaching Nesslers Grade 7 after testing.
2.11.9 Inspect the rotating direction of hydraulic motor.
2.11.10 After completion of commissioning of hydraulic system, initiate hydraulic motor to undergo idle run
for 5 minutes, with inspection of the entire system showing no leakage. Test and record the initiating
current of motor and the no load running current (see hydraulic system operation manual for the initial
adjustment after initiating the machine).
2.11.11 Hydraulic system testing pressure shall meet the requirements of GB1048 with pressure
maintained for 30 minutes. No leakage and deformation shall be present throughout the entire system.
2.11.12 Adjust the cylinder speed to meet the design requirements
2.12 Commissioning for Centralized Lubrication System
2.12.1 Inspect and confirm that lubrication oil pump adds oil to the oil level of the oil tank.
2.12.2 Inspect whether the pipeline joining is correct.
2.12.3 Inspect and confirm that the nameplate data of the motor are same as the design.
2.12.4 Inspect whether the wiring of the low oil level signaler and safety valve is correct and confirm that
the voltage grade is same as the design.
2.12.6 Inspect and confirm every phase sequence to ground insulation performance of motor of this
- 151 -
mechanism with insulation resistance meeting the requirements.

2.12.7 Set the parameters of the thermal relay of the motor of this mechanism, and the set value is 1 ~
2.12.8 Adjust motor rotating direction and initiate motor of this mechanism with 5 minutes of operation to
assure normal functioning of the motor.
2.12.9 Adjust pressure of relief valve and safety valve according to the requirements of lubrication system
operation manual and inspect whether there is any leakage in the pipeline and every lubricant point is
normally lubricated
2.12.10 Test and record starting current of motor
2.13 Commissioning for Belt Conveyor
2.13.1 Adjust the tight contact between rubber blocking flap on the guiding channel and conveying belt.
2.13.2 Adjust the joining degree of head sweeper and gap segment sweeper and conveying belt to meet
the requirements.
2.13.3 Adjusting tensioning device to the design requirement and tightening backstop nut.
2.13.4 Manually stimulate commissioning for device detecting deviation of conveying belt: giving off
warning signal for grade I deviation and stopping of operation of conveying belt for grade II deviation.
Repeat the process three times to assure reliable functioning.
2.13.5 Manually simulate commissioning of blocking switch, level switch, and emergent pull cord switch of
belt conveyor for 3~5 times to assure reliable functioning.
2.13.6 Inspect and confirm that the nameplate data of gear box, motor, braker, and cooling pump motor
are same as the design.
grounding of the main source of the mechanism and control power supply.
2.13.8 Inspect grounding insulation performance of every phase sequence of motor and braker and
whether insulation resistance meets the requirements.
2.13.9 Inspect all of the protective switch wiring for this mechanism is correct and confirm whether its
voltage grade is same as the design
2.13.10 Set the parameters of the motor and braker of this mechanism, and the set value is 1 ~ 1.2 folds
of the rated current.
2.13.11 Adjust the centering position of brakers and adjust the torque to the designed value. Initiate
brakers to undergo opening/closing action of brakers three times to assure that the action of
opening/closing inspection limit switch of brakers is reliable.
2.13.12 Confirm the rotating direction of motor. Initiate motor of belt conveyor with 5 min of operation in
both directions to assure that the motor functions normally. After operation of belt conveyor, observe and
correct the running deviation of the conveying belt.
- 152 -
2.13.13 Measure and record the current for motor initiation and no load operation
2.13.14 Under operating condition, inspect and confirm whether the speed measurement switch of belt
conveyor is reliable
3
Commissioning for Safety Interlocking Operation

After completion of no load test run, the shipunloader has already possessed the capability of having
each of its operating mechanism to undergo independent operation. To assure the smooth progress of the
later test runs, the task of inspection and confirmation of braker and interlocking limiting shall be carried
out.
The commissioning of every part can make reference to the corresponding process of no load
commissioning and can be carried out simultaneously.
3.1 Inspect and confirm that installation of every braker and the braking torque of braker have been
adjusted normally.
3.2 Inspect and confirm that every electrical limiting and interlocking device of the entire machine has
been correctly positioned with agile and reliable switch action
3.3 Itemized inspection and adjustment of the interlocking functions of shipunloader
3.3.1 Inspect and adjust the interlocking content of hoisting and opening/closing mechanisms, and the
specific is as follows:
l
Automatic emergent parking at maximal hoisting height;
Automatic parking when reaching normal highest hoisting height;
Automatic deceleration before reaching normal highest hoisting height;
Automatic parking at normal unloading height;
Automatic deceleration at normal unloading height;
Automatic deceleration at normal lowest position;
When the normal lowest position is reached, automatic parking will occur;
When the lowering reaches the maximal lowest position, emergent parking will occur
automatically;
When the lowering speed exceeds 15% of the rate value, automatic parking will occur for
speeding protection;
Prevent over-relaxation of rope and rope skipping.
3.3.2 Inspect and adjust the interlocking content of pitching mechanism, and the specific is as follows:
l
When the front girder is lowered to the normal lower limiting position, parking is automatically
activated;
When the front girder is hoisted to the normal upper limiting position, the action is automatically
stopped;
When the front girder is lowered to the normal lower limiting position, deceleration automatically
occurs;
When the front girder is hoisted to the normal upper limiting position, deceleration automatically
occurs;
- 153 -
When the front girder is hoisted to the maximal upper limiting position, emergent stop is
automatically activated;
When the pitching speed of the front girder exceeds 15% of the rated value, emergent brake
shall automatically be activated for speeding protection;
Limit rope relaxation and protection against rope skipping;
Interlocking with safety hook of front girder, assuring that pitching mechanism cannot perform
lowering action until the safety hook (pin) has been unhooked;
Interlocking with trolley, assuring that pitching mechanism can only be electrified and initiated
after drivers cab has returned inside the sea side door leg;
Interlocking with drivers cab, assuring that pitching mechanism can only be electrified and
initiated after drivers cab has returned inside the sea side door leg.
3.3.3 Inspect and adjust the interlocking content of traveling mechanism of long travel, and the specific is
as follows:
l
Interlocking with anchor/wind-proof mooring limit switch;
Interlocking with cable drum limit switch;
Interlocking with dock working/maximal limit switch;
Interlocking with acoustic-optic warning system;
Interlocking with rail clamper/trochus;
Interlocking with emergent button.
3.3.4 Inspect and adjust the interlocking content of hopper system of shipunloader, and the specific is as
follows:
l
Interlocking with the dock belt conveyor;
Mutual interlocking protection within the hopper system.
3.3.5 Inspect and adjust the interlocking content of trolley driving mechanism, and the specific is as
follows:
l
Interlocking with hopper land side wind damper of shipunloader;
Interlocking with hopper receiving plate of shipunloader;
Interlocking with trolley traveling limit switch;
Interlocking with water spraying and dust suppression system of shipunloader;
Interlocking with hopper sensor of shipunloader;
3.4 Inspect and confirm the normal and reliable function of every emergent shutdown button and switch.
3.5 Inspect and confirm whether every display and warning device is working normally.
3.6 Inspect and confirm the reliability of anchoring actions.
3.7 Inspect and confirm the normal clamping and loosening action of rail clamper/trochus.
3.8 Inspect and confirm normal Interlocking working state of collision protection device
3.9 Adjust initial value of every encoder.
- 154 -
4.

After completion of no load test run and safety and Interlocking action test run with no abnormality
found in every mechanism motor, transmission mechanism, support part, rope, and electrical equipment,
then static load test run can be carried out.
Static load test run is divided into full load and overload test runs. Its objective is: inspection of
strength and degree of deflection of transmission parts, linked parts, and metal structures, with further
adjustment of every braker and adjustment of overload limiter.
Anchor pin of the shipunloader shall be properly anchored or the stop block for the wheels of long
travel is properly used to prevent movement of the shipunloader during the course of the commissioning.
To protect against sudden occurrence of cyclone, wind-proof mooring rope of the shipunloader shall be
tied.
Static load test run requires to be carried out at wind speed of 8.3m/s (clear wind under class 5).
4.1 Loading Preparation
Prepare the grab and the counter weight blocks or section materials that are equivalent to the lifting
weight. The loading combination shall meet the weight distribution of test run as specified under Article 4
4.1.1
Rated hoisting load:
4.1.2
125% of Overloading of Static Load
4.1.3
Required Testing Weight:

G
Rated Value G
36t
45t
Unit: t
70%
110%
125%
25t
40t
45t
36t
Required Testing Speed: 135m/min

V
Rated Value V
Unit: m/min
20%
70%
100%
27
95
135
135
4.2 Static Load Test Run

Objective of static load test run: is to inspect the bearing capacity of every part and metal structure of
the product.
Label measuring reference points: A, B, C, D, and E.
l
Point A: position of frontreach
Point B: hinge point of front tension bar of trolley
Point C: center of hinge point of front tension bar and hinge point of front girder
- 155 -
Point D: center position of sea and land side frame
Point E: position of backreach
4.2.1
Trial Operation Prior to Static Load Testing
Lift 0.7G of weight and travels round-trip on the total length of the rail three times at 0.70V speed to
eliminate the internal stress of the structure. Inspect and confirm whether the joining state of steel
structures is sound.
Inspect and confirm that the hoisting and opening/closing and trolley driving mechanisms work
normally.
Inspect and confirm that the joining state of ropes is sound
4.2.2
Full Load Static Load Testing: (100% Load)
After completion of static load test run with no abnormality found in every mechanism motor,
transmission mechanism, support part, rope, and electrical equipment, then full load test run can be
carried out.
At Point A, B, C, D, and E separately, gradual increase from no impact to 1.0G with 100~200mm
above ground and maintain for 10min and repeat three times. Observe the condition of girder, door frame,
and tension bar, and examine whether the rated load indicator is normal. Inspect the steel structure,
which shall not have permanent deformation or fracture after removing the load.
4.2.3
Overload Static Load Testing: (125% Load)
After completion of full load static load test run with no abnormality found in every mechanism motor,
transmission mechanism, support part, rope, and electrical equipment, then overload test run can be
carried out.
At Point A, B, C, D, and E separately, gradual increase from no impact to 1.25G with 100~200mm
above ground and maintain for 10min and repeat three times. Observe the condition of girder, door frame,
and tension bar, with further adjustment of mechanism brake concurrently. Measure the deformation
value at Point A, B, C, D, and E. Inspect the steel structure, which shall not have permanent deformation
or fracture after removing the load.
- 156 -
Dynamic Load Test Run

After completion of static load test run with no abnormality found in every mechanism motor,
transmission mechanism, support part, rope, and electrical equipment, then dynamic load test run can be
carried out.
Prior to dynamic load test run, every transmission, joining parts, and the major welding seams of
metal structures shall be re-examined comprehensively. Abnormalities, such as residual deformation,
loosening, unsoldering, and fracture, shall not be present. Dynamic load test run can only be carried out
under the condition of every rope fitting and its fastening parts are firmly and reliably fixed.
During the dynamic load test run, the wind-proof mooring rope shall be un-tied, and the anchor pin is
raised, allowing the shipunloader to be at the normal shipunloading operation state.
Dynamic load test run requires to be carried out at wind speed of 8.3m/s. Every mechanism should
undergo testing separately first, and then linked testing is carried out
5.1 Hoisting and Opening/Closing Mechanisms Single Test Run: (100% Load)
Trolley travels to frontreach, mid-span, and backreach positions, and then, under condition of
hoisting of full load, test run of hoisting and lowering actions is carried out separately. Repeat the hoisting
and lowering actions 3~5 times. (mid-span is determined based on the actual situation).
First, hoist the load for approximately 0.5m and then stop the trolley. Working condition of braker is
inspected, and test run is continued after normal working condition is observed.
l
Inspect the heating situation and shaking condition of every motor and transmission
mechanism.
Inspect the working condition of brakers
Inspect the supporting condition of transmission mechanism.
Measure and record hoisting and opening/closing speed, motor voltage, current, rotating speed,
power, and temperature rise of motor.
5.2 Trolley Traveling Single Test Run: (100% Load)

After single dynamic load test run of the hoisting and opening/closing mechanisms, the single
dynamic load test run of trolley operation can only be carried out with every mechanism motor,
transmission mechanism, supporting parts, rope, and electrical equipment showing no abnormal
condition.
Lifting the rated load with round-trip operation of the total travel of trolley is carried out. Low speed
travel first and then followed by travel at rated speed in accordance with 4.1.3. Repeat the process 3~5
times for test run.
l
Inspect the contact situation of the trolley wheels and the rail and the contact situation of the
horizontal wheels and the side of rail.
Inspect the operating condition of every motor, gear box, and wheel bearing with inspection of
the joining condition of the gear box and the machine room base support.
- 157 -
Inspect the working condition of brakers.
Inspect the trolley rail joint at the hinge point of front and back girder.
Inspect the working condition of trolley tension system.
Inspect the working reliability of end-point limiting, deceleration limiting, and trolley parking
limiting.
5.3 Linked Operation of Hoisting and Opening/Closing and Trolley Travelling: (100% Load)
After independent test run and under no abnormal condition, linked operation test run for at least 20
minutes is then carried out.
Inspection Items: same as Article 5.1 and 5.2, with concurrent observation of the linked action and
coordination.
5.4 110% Overload Dynamic Testing
110% Overload dynamic test run is carried out with single action.
Testing Load: See Article 4.1.3
Trolley is positioned at Point A, C, and D, with hoisting and lowering of the specified load 3~5 times.
Inspection Items: same as Article 5.1 and 5.2.
5.5 Two-Hour Continuous Operation Testing
After comprehensive test run has been fully completed and every tested item has qualified,
eight-hour continuous operating testing can then be carried out.
Objective: Inspection of temperature rise of motor and bearing and the working reliability of every
mechanism component.
Inspect metal structure pieces for any abnormality.
The two-hour continuous cycle simulated testing of shipunloader: grab with the specified lifting
weight, action is carried out according to the simulated cycle curve from the ship hatch to the top of the
hopper. If heavy weight is used, the hopper does not have to be opened. The operation is carried out
continuously and ceaselessly for two hours. Otherwise, the entire testing has to be repeated. Every cycle
is completed within the shortest time possible.
Inspection after continuous operation: after the shipunloader has undergone two-hour continuous
cycle simulated operation, inspection is carried out on the transmission part of the mechanism: gear box,
rope, pulley, brake wheels, motor insulation, and temperature rise.
Additionally, two-hour continuous testing or actual ship operation can be carried out.
5.6 Cyclic Working Time Determination
5.6.1 Simulated Operating Cycle:
In pursuance to the requirements of the technical specification with the ship model, type of materials,
and density of materials specified by the contract, at mean tidal level, the grab is positioned at the middle
hatch of the ship, which is equivalent to the grabbing and unloading operation within the plane of half of
- 158 -
the molded depth.

5.6.2 Determination of Cycle Time
Under the aforementioned working conditions, the grab separately takes 5 buckets from each of the
2 hatches (excluding the time used for changing hatch). Take the total time of grab action and divided by
10 to derive a mean value, which is set to be a working cycle period for the shipunloader.
5.6.3 Calculation of Productivity:
The sum of the weight of loads obtained from the aforementioned testing divided by 10 is used as
the mean weight of every hopper.
The mean weight is divided by the pre-set working cycle. The resulting weight is the actual
productivity rate.
5.7 Continuous Shipunloading Inspection Acceptance Testing
During the operation period for inspection acceptance of shipunloader, the shipunloader has to
undergo continuous unloading of coal for 2~3 cargo ships. Evaluation is carried out regarding all items of
working performance index.
- 159 -
Shipunloader Inspection Acceptance Evaluation
After the shipunloader has completed and qualified all of the aforementioned test run items, the test
run group shall inspect and confirm that other technical documents and the corresponding spare parts
and tools are present.
The missing parts shall be replaced immediately, including the followings:
6.1 Set of documents that shall be provided;

l
Installation, operation, maintenance, and instruction manual
List of spare parts and tools;
Qualification certificate for outsourcing products
Duplicate copy of inspection and flaw detection report issued by the manufacturer;
Duplicate copy of inspection and flaw detection report issued by the installation institution;
Product qualification certificate for shipunloader;
Other related documents stipulated under the Contract.
(aforementioned technical documents can be submitted and bound as one volume)

6.2 The state general administration of quality supervision and inspection or the local quality technical
supervision authority shall issue a special equipment operation registration certificate.
6.3 Various spare parts and tools that should be provided;
6.4 Inspection of shipunloader for meeting the terms of delivery stipulated under the Contract without any
omission and missing parts.
- 160 -
Form: 1 Testing of Main Parameters of Shipunloader

China Huadian Engineering Co.,
Ltd.
List of Inspection Items for Test

Run
Product Name: TJB Project

1500t/h Shipunloader
Name of Inspection: Testing of Main Parameters of Shipunloader

Item
1
2
3
4
5
6
7
8
9
10
Content of Inspection
Inspection
Standard
Frontreach distance (with center of sea side rail as

reference)
35m
Backreach distance (with center of sea side rail as

reference)
18m
Rail gauge (from center of sea side rail to center of

land side rail)
22m
Plane height under the front girder from sea side rail
to shipunloader
28m
Net height from ground of sea and land side joining

cross beam
10m
18m
Base distance of sea side door frame
18m
Base distance of land side door frame

Overall width of shipunloader (distance between two
buffers)
29.268m
Frontreach distance of drivers cab (with center of sea

side rail as reference)
28m
Backreach distance of drivers cab (with center of sea

side rail as reference)
22m
Signature:
Representative of Owner:
Representative of Manufacturer:
Representative of Installation Company:
Time of Inspection
- 161 -
Testing
Result
Conclusion
Form: 2-1 Inspections Prior to Test Run---Installation

Ltd.

Run
Product Name: TJB

Project
Name of Inspection: Inspections Prior to Test Run---Installation

Item
Inspect that no defect, such as fracture, damage,

and deformation, is present on the outer
appearance of metal structures and that all welding
seams meets the design requirements
Inspect that the nameplate and parameters of each
driving mechanism meet the design requirements
Inspect that the installation of all transmission
mechanism is correct and that all parts are free of
damage and are not left out of installation
Inspect that no interference, jamming, and
obstruction are present in all mechanisms
Inspect that installation and nameplate of all
outsourcing parts meet the design requirements
Inspect that all fastening pieces have been fastened
according to requirements.
Inspect that all external protective devices, such as
limiting switch, running deviation switch, pulling wire
switch, emergent switch, and photoelectric encoder,
are all correctly and fully installed
Inspect that the ladder platform is in a safe and
reliable state
Inspect that the main parameters, model numbers of
every nameplate of shipunloader are complete and
correct
Inspect that appropriate draining holes are present
at structures where water accumulation is possible
Inspect that the painting of shipunloader is in good
state and meets the requirements of technical
specification
Inspect condition of every pulley and pulley shaft
and support
Inspect condition of every wheel shaft and hinge
pin-hole shaft
Inspect and adjust the straightness of drivers cab
and trolley rails
2
3
4
5
6
7
8
9
10
11
12
13
14
Signature:

Time of Inspection
- 162 -
Inspection
Standard
Testing
Result
Conclusion
2-2--- Form 2-2 Inspections Prior to Test Run---Lubrication

Ltd.

Run

Name of Inspection: Inspections Prior to Test Run---Lubrication

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
Inspection
Standard
Inspect lubrication state of hoisting and closing gear

box and drum end bearing
Inspect lubrication state of pitching gear box and
drum end bearing
Inspect lubrication state of hinge shaft of spreader
beam and gear box of long travel
Inspect lubrication state of pulley shaft and wheel
shaft
Inspect lubrication state of rope
Inspect lubrication state of driving device of drivers
cab
Inspect lubrication state of wind damper device
Inspect lubrication state of receiving plate driving
device
Inspection and maintenance of lubrication state of
travelling gear box and every rotating pieces
Inspect the oiling state of every oil tank
Inspect lubricating state of moving hinge shaft and
jib hinge point
Inspect the lubrication state of safety hook
Inspect the lubrication state of hinge shaft of grab
Inspect the lubrication state of the pyriform fitting
Inspect the normal working state of lubrication
system
Inspect lubrication state of every mechanism shaft
coupling
Inspect the oiling condition of every hydraulic
pushing impeller of braker
Inspect the lubrication state of every lubrication
point of the remaining parts
Inspect the lubrication state of the rotating part of
the shake-feeder
- 163 -
Testing
Result
Conclusion
20
21
22
Inspect that each lubrication point is equipped with

nozzle and that grease has been added according
to the corresponding requirements of the operation
manual
Inspect that the oil charging quantity and the
numbering of gear box oil tank meet the
requirements of the operation manual
Inspect whether connection of pipelines of every
centralized lubrication system is correct and reliable
Signature:
Time of Inspection
- 164 -
Form: 2-3 Inspections Prior to Test Run---Hydraulic

Ltd.

Run
Product Name: TJB

Project
--Name of Inspection: Inspections Prior to Test Run---Hydraulic

Item
1
3
4
Inspection
Standard
Inspect to make sure that the pipeline installation

and joining of every hydraulic component meet the
design requirements
Inspect and confirm that no impurity has entered the
entire hydraulic system and that seal ring is present
at every joining of flange and pipe fitting
Inspect and confirm that air has been eliminated
from the entire hydraulic system
Inspect and confirm that the oil position in the oil
tank of every hydraulic system has meet the
requirements
Signature:
Time of Inspection
- 165 -
Testing
Result
Conclusion
2-4--- Form: 2-4 Inspections Prior to Test Run---Water Spray and Dust Suppression
Ltd.

Run
Product Name: TJB

Project
--Name of Inspection: Inspections Prior to Test Run---Water Spray and Dust Suppression
Item
1
Inspection
Standard
Inspect and confirm that every water spray

components, installation pipelines, and connections
all meet the design requirements
Inspect and confirm that no impurity enters the
entire water spray pipeline system, with no blockage
at every water spray point
Inspect and confirm that water cable drum has been
correctly installed in accordance with the
requirements
Signature:
Time of Inspection
- 166 -
Testing
Result
Conclusion
2-5--- Form: 2-5 Inspections Prior to Test Run---Electrical Equipment

Ltd.
List of Inspection Items for

Test Run
Product Name: TJB

Project
--Name of Inspection: Inspections Prior to Test Run---Electrical Equipment

Item
1
5
6
8
9
10
11
Inspection
Standard
Inspect that testing of every high voltage

electrical equipment has been completed
according to the requirements
410
Inspect
the
grounding
resistance
of
shipunloader: to rail, not greater than 4; to the
entire machine, not greater than 10
Inspect that the grounding for direct and
alternate current drive control system is correct
and that the equipment operating handles are
agile and reliable
Inspect that the electrical layout has been
correctly installed according to the requirements
of drawings
Inspect that cable drum has been correctly
installed according to the requirements
Inspect that no short circuit has occurred for
every phase sequence to ground and
interphase of main power supply and main
power supply and control power voltage are in
normal state
Inspect that the insulation of ground cable
junction box, high voltage slip-ring box, high
voltage transformer, and all related cables
(including interphase insulation and every phase
to ground insulation) have met the design
requirements
Inspect that the optic connection device is in
good condition
Inspect that the electrical wiring is free of
omission and error and that all switches,
instruments, and indicators have been
calibrated
Inspect that the nameplate of every electric
component meets the design requirements
Inspect that the indoor illumination for platform
walkway, drivers cab, machine room, electrical
control room of machine room has met the
design requirements, and that the illumination
for work area is outdoor spotlight
- 167 -
Testing
Result
Conclusion
12
13
14
15
16
Inspect that the fire protection measures of

drivers cab, machine room, pitching operation
room, and electrical control cabinet have met
the requirements of the contract
Inspect that the illumination of shipunloader
meets the requirements of the contract
Inspect and confirm whether the insulation of
every motor is in good condition
Inspection of wiring and insulation of frequency
converter
Inspect whether the resistance value and power
of braking resistance meet the design
requirements and whether the wiring is correct
Signature:
Time of Inspection
- 168 -
Form: 3 Commissioning for Lift

Ltd.
List of Inspection Items

for Test Run
Product Name: TJB Project 1500t/h

Shipunloader
Name of Inspection: Commissioning for Lift

Item
1
6
7
8
9
10
Inspection
Standard
Inspect that electrical wiring and buttons are

correctly installed according to the
requirements
Inspect that the lift guiding rail and
installation support are correctly installed
according to the design requirements
Inspect that the lift door and limiters are all
properly installed and reliable with proper
functioning of lift door
Inspect that escape door is present inside
the lift and that escape ladders are present
along the travelling course of lift without any
obstruction
Electrifying for inspection of the buttons at
every level of lift and inside the car are safe
and effective
Lift car operates stably during the travelling
course of lift
Inspect that protection safety nets are setup
at the platforms and walkways along the
travelling course of the lift
Inspect that the load and speed of lift meet
the requirements of the contract
Completion of commissioning according to
the testing general outline provided by the
lift supplier
Whether operation permit issued by the
local technical supervision bureau has been
obtained
Signature:
- 169 -
Testing
Result
Conclusion
Time of Inspection
- 170 -
Form: 4-1 No Load Commissioning for Hoisting and Closing Mechanism

Ltd.

Run

Name of Inspection: No Load Commissioning for Hoisting and Closing Mechanism

Item
1
2
3
5
6
Inspection
Standard
Inspect whether the opening of grab meets the

design requirements
Inspect whether every part of grab is fastened and
connected normally and reliably
Inspect whether the joining ring and the pyriform
head device are in good condition without
abnormality
Inspect and confirm the weigh sensor model
number and installation meet the design
requirements
Inspect that the tightness of closing of grab meets
the design requirements
Inspect and confirm that joining of support of every
transmission component is in good condition after
and before operation
Inspect and adjust the length of hoisting rope and
maintaining the balance of grab
Signature:
Time of Inspection
- 171 -
Testing
Result
Conclusion

Ltd.

Run


Item
1
Inspection
Standard
Before the rope has been passed through,

electrifying for inspection and confirmation of the
machine is in good condition
1~1.2
Configure frequency converter parameters and set
the thermal relay and over-current relay at 1 ~ 1.2
folds of the rated current
Inspect and adjust the braking and synchronization
of every braker to be in good state and adjusting the
braking torque of brakers
Inspect and confirm the rotating direction and
synchronization of hoisting and closing motors to be
in good state
Inspect and confirm that the operation of driving
motor, gear box, and bearing is sound
Signature:
Time of Inspection
- 172 -
Testing
Result
Conclusion

Ltd.

Run


Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Inspection
Standard
Undergoing no load operation of hoisting closing

mechanism with joining of the grab after passing
through the rope
Inspect that the tightness of closed grab meets the
design requirements
Inspect and confirm that the hoisting closing
mechanism operates stably without abnormal
shaking and heating phenomena
Inspect and confirm the consistency of operating
handle and hoisting action
Inspect and confirm that the rope operation is sound
Inspect and confirm that the joining of every
transmission component support is in good
condition before and after operation
Inspect and adjust limiting switch with confirmation
of hoisting height, and maximal lowering depth
Inspect and confirm that the joining of hoisting and
closing ropes is in good condition after operation
//
Inspect and confirm that the handle direction is
consistent with the direction of hoisting/lowering and
opening/closing of the grab
Inspect and confirm whether the compensation
travel of closing rope and hoisting is synchronized
Inspect and confirm that the closing action of grab is
agile and whether the positioning block is in good
state and reliable after the grab is opened for
inspection
Inspect the consistency of operating handle and
hoisting action
-Inspect the operating condition of motor-gear boxbearing
Inspect the joining of support of every transmission
component
Inspect the braking state, synchronization state,
limiting switch working condition of every braker
- 173 -
Testing
Result
Conclusion
16
17
18
19
20
Inspect
the mechanism
working condition
undergoing hoisting and lowering at rated speed
Inspect the synchronization of hoisting and closing
mechanisms
Inspect the slowly hoisting of grab prior to the
end-point of hoisting
Inspect the slowly lowering of grab prior to the
end-point of lowering
Inspect every end-point limiting switch action
Signature:
Time of Inspection
- 174 -

Ltd.

Run


Item
(/)
Measure the maximal hoisting height of grab (above
rail and below rail)
/
Measure the rated speed of grab (full load/no load)
2
3
4
5
6
7
Record motor current when the grab is at rated

speed
Record motor rotating speed when the grab is at
rated speed
Inspect the slowly hoisting of grab prior to the
end-point of hoisting
Inspect the slowly lowering of grab prior to the
end-point of lowering
Inspect every end-point limiting switch action
Signature:
Time of Inspection
- 175 -
Inspection
Standard
Testing
Result
Conclusion
Form: 5-1 No load Commissioning of Trolley Traveling Mechanism

Ltd.

Test Run

Name of Inspection: No load Commissioning of Trolley Traveling Mechanism

Item
1
2
3
4
5
6
7
8
Inspection
Standard
Inspect and confirm that the installation of trolley

rail meets the design requirements
Inspect whether obstacle is present on the trolley
rail
Inspect that the motor rotating direction is
consistent
Inspect and adjust the gap between horizontal
wheel and rail to meet the design requirements
Inspect and confirm that the model number and
installation of trolley buffers meet the design
requirements
Inspect and confirm that the stop block on the end
of trolley traveling rail is safe and reliable
Inspect the contact condition between the wheel
tread and the rail plane
Inspect whether the rail gap at the hinge point of
front and back girders meets the requirements
Signature:
Time of Inspection
- 176 -
Testing
Result
Conclusion
Form 5-2 No load Commissioning of Trolley Traveling Mechanism

Ltd.

Test Run


Item
1
2
3
Inspection
Standard
Before the rope has been passed through, inspect

and confirm that the traveling mechanism of
trolley operates stably without abnormal shaking
and heating phenomena
Inspect and adjust the working condition of braker
and adjusting the braking torque of braker
Inspect and confirm the consistency of operating
handle and motor rotating direction
Signature:
Time of Inspection
- 177 -
Testing
Result
Conclusion
Form 5-3 No load Commissioning of Trolley Traveling Mechanism

Ltd.

Test Run


Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Inspection
Standard
Inspect and confirm the reliability of joining of

ropes after rope has been passed through
Inspect whether the safety ring of the left and right
ropes of trolley drum meets the requirements
Inspect the operation of driving device, assembly
bearing, and wheel bearing
Adjusting limiting switch so it can function
normally
Inspect the braking action of trolley
Inspect the action of trolley traveling to the hinge
point of rail joint
Inspect the consistency of traveling direction of
trolley and action of operating handle
35
Inspect whether the mechanism is normal after
trolley travels at high speed (frontward and
backward) for 3~5 times
()
Inspect whether the maximal limiting switch action
is normal (frontward and backward)
()
Inspect whether the deceleration limiting switch
action is normal (frontward and backward)
Inspect whether the parking position limiting
switch action is normal
Inspect interlocking of trolley anchor limiting
switch action
Inspect whether the trolley sea and land side
differentiation limiting switching is correct
Inspect the interlocking of hopper land side door
and trolley traveling limiting switch
Inspect the interlocking of receiving plate and
trolley traveling limit switch
Inspect the interlocking of hopper water spray and
trolley traveling limiting switch
Inspect the interlocking action of front girder
horizontal limiting action and trolley operation
- 178 -
Testing
Result
Conclusion
18
19
20
Inspect and adjust increase and decrease time

and acceleration and deceleration of trolley meet
(0)
Inspect and adjust the working condition of the
interlockingswitch, allowing trolley to operate only
when the level of front girder is at 0 position
Inspect whether the grab will produce abnormal
swing during trolley operation process
Signature:
Time of Inspection
- 179 -
Form: 5-4 No load Commissioning of Trolley Traveling Mechanism

Ltd.

for Test Run
Product Name: TJB

Project

Item
1
2
3
4
Inspection
Standard
Inspect trolley traveling speed

Inspect trolley motor voltage
Inspect trolley motor current
Inspect trolley motor rotating speed
Signature:
Time of Inspection
- 180 -
Testing
Result
Conclusion
Form: 5-5 No load Commissioning of Trolley Traveling MechanismMain Trolley

Ltd.

for Test Run
Product Name: TJB

Project
Name of Inspection: No load Commissioning of Trolley Traveling MechanismMain Auxiliary Trolley

Item
1
2
3
4
5
6
Inspection
Standard
Inspect and confirm main trolley rope reeling

and rope lubrication condition
Inspect and confirm trolley rope fixation and
trolley operating situation
/
Inspect and confirm installation state of main
trolley reverse roller/hook and adjust gap of
the entire traveling distance
Inspect and confirm that trolley tension
system meets the design requirements
Inspect and adjust the balance between the
left and right ropes of trolley
Inspect and adjust the relative position of
main trolley
Signature:
Time of Inspection
- 181 -
Testing
Result
Conclusion
Form: 5-6 No load Commissioning of Trolley Traveling MechanismFour-Drum

Ltd.

Test Run

Name of Inspection: No load Commissioning of Trolley Traveling MechanismFour-Drum

Item
1
2
3
4
5
6
7
Inspection
Standard
Inspect rope reeling condition of front and back

cantenary trolley
Inspect rope fixation and rope lubrication condition
of cantenary trolley
Inspect the relative positions of front and
backward cantenary trolleys and main trolley
/
Inspect installation of main/cantenary trolley
reverse rollers and adjust the gap of the entire
traveling distance
Inspect and confirm the tension system of
cantenary trolley meets the design requirements
Inspect and adjust the balance between the left
and right ropes of cantenary trolley
Inspect and adjust the rope and roller height of
cantenary trolley, allowing rope to deflect
downwardly to optimal condition
Signature:
Time of Inspection
- 182 -
Testing
Result
Conclusion
Form: 5-7 No load Commissioning of Trolley Traveling MechanismSelf-Traveling Trolley

Ltd.

Test Run

Name of Inspection: No load Commissioning of Trolley Traveling MechanismSelf-Traveling Trolley

Item
1
2
3
Inspection
Standard
Inspect whether the power supply method meets

Inspect whether the travel of trolley meets the
design requirements
Inspect whether the wheels of trolley slip
Signature:
Time of Inspection
- 183 -
Testing
Result
Conclusion
Form: 6-1 Commissioning of Pitching Mechanism

Ltd.

for Test Run
Product Name: TJB

Project
Name of Inspection: Commissioning of Pitching Mechanism

Item
1
Inspection
Standard
Inspect and confirm that every joining pin

shaft position of the front tension bar is in
sound condition with good lubrication
Inspect and confirm pulley and its support
base are in sound condition with good
lubrication of pulley
Inspect and confirm that pitching can only be
executed
when
trolley
and
pitching
interlockingswitch are activated
Signature:
Time of Inspection
- 184 -
Testing
Result
Conclusion

Ltd.

for Test Run
Product Name: TJB

Project

Item
1
Inspection
Standard
Prior to passing through rope, inspect and

confirm that the pitching mechanism can
operate stably without abnormal shaking and
heating phenomena
Inspect and confirm the action situation of
every braker (when working normally,
high-speed shaft braker is activated first.
Then the safety braker is activated. Under
speeding condition, safety braker shall brake
immediately). Adjust the braking torque of
braker
Inspect and confirm that the direction of
operating handle and motor rotating direction
are consistent
Signature:
Time of Inspection
- 185 -
Testing
Result
Conclusion

Ltd.

for Test Run
Product Name: TJB

Project

Item
1
2
3
5
6
7
8
9
10
11
12
13
14
15
16
17
18
Inspection
Standard
Initiating pitching traveling mechanism to

undergo no load operation after rope has
been passed through
Inspect and confirm the joining of support of
each transmission part
/
During the course of pitching, inspect and
confirm that no interference exists between
the hoisting/closing and trolley rope
During the course of pitching, inspect and
confirm the synchronization of two pitching
ropes
Inspect the braker action and limiting switch
action
Inspect the consistency between pitching
action and handle.
Adjust and inspect the self-balancing of safety
hook
Inspect the synchronization of two safety
hooks
Inspect decelerating limiting action prior to
hook advancement
Inspect girder end-point limiting action
Inspect girder maximal limiting action
Inspect hook raising limiting action
Inspect hook area limiting action
Inspect the deceleration limiting action prior to
lowering end-point of pitching
Inspect the lowering end-point limiting action
of pitching
2
Inspect the balance situation of 2 ropes
Inspect whether the rope has any interference
during the pitching process
Inspect whether drum rope safety ring meets
the requirements
- 186 -
Testing
Result
Conclusion
19
20
Inspect whether rope skipping protection

device meets the requirements
Inspect and adjust speeding switch to meet
Signature:
Time of Inspection
- 187 -

Ltd.

Test Run
Product Name: TJB

Project

Item
1
2
3
4
5
6
7
8
9
10
11
Inspection
Standard
Inspect every indicator display during pitching

action
Inspect the reliability of girder motion upon
operation of drivers cab
Inspect running condition of motor, gear box, and
bearing upon pitching
Inspect the joining condition of support of every
transmission part
Inspect the locomotion of rail joint of trolley during
pitching action
Inspect the locomotion of rail joint of drivers cab
during pitching action
Measure and record pitching time
Measure and record motor current
Measure and record motor rotating speed
Measure and record motor voltage
Inspect working condition of pitching emergent
mechanism
Signature:
Time of Inspection
- 188 -
Testing
Result
Conclusion
Form: 7 Commissioning for Drivers Cab and Traveling Mechanism

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning for Drivers Cab and Traveling Mechanism

Item
1
2
Inspection
Standard
Inspect and confirm that the installation of

buffers meets the design requirement
Inspect and confirm cable pulleys are
properly arranged on the rails without worry
and are firmly and reliably joined. Confirm
that the pulley blocks are fully lubricated
accordingly and that they are tightly joined
to the base with anti-loosening device.
Confirm that the horizontal wheels of pulley
blocks are agile and reliable
Inspection of the entire traveling course of
the drivers cab is free of obstacle. Drivers
cab and the upper hanger are tightly joined.
The main and driven wheels have good
contact with rails. Motor and electric wiring
are correct and firmly attached. Confirm
that the motor and gear box flange are
tightly and reliably joined
Inspect and confirm that brake device of
drivers cab is installed and adjust the braker
to operate normally
Inspect and confirm that anchor device and
limiting switches are setup according to the
design requirements and are safe and
effective
Inspect and confirm that every function
button, indicator, instrument, communication
equipment, air conditioning, illumination,
and fire protection equipment is fully
equipped
Inspect and confirm that the escape
platform of drivers cab is safe and reliable
for the drivers cab to be at any position
Inspect and confirm that the drivers cab can
only undergo pitching after stopping at the
designated position of the back girder
Inspect the effectiveness and proper
function of every interlocking and limiter
throughout the entire traveling course at
rated speed
- 189 -
Testing
Result
Conclusion
10
11
12
13
14
Inspect whether it is possible for the drivers

cab and cable to interfere with the platform
or guardrail throughout the entire traveling
course
Measure running motor current
Measure running motor voltage
Measure running motor rotating speed
Inspect whether shaking and noise of
drivers cab meet the design requirements
Signature:
Time of Inspection
- 190 -
8 Form: 8 Commissioning of No load of Hoppers

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning of No load of Hoppers

Item
1
5
6
7
8
9
10
11
12
13
14
15
16
Inspection
Standard
Inspect and confirm that no obstacle is

present within the operating boundary of
unloading system
Inspect and confirm the joining condition
between unloading system and dock belt
conveyor system
Inspect and adjust the interlocking function
and working reliability of each limiter switch
of unloading system
Inspect and confirm whether installation of
all parts of unloading system meets the
design requirements
Inspect working condition of grab closing
mechanism
Inspect working condition of shake-feeder
Inspect working condition of receiving plate
Inspect working condition of wind damper
Inspect working condition and protection
device of belt conveyor system
Inspect operating condition of motor and
gear box of all mechanisms
Inspect joining of rope, pulley block, and
transmission shaft
Inspect working condition of
component and hydraulic system
hydraulic
Inspect and adjust display of weight sensor

Inspect and adjust iron remover to ensure
normal and reliable working condition
Inspect and adjust large-size coal removing
assembly to ensure normal and reliable
working condition
Inspect the working condition of hopper wall
shaking motor
- 191 -
Testing
Result
Conclusion
Signature:
Time of Inspection
- 192 -
Form: 9-1 No load Commissioning for Traveling Mechanism of Long Travel

Ltd.

for Test Run
Product Name: TJB

Project
Name of Inspection: No load Commissioning for Traveling Mechanism of Long Travel

Item
1
2
3
6
7
8
10
11
12
13
14
Inspection
Standard

long travel driving mechanism meets the
design requirements
Inspect whether there are obstacles on or
around the rails of long travel
/
anchor device, windproof mooring rope, and
rail clamper meets the design requirements
Confirm that the nameplate and installation of
long travel buffers meet the design
requirements
Inspect all the limiting switch wirings of the
mechanism are correct and confirm the
voltage grade of limiting switch meet the
design requirements
Adjust encoder of traveling of long travel
Inspect and confirm every interlocking switch
of long travel driving mechanism
Inspect and adjust the direction of motor
rotating direction to be consistent with the
driving direction of long travel
Measure every phase sequence of inlet and
outlet of frequency converter and its
grounding insulation performance and inspect
whether the control board wiring of sensor is
correct
Inspect and confirm that the driving handle is
consistent with the driving direction of long
travel
Inspect and confirm the normal operation of
every motor, gear box and wheel bearing
Inspect and adjust braker with adjustment of
brake moment
Inspection direction and coordination of motor
action
Inspect action and interlocking condition of
anchor device
- 193 -
Testing
Result
Conclusion
15
16
17
18
19
Inspect the interlocking action of rail clamper

limiter switch
Inspect whether the action of rail clamper is
consistent with the button switch
Inspect whether there is any interference
along the rail of rail clamper
/
Inspect whether the direction of deployment
action of electric and water cable drum is
consistent with the driving direction of long
travel
Inspection of operating condition of driving
assembly and wheel bearing
Signature:
Time of Inspection
- 194 -
Form: 9-2 No load Commissioning for Traveling Mechanism of Long Travel

Ltd.

for Test Run

Shipunloader
Name of Inspection: No load Commissioning for Traveling Mechanism of Long Travel

Item
1
2
3
4
5
6
7
8
9
10
Inspection
Standard
Inspect the contact condition between wheel

and rail
Inspect ringing and warning signals of long
travel drive
Inspect reliability of emergent button of long
travel drive
Inspect
reliability
deceleration limiter
of
anti-collision
Inspect reliability of anti-collision terminal

limiter
Measure motor current
Measure motor voltage
Measure motor rotating speed
Measure traveling speed
Measure time for brake initiation
Signature:
Time of Inspection
- 195 -
Testing
Result
Conclusion
Form: 10 Commissioning of Electric and Water Cable Drum

Ltd.

for Test Run

Shipunloader
/
Name of Inspection: Commissioning of Electric and Water Cable Drum
Item
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Inspection
Standard
Inspect and confirm that proper installation

has been carried out and connections have
been firmly locked in accordance with the
drawings
Confirm all parameters meet the design
requirements
Confirm that system is fully lubricated and
that the turning part is installed with
protection cover
Confirm steering is not obstructed
Confirm that the endings are firmly and
reliably connected and that the sealing and
insulation meet the requirements
/
Inspect and adjust over-midpoint testing
switch of electric and water cable drum
Inspect and adjust over-tension and
anti-relaxation protection
/
Inspect and adjust electric and water cable
drum over-travel protection
/
Inspect and adjust terminal safety strap of
electric and water cable drum
Inspect and adjust the
protection of long travel drive
interlocking
Signature:
- 196 -
Testing
Result
Conclusion
Time of Inspection
- 197 -
Form: 11 Commissioning of Water Spray Dust Suppression System

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning of Water Spray Dust Suppression System

Item
1
2
3
4
6
7
8
Inspection
Standard
Inspect and confirm all parts are installed

correctly and reliably
Inspect and confirm whether all nameplate
parameters meet the design requirements
Inspect and confirm that no leakage is
present in the system
Inspect and confirm that every water spray
point is positioned according to the design
requirements and is firmly and reliably
placed
Inspect and adjust action of every
electromagnetic valve to meet the
interlocking requirements
Inspect and adjust tank level switch to meet
the requirements
Record motor starting current
Record motor operating current
Signature:
Time of Inspection
- 198 -
Testing
Result
Conclusion
12 Commissioning of Hydraulic System

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning of Hydraulic System

Item
1
2
3
4
5
Inspection
Standard
Inspect and determine all parts are installed

Inspect and determine all nameplate
parameters meet the design requirements
Inspect switch of every discharge valve of
hydraulic system
Inspect rotating direction of hydraulic motor
GB104830
Testing pressure of hydraulic system should
meet the requirements of GB1048, which is
maintaining pressure for 30 minutes without
any leakage or deformation at every
position of the assembly
Adjusting cylinder speed to meet design
requirements
Signature:
Time of Inspection
- 199 -
Testing
Result
Conclusion
Form: 13 Commissioning of Centralized Lubrication System

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning of Centralized Lubrication System

Item
1
2
3
4
5
6
Inspection
Standard

Inspect and determine whether all
nameplate parameters meet the design
requirements
Inspect switch of every discharge valve of
lubrication system
Adjust pressure of relief valve and safety
valve according to the requirements of
lubrication system operation manual and
inspect whether there is any leakage in the
pipeline and every lubricant point is
normally lubricated
Test and record starting current of motor
Test and record operating current of motor
Signature:
Time of Inspection
- 200 -
Testing
Result
Conclusion
14 Commissioning of Belt Conveyor

Ltd.

for Test Run

Shipunloader
Name of Inspection: Commissioning of Belt Conveyor

Item
1
2
4
5
7
8
9
10
Inspection
Standard

Inspect and determine whether all
nameplate parameters meet the design
requirements
Commissioning of blocking switch, level
switch, and emergent pull cord switch of belt
conveyor
Adjusting tensioning device to the design
requirement and tightening backstop nut
Inspect every phase sequence to ground
insulation performance of motor and braker
and whether insulation resistance meets the
requirements
Measure whether there is any presence of
short-circuit between the phase sequence
and grounding of the main power source of
the mechanism and control power supply
Adjust the center position of braker with
adjustment of moment to design value
Confirm the rotating direction of motor
Test and record starting current of motor
Test and record operating current of motor
Signature:
Time of Inspection
- 201 -
Testing
Result
Conclusion
Safety and Interlocking System Commissioning

Ltd.

for Test Run

Shipunloader
Name of Inspection: Safety and Interlocking System Commissioning

Item
1
2
5
6
7
8
9
Inspection
Standard
Inspect and adjust braking actions of every

braker
Inspect and adjust the normal installation of
every electric limiter and interlocking device
with sensitive and reliable actions
Inspect the reliability of all interlocking
functions and completeness of limiter for
shipunloader
Inspection and determination of normal and
reliable function of every emergent
shutdown button
Inspection and determination of normal
action of every display and warning device
Inspection of reliability of anchoring actions
/
Inspection of normal clamping and release
actions of rail clamp and wheel clamp
Inspection of normal interlocking operation
of device preventing collision
Adjustment of initial value for all encoders
Signature:
Time of Inspection
- 202 -
Testing
Result
Conclusion
From: 16-1 Static Load Test Run

Ltd.

Test Run
Product Name: TJB

Project
Name of Inspection: Static Load Test Run

Item
0.7G,0.7V
Lift 0.7G at 0.7V speed with full distance
round-trip operation three times and inspect the
outer appearance of structure
A
Measure Reference Point A as the maximal
frontreach distance of trolley
B
Measure Reference Point B as position of front
tension bar of trolley
C
Measure Reference Point C as center of hinge
point of front tension bar and hinge point of front
girder
D
Measure Reference Point D as Center of Land
and Sea gantry
E
Measure Reference Point E as maximal
backreach distance
0.7G100200mmAABCDE
Lift 0.7G 100~200mm above ground and stop at
Point A and check the outer appearance of the
steel structure and degree of deflection at Point
A, B, C, D and E
0.7G100200mmBABCDE
Point B and check the outer appearance of the
A, B, C, D and E
0.7G100200mmCABCDE
Point C and check the outer appearance of the
A, B, C, D and E
0.7G100200mmDABCDE
Point D and check the outer appearance of the
A, B, C, D and E
0.7G100200mmEABCDE
Point E and check the outer appearance of the
A, B, C, D and E
2
3
4
5
6
7
10
Signature:
- 203 -
Inspection
Standard
Testing
Result
////
////
////
////
////
Conclusion
Time of Inspection
- 204 -
Form 16-2 Static Load Test Run

Ltd.

for Test Run
Product Name: TJB

Project
Name of Inspection: Static Load Test Run

Item
1.0G100200mmAABCDE
Lift 1.0G 100~200mm above ground and stop
at Point A and check the outer appearance of
the steel structure and degree of deflection at
Point A, B, C, D and E
1.0GB100200mmABCDE
at Point B and check the outer appearance of
1.0G100200mmCABCDE
at Point C and check the outer appearance of
1.0G100200mmDABCDE
at Point D and check the outer appearance of
1.0G100200mmEABCDE
at Point E and check the outer appearance of
,
Inspection and adjustment of load indicator
are normal during the aforementioned actions
1.25GAABCDE
Lift 1.25G and stop at Point A and check the
outer appearance of the steel structure and
degree of deflection at Point A, B, C, D and E
1.25GBABCDE
Lift 1.25G and stop at Point B and check the
1.25GCABCDE
Lift 1.25G and stop at Point C and check the
1.25GDABCDE
Lift 1.25G and stop at Point D and check the
1.25GEABCDE
Lift 1.25G and stop at Point E and check the
,
Inspect and adjust braker for normal and
reliable operation during the aforementioned
actions
6
7
10
11
12
- 205 -
Inspection
Standard
Testing
Result
////
////
////
////
////
////
////
////
////
////
Conclusion
Signature:
Time of Inspection
- 206 -
Form 17-1 Rated Load and Dynamic Load Test Run---Hoisting and Closing Mechanism
Ltd.

for Test Run
Product Name: TJB

Project
--Name of Inspection: Rated Load and Dynamic Load Test Run---Hoisting and Closing Mechanism
Item
Inspection
Standard
I. Testing of full load hoisting and lowering actions of

trolley positioned at frontreach distance
1
Inspection of heating condition and shaking
and noise states of motor and transmission
mechanism
2
Inspection of working condition of braker
3
Inspection of supporting condition of
transmission mechanism
4
Inspection of working condition of rail at
positions in front of and back of hinge point
5
Measure and record hoisting and lowering
speed
6
speed, acceleration, motor voltage, current,
rotating speed, power, and temperature rise of
motor
7
8
9
10
Measure and record motor power
11
Measure and record temperature rise of motor
II. Testing of full load hoisting and lowering actions of
trolley positioned at backreach distance
1
Inspection of heating condition and shaking
and noise states of motor and transmission
mechanism
2
Inspection of working condition of braker
3
Inspection of supporting condition of
transmission mechanism
4
Inspection of working condition of rail at
positions in front of and back of hinge point
5
speed
- 207 -
Testing
Result
Conclusion
7
8
9
10
11

speed, acceleration, motor voltage, current,
rotating speed, power, and temperature rise of
motor
Signature:
Time of Inspection
- 208 -
Form: 17-2 Rated Load and Dynamic Load Test Run---Trolley Running
Ltd.

for Test Run

Shipunloader
--Name of Inspection: Rated Load and Dynamic Load Test Run---Trolley Running
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Inspection
Standard
Full-range operation of grab lifting rated load

at different speeds
Inspect the contact state of wheel and rail
Inspect the operating state of motor, gear box,
floating joint shaft, and wheel bearing
Inspect trolley support and support of all
driving mechanisms
Inspect the working condition of braker
Inspect the action of gear box limiter
Inspect the reliability of terminal limiting switch
Inspect the joining of trolley rail
Measure and record running speed
Signature:
- 209 -
Testing
Result
Conclusion
Time of Inspection
- 210 -
Form: 18 Full Load Linked Test Run of Hoisting, Closing, and Trolley
Ltd.

for Test Run
Product Name: TJB

Project
Name of Inspection: Full Load Linked Test Run of Hoisting, Closing, and Trolley
Item
1
2
3
4
5
6
7
8
9
10
11
12
Inspection
Standard
Inspection
of
operating condition
of
transmission parts, such as motor, gear box,
and bearing
Inspection of working reliability of every braker
Inspection of reliability of every limiting switch
Inspection of joining condition of every
support and condition of metal structure
Measure and record motor voltage of hoisting
and closing
Measure and record motor current of hoisting
and closing
Measure and record motor rotating speed of
hoisting and closing
Measure and record motor power of hoisting
and closing
Measure and record motor voltage of trolley
Measure and record motor current of trolley
Measure and record motor rotating speed of
trolley
Measure and record motor power of trolley
Signature:
- 211 -
Testing
Result
Conclusion
Time of Inspection
- 212 -
Form: 19 110% Overload Dynamic Testing

Ltd.

Test Run
Product Name: TJB

Project
Name of Inspection: 110% Overload Dynamic Testing

Item
Inspection
Testing
Conclusion
Standard
Result
I. Lifting the required weight once for hoisting and once for lowering with position at outreach distance and
10 meter above ground
1
speed
2
3
4
5
II. Lifting the required weight once for hoisting and once for lowering with position at backreach distance
1
speed
2
3
4
5
III. Lifting the required weight once for hoisting and once for lowering with position at the center point of
land and sea gantry and 10 meter above ground
1
speed
2
3
4
5
IV. Simultaneous inspection at the aforementioned three positions
1
Inspection of operating condition of motor, gear
box, and bearing
2
Inspection of working reliability of braker
3
Inspection of joining condition of mechanism
bearing support
4
Inspection of condition of metal structure
- 213 -
Signature:
Time of Inspection
- 214 -
20-1 Form: 20-1 Testing of Rated Productivity

Ltd.

for Test Run

Shipunloader
Name of Inspection: Testing of Rated Productivity

Item
1
2
3
4
5
6
7
8
9
10
11
12
13
Inspection
Standard
Testing of operation under required working

routes with the grab freely grabbing
materials
Inspection of operation condition of hoisting,
closing, and trolley motors
Inspection of condition of rise in
temperature of hoisting, closing, and trolley
motors
Inspection of working condition of gear box,
bearing, and transmission
Inspection of braker for reliability
Inspection of condition of metal structure
Inspection of rope system for normal
operation
Inspection of pulley system for normal
operation
10
Measure and record mean time of 10 cyclic
operations
Measure and record Mean weight of 10
cyclic operations of grab
Productivity calculated from Item 9 and Item
10
Evaluation
of
shipunloading
two-hour
continuous
Evaluation of continuous shipunloading
Signature:
- 215 -
Testing
Result
Conclusion
Time of Inspection
- 216 -
Form: 21-2 Testing of Rated Productivity

Ltd.

for Test Run

Shipunloader
Name of Inspection: Testing of Rated Productivity
1
First Grab
2
Second Grab
3
Third Grab
4
Fourth Grab
5
Fifth Grab
6
Sixth Grab
7
Seventh Grab
8
Eighth Grab
9
Ninth Grab
10
Tenth Grab
Testing Time for Single

Grab Operation
Working Weight of
Single Grab
Remark
Calculation of
Productivity
Calculated Mean Value
Signature:
Time of Inspection
- 217 -
Form: 22 Inspection Acceptance and Evaluation of Shipunloader

Model
Site of Inspection Acceptance
Manufacturer
Driver
Temperature of Environment
Person Responsible for Commissioning
Humidity of Environment
Person Responsible for Inspection Acceptance
Date of Inspection Acceptance

Ltd.
Year
Month

for Test Run
Day

Shipunloader
Name of Inspection: Inspection Acceptance and Evaluation of Shipunloader

Item
Whether normal test run of linked operation

of hoisting, closing, and trolley is achieved
Whether normal 110% overload dynamic
testing is achieved
Whether normal rated productivity is
achieved
Whether normal two-hour continuous testing
is achieved
Whether normal Continuous Shipunloading
Testing is achieved
Whether all spare parts and accompanied
tools are delivered
Whether the complete set of documents
stated under Item 6.1 of Manual for Test
Run and Inspection Acceptance of
Shipunloader has been submitted
Inspection of shipunloader for meeting the
terms of delivery stipulated under the
Contract without any omission and missing
parts
2
3
4
5
6
7
Signature:
Time of Inspection
- 218 -
Inspection
Standard
Testing
Result
Conclusion
Part IV: Manufacturers specials OEM

(installation instructions of original equipment manufacturer)
- 219 -
CONTENTS
NO.
Title
1.
Rail-clamper Instruction Manual
Hydraulic System Instruction Manual
Spraying & Lubrication Instruction Manual
10
Vibration feeder Instruction Manual
11
Scale sensor Instruction Manual
12
Elevator Instruction Manual
Note: The data aboved please see the details of respective OEM
installation instruction.
- 220 -
Part V:Machine Drawings
- 221 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
GSU0702.Erc.List
B-CHA-M-BV-8001
List of drawing
A0
GSU0702.Erc.00
B-CHA-M-BV-1001
General Arrangement
A0
GSU0702.Erc-1(1/2)
B-CHA-M-BV-1002
General Notes and Erection

Sequences
A0
GSU0702.Erc-1(2/2)
B-CHA-M-BV-1003

Sequences
A0
GSU0702.Erc.01
B-CHA-M-BV-8002
Steel Structure
A1
GSU0702.Erc.01.01
B-CHA-M-BV-8003
Front girder
A1
GSU0702.Erc.01.02 A
B-CHA-M-BV-8004
Front Tension Bar
A2
GSU0702.Erc.01.03
B-CHA-M-BV-8005
Main Hinge
A1
GSU0702.Erc.01.04
B-CHA-M-BV-8006
Pylon
A2
GSU0702.Erc.01.04.03
B-CHA-M-BV-8007
Maintenance Hoist
A2
10
GSU0702.Erc.01.05 A
B-CHA-M-BV-8008
Back Tension Bar
A2
11
GSU0702.Erc.01.08
B-CHA-M-BV-8009
End Grider
A1
12
GSU0702.Erc.01.09A
B-CHA-M-BV-8010
Frame
A0
13
GSU0702.Erc.01.09B
B-CHA-M-BV-8011
Frame
A0
14
GSU0702.Erc.01.09-1
B-CHA-M-BV-8028
W.S.Sill Beam
A2
15
GSU0702.Erc.01.09-2
B-CHA-M-BV-8038
Underside W.S Legs
A2
16
GSU0702.Erc.01.09-3
B-CHA-M-BV-8041
L.S.Sill Beam
A2
17
GSU0702.Erc.01.09-4
B-CHA-M-BV-8042
Fixed Tie Links I
A2
18
GSU0702.Erc.01.09-5
B-CHA-M-BV-8043
Horizontal Beam I
A2
19
GSU0702.Erc.01.09-6
B-CHA-M-BV-8044
Upside W.S.Legs
A2
20
GSU0702.Erc.01.09-7
B-CHA-M-BV-8045
Underside L.S.Legs
A2
21
GSU0702.Erc.01.09-8
B-CHA-M-BV-8046
Upside L.S.Legs
A2
22
GSU0702.Erc.01.09-9
B-CHA-M-BV-8047
Fixed Tie Links II
A1
- 222 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
23
GSU0702.Erc.01.09-10
B-CHA-M-BV-8029
Horizontal Beam of W.S
A2
24
GSU0702.Erc.01.9-11 A
B-CHA-M-BV-8030
Horizontal Beam II
A1
25
GSU0702.Erc.01.09-12
B-CHA-M-BV-8031
Horizontal Beam of L.S
A2
26
GSU0702.Erc.01.09-13
B-CHA-M-BV-8032
Fixed Tie Links III
A2
27
GSU0702.Erc.01.09-14
B-CHA-M-BV-8033
Support
A2
28
GSU0702.Erc.01.09-15
B-CHA-M-BV-8034
Anchor Support
A2
29
GSU0702.Erc.01.09-17
B-CHA-M-BV-8035
Short Fixed Tie Link
A2
30
GSU0702.Erc.01.09-18
B-CHA-M-BV-8036
Horizontal Beam
A1
31
GSU0702.Erc.01.09-19
B-CHA-M-BV-8037
Landside Portal
A1
32
GSU0702.Erc.01.09-20A
B-CHA-M-BV-8039
Belt system support
A0
33
GSU0702.Erc.01.09-20B
B-CHA-M-BV-8040
Belt system support
A1
34
GSU0702.Erc.01.10
B-CHA-M-BV-8048
Fixed Tie Links assemble
A2
35
GSU0702.Erc.01.09.01
B-CHA-M-BV-8012
Waterside Portal
A1
36
GSU0702.Erc.01.02B
B-CHA-M-BV-8013
Front Tension Bar
A2
37
GSU0702.Erc.01.05B
B-CHA-M-BV-8014
Back Tension Bar
A2
38
GSU0702.Erc.01.9-11B
B-CHA-M-BV-8015
Horizontal Beam II
A1
39
GSU0702.Erc.01.9-20C
B-CHA-M-BV-8016
Belt system support
A1
40
GSU0702.Erc.01.09-21
B-CHA-M-BV-8017
Horizontal Beam
A2
41-50
No Use
51
GSU0702.Erc.02
B-CHA-M-BV-8049
grab assembly
A2
52
GSU0702.Erc.03
B-CHA-M-BV-8050
Main-trolley
A1
53
GSU0702.Erc.03-1
B-CHA-M-BV-8058
Anchor
A2
- 223 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
54
GSU0702.Erc.03.05
B-CHA-M-BV-8051
Platforms
A2
55
GSU0702.Erc.03.05-1
B-CHA-M-BV-8052
Platform_I
A2
56
GSU0702.Erc.03.01
B-CHA-M-BV-8053
Main-trolley Assembly
A2
57
GSU0702.Erc.03.05-2
B-CHA-M-BV-8054
Ladder
A2
58
GSU0702.Erc.03.05-3
B-CHA-M-BV-8055
platform II
A2
59
GSU0702.Erc.03.05-4
B-CHA-M-BV-8056
support
A2
60
No Use
61
GSU0702.Erc.04 A
B-CHA-M-BV-8059
Operator Cab
A1
62
GSU0702.Erc.04-3
B-CHA-M-BV-8067
Operator Cab Structure
A0
63
GSU0702.Erc.04.02
B-CHA-M-BV-8060
Locking unit
A3
64
GSU0702.Erc.04.04
B-CHA-M-BV-8061
Running limit switch
A1
65
GSU0702.Erc.04 B
B-CHA-M-BV-8062
Operator Cab
A1
66
GSU0702.Erc.04.01
B-CHA-M-BV-8063
Operator cab hanger
A1
66-68
No Use
69
GSU0702.Erc.05 B
B-CHA-M-BV-8067
Safety Hook
A1
70
GSU0702.Erc.05 A
B-CHA-M-BV-8068
Safety Hook
A1
71
GSU0702.Erc.06
B-CHA-M-BV-8069
Boom-Hoist-CAB
A1
72
GSU0702.Erc.07A
B-CHA-M-BV-8070
Boom-Machinery
A1
73
GSU0702.Erc.07-9
B-CHA-M-BV-8080
A3
74
GSU0702.Erc.07.01
B-CHA-M-BV-8071
Roller Assembly
A2
75
GSU0702.Erc.07.02
B-CHA-M-BV-8072
Anti-ropeskiping
A2
76
GSU0702.Erc.07.03
B-CHA-M-BV-8073
Camming Limitator
A2
- 224 -
Fix-Block2
Item
No.
CHEC
Drawing No.
77
No Use
78
GSU0702.Erc.07B
79-82
SUMITOMO
Drawing No.
Rev.
B-CHA-M-BV-8075
Format
Drawing
Quantity
Boom-Machinery
A1
Description
No Use
83
GSU0702.Erc.08A
B-CHA-M-BV-8081

device
A0
84
GSU0702.Erc.08-6
B-CHA-M-BV-8093
Wedge
A3
85
GSU0702.Erc.08-8
B-CHA-M-BV-8094
Limit Switch Support
A2
86
GSU0702.Erc.08.01
B-CHA-M-BV-8082
Drift shaft
A1
87
GSU0702.Erc.08.02
B-CHA-M-BV-8083
Drum
A2
88
GSU0702.Erc.08.04
B-CHA-M-BV-8084
Support
A1
89
GSU0702.Erc.08.05
B-CHA-M-BV-8085
Safty-Device I
A2
90
GSU0702.Erc.08.06
B-CHA-M-BV-8086
Safty-Device II
A2
91
GSU0702.Erc.08.07
B-CHA-M-BV-8087
Safty-Device III
A1
92
GSU0702.Erc.08B
B-CHA-M-BV-8088

device
A0
93-96
No Use
97
GSU0702.Erc.09(1/3)
B-CHA-M-BV-8095
Machinery G.A
A1
98
GSU0702.Erc.09(2/3)
B-CHA-M-BV-8096
Machinery G.A
A1
99
GSU0702.Erc.09(3/3)
B-CHA-M-BV-8097
Machinery G.A
A1
100
GSU0702.Erc.09-1A
B-CHA-M-BV-8132
Distance wall
A3
101
GSU0702.Erc.09-1B
B-CHA-M-BV-8133
Distance wall
A3
102
GSU0702.Erc.09-2
B-CHA-M-BV-8136
Inclined ladder
A2
103
GSU0702.Erc.09-3
B-CHA-M-BV-8137
Grider
A2
104
GSU0702.Erc.09-4
B-CHA-M-BV-8138
A2
105
GSU0702.Erc.09-7
B-CHA-M-BV-8139
Maintenance flat roof
A3
106
GSU0702.Erc.09-8
B-CHA-M-BV-8140
Ladder used by
maintenace flat roof
A3
- 225 -
Walkway 1
Item
No.
CHEC
Drawing No.
107
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
GSU0702.Erc.09-9
B-CHA-M-BV-8141
Upright ladder
A3
108
GSU0702.Erc.09-10
B-CHA-M-BV-8134
Roller(Or)
A3
109
GSU0702.Erc.09-11
B-CHA-M-BV-8135
Handle of the Machinery
A1
110
GSU0702.Erc.09.01A
B-CHA-M-BV-8098
Machinery Structure
A1
111
GSU0702.Erc.09.01B
B-CHA-M-BV-8099
Machinery Structure
A2
112
GSU0702.Erc.09.01-1A
B-CHA-M-BV-8100
The water side wall
A1
113
GSU0702.Erc.09.01-1B
B-CHA-M-BV-8101
The water side wall
A2
114
GSU0702.Erc.09.01-2A
B-CHA-M-BV-8102
The land side wall
A1
115
GSU0702.Erc.09.01-2B
B-CHA-M-BV-8103
The land side wall
A2
116
GSU0702.Erc.09.01-3A
B-CHA-M-BV-8104
The right side wall
A1
117
GSU0702.Erc.09.01-3B
B-CHA-M-BV-8105
The right side wall
A2
118
GSU0702.Erc.09.01-4A
B-CHA-M-BV-8106
The left side wall
A1
119
GSU0702.Erc.09.01-4B
B-CHA-M-BV-8107
The left side wall
A2
120
GSU0702.Erc.09.02
B-CHA-M-BV-8108
Ventilator I
A3
121
GSU0702.Erc.09.03
B-CHA-M-BV-8109
Luffing rope gate
A3
122
GSU0702.Erc.09.04
B-CHA-M-BV-8110
Hoist rope gate
A3
123
GSU0702.Erc.09.05
B-CHA-M-BV-8111
Ventilator II
A3
124
GSU0702.Erc.09.06
B-CHA-M-BV-8112
Wall indoor
A3
125
GSU0702.Erc.09.07
B-CHA-M-BV-8113
Walkway 2
A2
126
GSU0702.Erc.09.08
B-CHA-M-BV-8114
Walkway 3
A3
127
GSU0702.Erc.09.09
B-CHA-M-BV-8115
Inclined flat roof1
A3
- 226 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
128
GSU0702.Erc.09.10
B-CHA-M-BV-8116
Inclined flat roof2
A3
129
GSU0702.Erc.09.11A
B-CHA-M-BV-8117
UNDERFRAME OF
M.R&E.R
A0
130
GSU0702.Erc.09.11B
B-CHA-M-BV-8118
UNDERFRAME OF
M.R&E.R
A0
131
GSU0702.Erc.09.11C
B-CHA-M-BV-8119
UNDERFRAME OF
M.R&E.R
A1
132
GSU0702.Erc.09.11D
B-CHA-M-BV-8120
UNDERFRAME OF
M.R&E.R
A1
133
GSU0702.Erc.09.11.01
B-CHA-M-BV-8121
Cover
A2
134-143
No Use
144
GSU0702.Erc.11
B-CHA-M-BV-8142
NAME PLATE
A1
145
GSU0702.Erc.11-1
B-CHA-M-BV-8145
data plate
A3
146
GSU0702.Erc.11.01
B-CHA-M-BV-8143
name plate for chec
A1
147
GSU0702.Erc.11.02
B-CHA-M-BV-8144
capacity plate
A1
148
GSU0702.Erc.12
B-CHA-M-BV-8146
Power cable reel
A1
149
GSU0702.Erc.15
B-CHA-M-BV-8147
Front cantenary trolley
A2
150
GSU0702.Erc.15.04
B-CHA-M-BV-8148
Protect wheel
A3
151
GSU0702.Erc.16(1/2)
B-CHA-M-BV-8149
GANTRY
A0
152
GSU0702.Erc.16(1/2)
B-CHA-M-BV-8149
GANTRY
A0
153
GSU0702.Erc.16-1
B-CHA-M-BV-8166
Upper beam
A1
154
GSU0702.Erc.16-14
B-CHA-M-BV-8167
GROUNDING DEVICE
A3
155
GSU0702.Erc.16-15
B-CHA-M-BV-8168
anchor device
A1
156
GSU0702.Erc.16-16
B-CHA-M-BV-8169
RAIL CAMP ASSEMBLY
A2
157
GSU0702.Erc.16.03
B-CHA-M-BV-8151
A3
- 227 -
Buffer
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
158
GSU0702.Erc.16.04
B-CHA-M-BV-8152
SAFTY DEVICE
A0
159
GSU0702.Erc.16.05
B-CHA-M-BV-8153
STORM TIE
A1
160
GSU0702.Erc.16.FWI
B-CHA-M-BV-8154
Four wheel Assembly(I)
A1
161
GSU0702.Erc.16.FWII
B-CHA-M-BV-8155
Four wheel Assembly(II)
A1
162-171
No Use
172
GSU0702.Erc.17
B-CHA-M-BV-8170
Hopper System
A0
173
GSU0702.Erc.17-1
B-CHA-M-BV-8196
Shell
A2
174
GSU0702.Erc.17-2
B-CHA-M-BV-8197
Support I
A0
175
GSU0702.Erc.17-3
B-CHA-M-BV-8198
Base
A0
176
GSU0702.Erc.17-4
B-CHA-M-BV-8199
Feeder
A3
177
GSU0702.Erc.17.01
B-CHA-M-BV-8171
Dust prot walls(right)
A0
178
GSU0702.Erc.17.02
B-CHA-M-BV-8172
Dust Prot Gate
A0
179
GSU0702.Erc.17.03
B-CHA-M-BV-8173
Dust Prot Gate(Left)
A0
180
GSU0702.Erc.17.04
B-CHA-M-BV-8174
Support II
A0
181
GSU0702.Erc.17.05
B-CHA-M-BV-8175
Spillage-flap
A0
182
GSU0702.Erc.17.06A
B-CHA-M-BV-8176
Hopper
A0
183
GSU0702.Erc.17.06B
B-CHA-M-BV-8177
Hopper
A0
184
GSU0702.Erc.17.06C
B-CHA-M-BV-8178
Hopper
A0
185
GSU0702.Erc.17.06D
B-CHA-M-BV-8179
Hopper
A1
186
GSU0702.Erc.17.06E
B-CHA-M-BV-8180
Hopper
A0
- 228 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
187
GSU0702.Erc.17.06-2
B-CHA-M-BV-8181
Base I,II
A0
188
GSU0702.Erc.17.07
B-CHA-M-BV-8182
Discharge Door
A0
189
GSU0702.Erc.17.08
B-CHA-M-BV-8183
Chute&Support
A0
190
GSU0702.Erc.17.08-2
B-CHA-M-BV-8184
Conveyor Steel Structure
A0
191
GSU0702.Erc.17.09
B-CHA-M-BV-8185
A1
A2
A1
192-201
Anti-vibration-suppor
No Use
202
GSU0702.Erc.18
B-CHA-M-BV-8200
203
GSU0702.Erc.19A
B-CHA-M-BV-8201
204
GSU0702.Erc.19.01
B-CHA-M-BV-8202
Movable Block
A3
205
GSU0702.Erc.19.02
B-CHA-M-BV-8203
Landside Pulley
A3
206
GSU0702.Erc.19.03
B-CHA-M-BV-8204
Seaside Pulley
A3
207
GSU0702.Erc.19.04
B-CHA-M-BV-8205
Upside Pulley
A3
208
GSU0702.Erc.20
B-CHA-M-BV-8206
Rope system
A1
209
GSU0702.Erc.20-1
B-CHA-M-BV-8214
Rope guide support
A2
210
GSU0702.Erc.20.01A
B-CHA-M-BV-8207
Trolley rope system
A1
211
GSU0702.Erc.20.02
B-CHA-M-BV-8208
Boom Hoist Rope System
A1
212
GSU0702.Erc.19B
B-CHA-M-BV-8209
A1
213
GSU0702.Erc.20.01B
B-CHA-M-BV-8210
Trolley rope system
A1
214
GSU0702.Erc.20.01C
B-CHA-M-BV-8211
Trolley rope system
A1
215-216
Backword cantenary trolley

Cab Safeguard
Cab Safeguard
No Use
217
GSU0702.Erc.22
B-CHA-M-BV-8215
Limits for ship-unloader
A2
218
GSU0702.Erc.22-1A
B-CHA-M-BV-8216
Limits for trolley
A2
219
GSU0702.Erc.22-1B
B-CHA-M-BV-8217
Limits for trolley
A2
- 229 -
Item
No.
220-224
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
Drawing
Quantity
No Use
225
GSU0702.Erc.24(1/5)
B-CHA-M-BV-8223
dust spray system
A1
226
GSU0702.Erc.24(2/5)
B-CHA-M-BV-8224
dust spray system
A1
227
GSU0702.Erc.24(3/5)
B-CHA-M-BV-8225
dust spray system
A2
228
GSU0702.Erc.24(4/5)
B-CHA-M-BV-8226
dust spray system
A2
229
GSU0702.Erc.24(5/5)
B-CHA-M-BV-8227
dust spray system
A1
230-234
No Use
235
GSU0702.Erc.26(1/2)
B-CHA-M-BV-8233
Hydraulics System
A0
236
GSU0702.Erc.26(2/2)
B-CHA-M-BV-8234
Hydraulics System
A0
237-239
No Use
240
GSU0702.Erc.27
B-CHA-M-BV-8238
Control cable reel
A1
241
GSU0702.Erc.14
B-CHA -M-BV -8239
Stairs & platforms
A0
242
GSU0702.Erc.14.01 A
B-CHA -M-BV -8240
L.S.Legs Staircase &

Platform
A1
243
GSU0702.Erc.14.01 B
B-CHA -M-BV -8241

Platform
A1
244
GSU0702.Erc.14.01 B
B-CHA -M-BV -8242

Platform
A2
245
GSU0702.Erc.14.01-1
B-CHA -M-BV -8243
Stairs I
A2
246
GSU0702.Erc.14.01-2
B-CHA -M-BV -8244
Platform I
A1
247
GSU0702.Erc.14.01-3
B-CHA -M-BV -8245
Stairs II
A2
248
GSU0702.Erc.14.01-4
B-CHA -M-BV -8246
Platform II
A2
249
GSU0702.Erc.14.01-5
B-CHA -M-BV -8247
Platform III
A2
250
GSU0702.Erc.14.01-6
B-CHA -M-BV -8248
Stairs III
A2
251
GSU0702.Erc.14.01-7
B-CHA -M-BV -8249
Platform IV
A2
252
GSU0702.Erc.14.01-8
B-CHA -M-BV -8250
Stairs IV
A2
- 230 -
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
253
GSU0702.Erc.14.01-9
B-CHA -M-BV -8251
Platform V
A2
254
GSU0702.Erc.14.01-10
B-CHA -M-BV -8252
Platform VI
A2
255
GSU0702.Erc.14.01-11
B-CHA -M-BV -8253
Platform VII
A2
256
GSU0702.Erc.14.01-12
B-CHA -M-BV -8254
Stairs V
A2
257
GSU0702.Erc.14.01-13
B-CHA -M-BV -8255
Stairs VI
A2
258
GSU0702.Erc.14.01-14
B-CHA -M-BV -8256
Stairs VII
A2
259
GSU0702.Erc.14.01-15
B-CHA -M-BV -8257
Stairs VIII
A2
260
GSU0702.Erc.14.01-16
B-CHA -M-BV -8258
Platform VIII
A2
261
GSU0702.Erc.14.01-17
B-CHA -M-BV -8259
Ladder
A2
262
GSU0702.Erc.14.01-18
B-CHA -M-BV -8260
Platform IX
A1
263
GSU0702.Erc.14.01-19
B-CHA -M-BV -8261
Stairs IX
A2
264
GSU0702.Erc.14.01-20
B-CHA -M-BV -8262
Platform X
A2
265
GSU0702.Erc.14.01-21
B-CHA -M-BV -8263
Stairs X
A2
266
GSU0702.Erc.14.01-22
B-CHA -M-BV -8264
Platform XI
A1
267
GSU0702.Erc.14.01-23
B-CHA -M-BV -8265
Stairs support
A1
268
GSU0702.Erc.14.01-24
B-CHA -M-BV -8266
Stairs XI
A2
269
GSU0702.Erc.14.01-25
B-CHA -M-BV -8267
Platform XII
A3
270
GSU0702.Erc.14.01-26
B-CHA -M-BV -8268
Stairs XII
A2
271
GSU0702.Erc.14.01-27
B-CHA -M-BV -8269
Platform XIII
A2
272
GSU0702.Erc.14.01.01
B-CHA -M-BV -8270
Spring Door
A2
273
GSU0702.Erc.14.02A
B-CHA -M-BV -8271
Stairs & Platforms of

Girders
A0
274
GSU0702.Erc.14.02B
B-CHA -M-BV -8272

Girders
A3
275
GSU0702.Erc.14.02-1
B-CHA -M-BV -8273
Platforms of Front Girders
A0
- 231 -
Drawing
Quantity
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
276
GSU0702.Erc.14.02-2
B-CHA -M-BV -8274
Platforms of Rear Girders
A0
277
GSU0702.Erc.14.02-3
B-CHA -M-BV -8275
Front Section of
Emergency Passway
A0
278
GSU0702.Erc.14.02-4
B-CHA -M-BV -8276
Rear Section of
Emergency Passway
A0
279
GSU0702.Erc.14.02-5
B-CHA -M-BV -8277
Ladder
A2
280
GSU0702.Erc.14.02-6
B-CHA -M-BV -8278
Stairs I
A2
281
GSU0702.Erc.14.02-7
B-CHA -M-BV -8279
Stairs II
A2
282
GSU0702.Erc.14.02-8
B-CHA -M-BV -8280
Stairs III
A2
283
GSU0702.Erc.14.02-9
B-CHA -M-BV -8281
Transition platform
A2
284
GSU0702.Erc.14.02-10
B-CHA -M-BV -8282
Transition platform
II
A2
285
GSU0702.Erc.14.02-11
B-CHA -M-BV -8283
Stairs IV
A2
286
GSU0702.Erc.14.03
B-CHA -M-BV -8284

Machinery House
A0
287
GSU0702.Erc.14.03-1
B-CHA -M-BV -8285
Stairs I
A2
288
GSU0702.Erc.14.03-2
B-CHA -M-BV -8286
Stairs II
A2
289
GSU0702.Erc.14.03-3
B-CHA -M-BV -8287
Stairs III
A2
290
GSU0702.Erc.14.03-4
B-CHA -M-BV -8288
Platform
A3
291
GSU0702.Erc.14.04
B-CHA -M-BV -8289

Pylon
A0
292
GSU0702.Erc.14.04-1
B-CHA -M-BV -8290
Platform
A1
293
GSU0702.Erc.14.04-2
B-CHA -M-BV -8291
Platform
II
A1
294
GSU0702.Erc.14.04-3
B-CHA -M-BV -8292
Stairs I
295
GSU0702.Erc.14.04-4
B-CHA -M-BV -8293
Platform
296
GSU0702.Erc.14.04-5
B-CHA -M-BV -8294
Ladder
A2
297
GSU0702.Erc.14.04-6
B-CHA -M-BV -8295
Platform IV
A2
298
GSU0702.Erc.14.04-7
B-CHA -M-BV -8296
Stairs II
A2
- 232 -
A2
III
A2
Drawing
Quantity
Item
No.
CHEC
Drawing No.
SUMITOMO
Drawing No.
Rev.
Description
Format
299
GSU0702.Erc.14.04-8
B-CHA -M-BV -8297
Stairs III
A2
300
GSU0702.Erc.14.04-9
B-CHA -M-BV -8298
Stairs IV
A2
301
GSU0702.Erc.14.05
B-CHA -M-BV -8299
Stairs & platforms of

Hopper
A0
302
GSU0702.Erc.14.05-1
B-CHA -M-BV -8300
Ladders I
A3
303
GSU0702.Erc.14.05-2
B-CHA -M-BV -8301
Platform I
A2
304
GSU0702.Erc.14.05-3
B-CHA -M-BV -8302
Maintenance platform
A3
305
GSU0702.Erc.14.05-4
B-CHA -M-BV -8303
Stairs I
A2
306
GSU0702.Erc.14.05-5
B-CHA -M-BV -8304
Stairs II
A2
307
GSU0702.Erc.14.05-6
B-CHA -M-BV -8305
Connection Platform
A2
308
GSU0702.Erc.14.05-7
B-CHA -M-BV -8306
Stairs III
A2
309
GSU0702.Erc.14.05-8
B-CHA -M-BV -8307
Ladder II
A3
310
GSU0702.Erc.14.05-9
B-CHA -M-BV -8308
Transition platform
A3
311
GSU0702.Erc.14.05-10
B-CHA -M-BV -8309
Platform II
A2
312
GSU0702.Erc.14.05-11
B-CHA -M-BV -8310
Ladder III
A3
313-327
No Use
328
GSU0702.Erc.25
B-CHA -M-BV -8326
Lubrication Systems
General Arrangement
A1
329
GSU0702.Erc.25-1
B-CHA -M-BV -8327
M.TROLLEY LUB.SYS.
A2
330
GSU0702.Erc.25-2
B-CHA -M-BV -8328
B.H.HINGE AND
ROLLERS LUB.SYS.
A2
331
GSU0702.Erc.25-3
B-CHA -M-BV -8329
WIRE ROPE LUB.SYS.
A1
332
GSU0702.Erc.25-4
B-CHA -M-BV -8330
MECHINARY HOUSE
LUB.SYS.
A2
333
GSU0702.Erc.25-5
B-CHA -M-BV -8331
DIFFERENTIAL TRUNK
LUB.SYS.
A1
334
GSU0702.Erc.25-6
B-CHA -M-BV -8332
L.S.C.TROLLEY
LUB.SYS
A2
- 233 -
Drawing
Quantity
Item
No.
CHEC
Drawing No.
335
GSU0702.Erc.25-7
B-CHA -M-BV -8333
G.Traveller Lub.SYS.
A1
336
GSU0702.Erc.25-8
B-CHA -M-BV -8334
W.S.C.TROLLEY
LUB.SYS.
A2
337-340
SUMITOMO
Drawing No.
Rev.
No Use
- 234 -
Description
Format
Drawing
Quantity

PO NO.: 145236.61.0401
DOCUMENT: Ship Unloader Operation & Maintenance
Manual(Mechanical)
DOCUMENT NO.: IM0401-3.1.1-2
REV.
2009-12-08
DATE
FOR
CONSTRUCTION
DESCRIPTION
102
TOTAL
PAGES
1 of 102
PREPARED
CHECKED
APPROVED

GSU1500.35/22 Grab Shipunloader
PURPOSE:
This document contains the maintenance instructions for the

GSU1500.35/22 Grab Shipunloader.
SCOPE:
In order to improve both the format and the overall understanding

of the maintenance and operating ; the document have been
separated into seven sections.
i) General Documentation
ii) Description of the Equipment
iii) Maintenance Documentation
iv) Manufacturers specials OEM (instructions of original
equipment manufacturer
v) Machine Drawings
2 of 102
Part I: General Documentation
3 of 102
CONTENTS
NO.
Title
Page
General
Symbol Definition
Users Guide
Safety Note
4 of 102
1 General
This manual was compiled by CHEC, with this manual, the user may familiarize and understand the
structure and purposes of the machine. The equipment operation and maintenance staff, and persons
responsible for consumables and materials must obey the requirements of this manual. Only operate
according to the instruction of this manual, errors may be avoided during the operation, repair and
maintenance of the machine, thus, ensure the fault free operations.
The assumed conditions for all description in this manual are only the skillful persons received the
enough training may operate this machine.
This manual does not include the description and instruction on major repair. As necessary, CHEC
may appoint the qualified skillful persons to check and repair the machine.
This manual will support you in using and handling of the Grab Shipunloader in a safe and proper
way.
2 Sy mbol Definition
2.1
2.2
General definition of symbols

CHEC
GSU
Grab Shipunloader
Drawing No. Definition
2.2.1 Machinery Drawing No.

GSU 0702. User.01.01. .01-1
Part Drawing NO. . 1,2,3,,n
Class n Assembly Drawing NO. 01,02,03,,n
Class II Assembly Drawing NO. 01,02,03,,n
Class I Assembly Drawing NO. 01,02,03,,n
For example:
GSU 0702. User.00 = General Assembly Drawing of GSU for End-user
GSU 0702. User.01 = General Assembly Drawing of Steel Structure for End-user
User = Drawing for End-user
GSU 0702 = CHEC Drawing NO. for GSU of TJB Project
GSU1500.35/22
22= 22m , Span

35=35m, Outreach Distance
1500=1500t/h, Nominal Capacity
GSU= Grab Shipunloader
5 of 102
2.3 Warning Sign and Symbols

In the manual the following terms (warnings) are used for a very important information
(instruction).
The following symbols and signal words are used for safety signs in this manual:
ATTENTION
Is an information or instruction (mandatory or prohibitive) to prevent
equipment damage to the machine.
DANGER!
Is information or instruction (mand atory or prohibitiv e) to prevent
personal injury or extensive equipment damage to the machine.
3 Users Guide
3.1 How to Use the Manual in Different Cases
During the operation of the Grab Shipunloader various cases could occur, which require different
ways of using the manual.
The following information should give you general instructions for using this manual.
3.2 In Case of Maintenance
Before carrying out any maintenance work, read the information given in the specific
Section, where the subject of maintenance is mentioned.
Check the maintenance and read the specific sections of the OEM-Manual.
Check the Drawing List and collect the relevant drawings.
For equipment supplied by Vendors check the relevant section in the OEM-Manual for
drawings and additional information about maintenance and safety.
Before carrying out any maintenance work make sure the necessary spare parts or
materials are available or can be ordered and supplied in time to meet the work
schedule.
Use only the recommended lubricants. Before commencing any work read the safety
precautions, given in the relevant chapter of the instruction (OEM).
Make sure you have prepared all possible safety devices before commencing with the
maintenance work.
Note all completed maintenance activities in a maintenance book or maintenance

program.
3.3 In Case of Repair

If failure occurs, and repair work has to be carried out:
For repair of equipment, which is within an OEM check the relevant sections in the
OEM-Manual for specific information, drawings and safety instructions.
6 of 102
Check the Drawing List and collect the relevant drawings for repair of
structural equipment.
If spare parts are necessary to fix the failure, check the relevant chapter in the
OEM-Manual and the spare part lists of the mechanical equipment.
If the necessary parts are not in store on site, order these parts immediately to
ensure the earliest possible delivery.
Before starting with any work read the general safety precautions. When working on
components read the safety instructions in the relevant OEM-manuals.
Make certain that all site safety procedures have been carried out prior to
commencing any repair or maintenance activities.
3.4 In Case of Ordering Spare Parts

If spare parts have to be ordered, two factors have to be identified.
(1) Spare parts (for example gear units), which are supplied by CHEC, are specified in the
relevant section of the OEM manuals. The relevant drawings and spare part ID-codes are
also included in these sections.
(2) Parts, which are manufactured by CHEC, can be identified by the use of the relevant
drawings of CHEC. Each spare part supplied by CHEC, has its own ID-code. This ID-code
can be found in the relevant bills of material.
3.5
Procedure to identify spare parts for ordering

Identify the main component and read the relevant drawings of CHEC. For more details use the
given references in the equipment manual to find relevant drawings and OEM-Manuals.
4 Safety Note
4.1 General
The Grab Shipunloader may be operated by authorised personnel only.
Nobody should be in the surrounding of the Grab Shipunloader without having good reasons, even
if it is out of operation.
NOTE:
If work or inspection on the Machine has to be done each individual is self
responsible to follow strictly the owners instructions and the given isolation
procedures.
During the operation it is prohibited to stay within the following zones:
within the reach of the Grab
within the long travel arrangement
within the Grab Dolly
within the loading area range, especially chute areas
within the material conveyor line
7 of 102
In general nobody should be allowed to enter the machine during operation other than for
inspection and operation purposes. Carrying out such tasks requires high pre-caution and
carefulness.
Any movement of the machine is automatically indicated by warning facilities like sirens and
flashing lights to give warning to anybody in the vicinity of the Shipunloader.
In cases of danger the machine must immediately be stopped by pushing one of the
EMERGENCY-STOP push buttons.
These emergency stop buttons will trip the power supply to all drives and controls but will not
isolate and services such as lighting and power outlets.
Before putting the machine out of operation it is required that it is in a safe position:
The machine must be storm locked
Repair and/or maintenance work may never be carried out when the machine is operating.
The machine must be protected from unintentional starting during repair and/or maintenance work.
Prior to inspection, repair and/or maintenance work the appropriate equipment shall be
de-energised and locked out in accordance with the isolation procedures.
Repair and maintenance work must never be carried out in the hazardous zones.
Work at the electric and hydraulic systems may be carried out by authorised personnel only.
NOTE:
ALL RE GULATIONS ISSUED BY
COMPETE NT AUTHORITIES,
RELEVANT TO OPERATION AND MAINTENANCE OF THE MACHINE

MUST STRICTLY BE OBSERVED.
4.2 Organisation
The operator's manual must always be ready to hand at the place of machine application!
Supplementary to the manual, common legal and other binding regulations relating to the
prevention of accidents and to the conservation of the environment must separately be prescribed
and observed!
Such duties also cover: handling of dangerous substances, making available/wearing of personal
safety equipment or traffic regulations.
The operator's manual shall be supplemented with instructions relating to service particulars
regarding work organisation, sequence of operations and the personnel required. The main
operator must clearly define all obligations regarding supervision and reporting.
Before any work is started, the personnel operating the machine must have read the operator's
manual.
NOTE:
8 of 102
During the operation it certainly will be too late.

This applies especially to personnel who work at the machine only occasionally
that means during set-up, maintenance and transportation for example. Make sure to periodically
check if the personnel observes the safety instructions of this manual and does neglect neither
precautions nor dangers.
It is recommended and oblique that the personnel in charge of the machine operation should:
wear safety equipment in accordance with the safety regulations
do not have long, open hair
do not wear loose clothing and
do not wear jewellery, including rings and ear-rings
which could be caught by the machine and cause injuries.

Special instructions should prescribe the use of safety equipment such as safety glasses, hard
heads, earmuffs, and safety boots for the operating personnel.
The personnel's attention shall be drawn to all safety and danger signs on and at the machine.
These signs shall be kept evident and legible.
In case safety relevant alterations or changes are noticed at the machine or at its behaviour or
performance (noise, speed,....), it must be stopped immediately and the failure be reported to the
competent person and/or department (obligation of notification) and the machine must not be
started prior to an intensive inspection and analysis.
The welding seams of main components e. g. bogies, portal frame, boom etc. have been welded
with high accuracy and quality in accordance with special regulations and testing procedures.
NOTE:
No modifications, attachments or re-constructions may be made at the
machine without prior notification of and approval by the manufacturer!
This also applies for the installation and the adjustment of safety devices and valves
as well as for welding and drilling at supporting members.
Hydraulic piping and flexible lines (hoses) must be replaced in appropriate intervals, even if no
operation-relevant defects can be noticed.
Intervals for daily, weekly and monthly checks and inspections, as prescribed or specified in the
manual, must be kept. A suitable tool stock is required for these activities.
NOTE:
The operating personnel must be familiar with the fire alarm system and the
possibilities of fire fighting.
All spares used must correspond with the technical requirements as specified by the
machine manufacturer. The spare and wear parts supplied by the manufacturer together with the
machine or at a later date, meet these requirements.
9 of 102
4.3 Qualification and Selection of Personnel

The reliability of the personnel is essential for working at and with the machine.
Only appropriately trained personnel should work on and with the machine. Make sure the crew
members have the legally prescribed minimum age.
The personnel in charge of any activity on or around the machine must be well trained and
instructed. The competencies and responsibilities of the crew members for the operation, set-up,
maintenance and repair must be clearly defined! It must be ensured that authorised personnel only
are allowed to set activities at the machine.
Personnel being trained or instructed or such personnel undergoing a general course of training
must be under continuous supervision of a person having profound experience with this machine.
Work at the electric and electronic equipment may be carried out by skilled electricians only, or by
trained personnel under the direction and supervision of a skilled electrician in accordance with the
regulations.
Work at the drive and brake systems may be carried out by well trained/skilled personnel only.
Work at the hydraulic shall only be carried out by personnel having special knowledge in this field.
4.4 Safety Instructions for Special Operation Phases
Normal Operation
No risky or endangering procedures shall be carried out!
It is very important to ensure that the machine is operated in a safe and well functioning condition
only.
The machine must never be put into operation unless all protection and safety devices, i.e. the
removable protection devices, emergency-OFF switch, sound insulation, coverings and the like
are available and operative.
Before any work is started the crew shall investigate the environment e.g. any obstacles in the
working and traversing area.
Once in every shift the machine must be checked for externally noticeable defects! Alterations and
malfunctions, including those of the performance, must immediately be reported to the competent
department. Immediate shut-down and safeguarding of the machine will be necessary.
Starting and stopping procedures, as well as the supervision of controls and indicators must be
carried out according to the operator's manual.
Before starting respectively putting the machine into operation, it is the operator's duty to ensure
that nobody is endangered by the operating machine.
Before the operation is started and/or the first movements are made, the proper functioning of
signals and lighting equipment must be checked.
Before setting the machine into operation all tools and mounting devices must safely be stored, so
not to risk any accidents.
DANGER:
Do not carry out any operation affecting the stability of the machine.
4.5 Special Work, Maintenance/Repair, Waste Disposal
The maintenance, adjustment and inspection activities as specified in the operator's manual and
their prescribed intervals must be kept. The periods indicated are to be considered as the
10 of 102
maximum and must not be exceeded. These kinds of activities as well as the replacement of parts
are reserved to experts.
Note:
Use the relevant instructions in the OEM-Documents of the manufacturer of
components or the defined job-plans based of information out of this
manual.
The operating personnel must be informed before any special, maintenance or re-setting work is
started. For all such activities it is necessary to nominate a supervisor.
For all activities having an effect on the operation, the scope of production, resetting or adjustment
of the machine and its safety equipment, as well as on the inspection, maintenance and repair, the
starting and shut-down procedures as specified in the manual and the special references on
maintenance work must be observed.
During such work the operative range of the machine must be safeguarded and cordoned off, if
necessary. Trespassing of unauthorised persons is prohibited.
Maintenance and repair work may only be carried out when the machine is secured against
moving.
During maintenance or repair work the relevant equipment has always to be isolated according to
the regulations.
DANGER
It is emphasised that a pressed emergency-OFF switch does not represent a
protection against unauthorised starting of the machine equipment.
When dismantling and assembling large components and complete assemblies, it is necessary to
thoroughly fasten and secure them on lifting devices. Only suitable and technically perfect lifting
devices and load carrying equipment having sufficient carrying capacity may be used. It is
prohibited to stay or work under suspended loads.
Before any activity at the machine is taken up, all handles, step plates, rails, pedestals, and
platforms must be cleaned from dirt or spillage.
For overhead assembly work available elevating and/or working platforms or other such safe
facilities shall be used. It is prohibited to use machine parts for climbing up, or the loading device
as elevating platform.
Prior to any maintenance or repair the machine and especially the connections, unions and fittings
must be cleaned from oil, fuel or lubricants. No aggressive detergents must be used. The cleaning
cloths must be lint free.
All openings which must be prevented for safety or for functional reasons from the penetration of
water, steam or detergent, shall be covered and/or sealed before the machine is cleaned with
water or steam jet (high-pressure cleaner) or other detergents. Electric motors and electronic
switch panels are specially endangered.
As soon as the cleaning work is completed all coverings must be removed.
After cleaning, lubrication and hydraulic lines must be checked for leakage, loose connections,
wear and damage. Defects, if any, must be eliminated immediately. Retighten screwed
11 of 102
connections which have been loosened during maintenance and repair. Pay attention to the
specified torques.
In case it became necessary to remove safety devices for the maintenance, set-up and repair work,
the removed safety devices must be remounted immediately after completion of work and its
proper functioning must be checked.
Process materials, utilities and replacement parts must safely and without harming the
environment be disposed off.
The relevant local regulations shall be observed.
4.6 Special Sources of Danger
4.6.1 Electric Energy
ATTENTION.
In case of failures in the power supply the machine must immediately be
shut-down.
Any work at the electric system or equipment may only be carried out by a skilled electrician or by
instructed personnel under the direction and supervision of an authorised electrician.
The electric system of the machine must be checked in regular intervals. Defects must be reported
and eliminated immediately.
Should there any work on live components become necessary - and the component cannot be
disconnected - a second person who actuates the emergency-OFF or the master switch in
emergency cases, must be present. The working area must be cordoned off by a red/white safety
chain and protected by a warning sign. For such work all tools used must be insulated.
For the inspections, maintenance and/or repair work the machine must be de-energised. The
disconnected components must be checked if they are dead, then connected to ground and
short-circuited. The adjacent energised components must be isolated.
DANGER:
Should the machine become live due to cutting a power cable for instance the
following regulations must be observed:
Do not leave or touch the machine.
Warn people in the vicinity against approaching and touching the
machine.
Do not leave the machine before it is ascertained that the
touched/damaged power cable is de-energised.
De-energise the machine as soon as possible.
4.6.2 Gas, Steam, Smoke, Dust

Welding, burning and grinding work at the machine are subject to approval, due to fire and
explosion hazards.
Before such work is carried out, the machine must be cleaned and ventilation must be sufficient.
12 of 102
In case the maintenance work is carried out in a closed area, sufficient aeration must be provided.
4.6.3 Hydraulics
All work at the hydraulic and systems are reserved to persons with special knowledge and
experience with the machine.
All pipe lines, flexible hoses and screwed fittings must be checked in regular intervals for leakage
and external damages. Defective components must immediately be replaced. Spurting hydraulic
fluid can cause injuries, incendiaries and fire.
If it becomes necessary to remove pipe lines, hoses, flexible lines or other hydraulic components,
it is essential to de-pressurise the respective system section according to the hydraulic circuit
diagram.
Hydraulic lines must be mounted according to the state of the art. Connections must not be
confounded. The fittings, as well as length and quality of the flexible and pipe lines must meet the
requirements.
4.6.4Noise
All sound insulation equipment at the machine must be in the protective position during the
operation
In order to prevent long-term harms to personnel, wearing of ear plugs is recommended.
4.6.5 Oils, Greases and other Chemicals
When handling oils, greases and other chemicals, the safety regulations for the respective product
must be observed.
Special care must be taken when dealing with hot utilities and process material (e.g. hydraulic
fluid).
4.7Dangerous Areas
During the operation but also during shut-down periods the machine involves hazards for man and
material in case of improper handling and unauthorised stay.
Unintentional actuation of the drives may cause unexpected movements of the machine. Persons
or equipment standing beside the machine might get squeezed or overrun.
It shall be considered that limbs, clothing, ribbons, ropes, chains, cables and rags can be seized
and dragged by rotating parts.
It is prohibited to stay on and under the loading table, within the trolley travel, under the grab,
under the boom as well as on and under the conveyor even during machine standstills. During
work on and at these components maximum caution is required and the safety regulations must be
observed.
DANGER:
During the operation of the machine NOBODY is allowed to stay within the
dangerous areas
Due to the described specific dangers in connection with the machine operation, i.e. when the
energy supply is switched on, the following areas are dangerous:
in front of and beside the long travel drives
the Grab Dolly operation area
beside the Hoist, Close and trolley drives
beside the Boom Machinery Drive
hopper area
13 of 102
4.8Machine Stability
The Shipunloader incorporates high masses at large distances. The entire machine is carefully
balanced. However, external forces or removal of weight from the machine can significantly
influence the location of the centre of stability. Therefore it is imperative to be fully familiar with the
potential impacts of the conditions that will influence the stability, which are listed in the next
chapters.
14 of 102
Part II: Description of the Equipment
15 of 102
CONTENTS
NO.
Title
Page
Technical Data
20
Description of the Equipment subassembly & Functions
25
16 of 102
16
1.
1.1 General
The coal shall be delivered to the wharf through coal transport ship, the grab is used for unloading the
coal into hopper, the maximum outreach distance of shipunloader is 35m (the maximum distance from
the sea side rail center to sea side of trolley). The coal is discharged from the hopper, selectively
conveyed onto two belt conveyors on wharf through coal feeder and tee hopper. The dust guard and
water spraying system were installed around the hopper to prevent the dust formation. The water is
fed into the water tank on shipunloader through hose. At both the upper and lower outlets of hopper,
all points of falling materials were equipped with the water supply and nozzle, the pipe water is output
through water pump to form the water curtain after nozzles to control the dust formation at all falling
points of materials.
The shipunloader still has the anchoring device and warping device to prevent the typhoon under nonworking conditions.
The sea side main beam may be lifted 80, no influences to ship arrival and departure etc
This machine is powered through surface connection box, 10kv, 3 phase, and 50Hz, with the surface
connection box, the cable reel of shipunloader is fed to the main switch cabinet, and respectively
output to the main and auxiliary transformers, then entered into the main drive and auxiliary switch
cabinet of machine room.
The shipunloader control is realized with digital control adjustable-speed driver, the programmable
controller comes from Siemens. Apart from the advanced digital control system, this machine still has the
automatic auxiliary control system and advanced communication network system, which ensure high
automation, safety and reliability of shipunloader during the ship unloading.
17 of 102
36 t
1500t/h
Picture 1: Grab Shipunloader
1.2
1.3
Drawing References
Drawing No.
Drawing Title
GSU0702.User.00
General Arrangement
Assembly Groups Of The Equipment

The following equipment is installed on the Grab Shipunloader:
1 Steel Structure (Detail see drawing: GSU0702.Usr.01 Steel Structure)
2 Grab assembly (Detail see drawing: GSU0702.Usr.02 grab assembly)
3 Main-trolley (Detail see drawing: GSU0702.Usr.03 Main-trolley)
4 Operator Cab (Detail see drawing:GSU0702.Usr.04 Operator Cab)
5 Safety Hook (Detail see drawing:GSU0702.Usr.05 Safety Hook)
6 Boom-Hoist-Cab (Detail see drawing:GSU0702.Usr.06 Boom-Hoist-cab)
7 Boom-Machinery (Detail see drawing:GSU0702.Usr.07 Boom-Machinery)
8Hoist,Close and trolley device (Detail see drawing:GSU0702.Usr.08 Hoist,Close and
18 of 102
trolley device)
9 Machinery G.A (Detail see drawing:GSU0702.Usr.09 Machinery G.A)
10
Name plate (Detail see drawing:GSU0702.Usr.11 Name plate)
11Power cable reel (Detail see drawing:GSU0702.Usr.12 Power cable reel)

12
13
Elevator (Detail see drawing:GSU0702.Usr.13 Elevator)

Stairs & platforms (Detail see drawing:GSU0702.Usr.14 Stairs & platforms)
14
Front cantenary trolley (Detail see drawing:GSU0702.Usr.15 Front cantenary trolley)
15
Gantry (Detail see drawing:GSU0702.Usr.16 Gantry)
16
Hopper System (Detail see drawing:GSU0702.Usr.17 Hopper System)
17Backword cantenary trolley (Detail see drawing:GSU0702.Usr.18 Backword cantenary

trolley)
18
19
Cab Safeguard (Detail see drawing:GSU0702.Usr.19 Cab Safeguard)

Rope system (Detail see drawing:GSU0702.Usr.20 Rope system)
20
Rail-layout (Detail see drawing:GSU0702.Usr.21 Rail-layout)
21
Limits for ship-unloader (Detail see drawing:GSU0702.Usr.22 Limits for ship-unloader)
22
Assistant cab (Detail see drawing:GSU0702.Usr.23 Assistant cab)
23
Dust spray system (Detail see drawing:GSU0702.Usr.24 dust spray system)
24Lubrication Systems General Arrangement (Detail see drawing:GSU0702.Usr.25 Lubrication

Systems General Arrangement)
25
Hydraulic system (Detail see drawing:GSU0702.Usr.26 hydraulic system)
26Control Cable Reel (Detail see drawing:GSU0702.Usr.27 Control Cable Reel)
1.4
Machine Identification
One (1) rail mounted Two(2) Grab Shipunloaders at the site TJB with the CHEC-Code:
CHEC GSU15003 5/22
Denomination:
CHEC GSU CHEC Grab Shipunloader
1500
t/h
35

Outreach
19 of 102
22
1.5
1.5.1
Span
Design Criteria Data

Material to be handled
Coal
density = 0.85 t/m3
1.5.2
Ambient Conditions
Environment
Annual Average Temperature
Relative Humidity
ocean sea climatic and dusty
27 C
50%- 92%
Design Wind speeds
1.5.3
in operation
20 m/sec
travelling to anchor position, no operation
35 m/sec
max. wind /out of operation
55 m/sec
Rates of Handling
The Grab Shipunloader is designed to service the bulk material handling system and is suitable for
continuous operation for 24 hours a day, 7 days a week in the prevailing dusty and corrosive
environment.
The Grab Shipunloader is designed for an average capacity of 1500 to/hour.
1.5.4
Codes and Standards

The structural steelwork is designed according to the latest editions of FEM and other applicable
standards not listed as per contract.
20 of 102
2. T echnical Data
Regardless of the speeds necessary at the specified rate, the Grab Shipunloaderwill be
capable of motion speeds as detailed in the Technical Data Sheets.
2.1 Grab Shipunloader Guaranteed Performance

1500t/h
2.2 Design Data

Max Wind speed in operation
20m/sec
Serviceability wind speed
30m/ sec
Ultimate wind speed
55m/sec
Earthquake
YES, as per contract
2.3 General Dimensions

Outreach distance (centre of of sea travel rails to Max.
travel sea distance of Grab )
35,000
mm
18,000
mm
Inreach distance (centre of sea travel rails to

Max. travel land distance of Grab )
Track Gauge (centre to centre of travel rails)

22,000
mm
Travel Rail Size
QU100
Travel Rail Standard
Chinese standard
Overall Height (Top of rail to Top of Front

Girder)
2.4 Storm Tie Down Requirements
21 of 102
approx. 70
Grab Shipunloader Service Area Requirements

Storm Tie Down
Yes
2.5 Equipment Weights

Mass of Grab Shipunloader
Complete Machine
1193775
kg
2.6 Electrical Data

Power Supply Cable reel
Power Cable Length in reel
Approx. 150
control Cable Length in reel
Approx. 150
Control Cable reel
2.7 Boom Machinery Operating Data

Maximum Inclination
About 80
degrees
Boom Hoisting Time
About 6
min
Boom Machinery Drive Data

Manufacturer
CHEC
Motor
Manufacturer
Siemens
Power Rating
90
kW
Rated Speed
988
rpm
Power Supply
500/3/50
Gearbox
Type
M4PSF90E
Manufacturer
Sew
Reduction
140.28
22 of 102
Volts/Ph/Hz
Lubrication Method
Splash lubrication
Disc
Manufacturer
ZPMC
Brake
(at hight axis)
Model and Size
YP21-800-500X30-II.H.RL.HL
Release Method
electrical
Disc
Manufacturer
ZPMC
Brake
(at low axis)
Model and Size
SB250-1700X36
Release Method
hydraumatic
2.8 Hoist, Close and trolley Operating Data
Hoist speed
130/150
m/min
Trolley speed
220
m/min
Manufacturer
CHEC
Hoist Motor
Manufacturer
Siemens
Power Rating
500
kW
Rated Speed
992/1100
rpm
Power Supply
500/3/50
Volts/Ph/Hz
Manufacturer
Siemens
Power Rating
500
kW
Rated Speed
992/1100
rpm
Power Supply
500/3/50
Volts/Ph/Hz
Close Motor
23 of 102
Trolley Motor
Manufacturer
Siemens
Power Rating
315
kW
Rated Speed
993
rpm
Power Supply
500/3/50
Type
PDR40-00
Manufacturer
Nanjing High-Speed & Accurate Gear Group Co., Ltd.,
Reduction
31.21(Hoist,Close)
Lubrication Method
Splash lubrication
Volts/Ph/Hz
Gearbox
18.74(Trolley)
Brake
(Hoist,Close)
Disc
Manufacturer
ZPMC
Model and Size
YP31-3000-710X30I(II).H.RL.HL
Release Method
electrical
Disc
Manufacturer
ZPMC
Model and Size
YP31-2000-710X30II.H.RL.HL
Release Method
electrical
Brake
(Hoist,Close)
2.9 Long Travel Data

Travel Speed
approx.25
m/min
Number of Drive Wheels
16
off
Number of Idle Wheels
16
off
Operation speed
Travel Wheels
mm
Tread Diameter
710
24 of 102
mm
Tread Width
135
mm
Flange Outside Diameter
760
mm
Tread Material & Grade
cast
Tread Hardness
320-380 HB at surface
HB320-380
Drive Wheel
Bearing Type & Size
Bearing Type & Size
Bearing Type & Size
- 53530
Idler Wheel
- 53530
Bearing Type & Size
Coefficient of Friction, Wheel to Rail

Dry Rail,
0.14
Wet Rail,
0.10
Rail Clamper
Number
Type
off
spring loaded
Manufacturer
Shanghai Gangan
Model and Size
400KN
Application Method
Spring
Release Method
Hydraulic
IP Protection Class
IP 55
Manufacturer
Sew
Travel Drive
Model Number
Motor
Number
off
Manufacturer
Sew
Power Rating
18.5
kW
Rated Speed
0-1440
rpm
Frame Size
Standard flange type
Power Supply
400/ 3/ 50
IP Protection Class
55
Means of Speed Control
VVVF Control
Number
Type
Helical bevel gear-
Manufacturer
Sew
Gearbox
25 of 102
off
Model and Size
Reduction
42.33
:1
Lubrication Method
Splash oil
Brake
Number
Disk
Manufacturer
Sew
IP Protection Class
55
Number
off
Travel Buffers
Manufacturer
Chinese supply
Type
hydraumatic buffer
HY100-250
3.
Description of the Equipment subassembly & Functions
3.1 Gantry (Detail see drawing:GSU0702.Usr.16 Gantry)
3.1.1
Structure and properties
1) Structure
The gantry is a driver of shipunloader moving along the rail. The cross beam under the sea side and
land side framework are hinged respectively with two travel trolleys, each set of travel driver consists
of two AC frequency-varying motor (with brake), gearbox, coupling, walking beam, trolley carrier and
wheel etc, the low speed axis of gearbox is connected to the driving wheel shaft indirectly through the
open type gear, each driver may drive two driving wheels, before the gantry travel, open the rail
clamper, and tightly clamp the rail as stop. The walking beam is box welding structure. Both ends of
gantry are equipped with the hydraulic travel buffers and rail cleaners, with the lifting support for the
adjustment and repair of gantry. Generally, both the lifting support and accessories are not attached
on the crane, but should be individually stored and maintained.
The gantry mainly composes of the following components:
(1) 3-in-1 motor, a product of SEW
Integrates the brake, gearbox and motor together.
(2) Rail clamper
26 of 102
The rail clamper is mounted on the anchored support, respectively two clampers at both the sea and
land sides, driven by a hydraulic system, it is a normally-closed rail clamper. The rail clamper is used
for windproof brake of shipunloader under working conditions, or auxiliary windproof safety device
under non-working conditions.
(3) Wheel bearing
The wheel adopts the double centripetal spherical rolling bearing, which shall be able to
automatically align, with inner and outer retaining rings tilted 0.52, suitable for withstanding the
radial loads under heavy load, and the relevant axial loads.
(4) Wheel
The wheel has double rims, with diameter 710, forged with 55# steel, tread quenched, with high
hardness, quenched layer 10mm deep.
(5) Gantry and walking beam
The gantry and walking beam are welded with Q345B steel plate.
(6) Limit switch and hydraulic travel buffers
In order to prevent accidental collision of shipunloader with other equipment, the gantry is equipped
with limit switch, and the wharf bumper has been mounted with link stopper and baffle board. If there
are any operators incorrect operations or accidents, when the shipunloader head rush to wharf and
the distance to the wharf is 3.5m, the last limit switch shall be functioned. Only under the extreme
cases, the hydraulic travel buffer may be collided with the wharf bumper, the travel buffer absorbs
most of collision energy, moreover, one of the wheel shafts is equipped with an absolute position
encoder to accurately transfer the relative position of shipunloader on wharf to operator cab and wharf
central control room.
(7) Centralized lubrication system of gantry
All lubrication points of gantry adopt the centralized lubrication system. The electric lubricating pump
and distributor shall pump the grease to all lubrication points. This system reduces the workload of
repair, and improves the lubrication quality.
1)Performances
Travel speed: 0~25m/min
Wheel diameter:7100mm
Travel rail size: QU100
3-in-1 motor (with brake)
27 of 102
Model: KF107DV180M4/BM/HF/MIC/TH/STH/C
Power: 18.5kW
Hydraulic travel buffer
Model: HYG100-250
Stroke: 250mm
Capacity: 100KN.m
Buffer force: 500KN
3.1.2
Precautions for repair and maintenance
1) Lubrication
Before renew the oil of gearbox, firstly drained out all oil in it.
All rotary shafts and bearings shall be lubricated through the centralized lubrication system on the
gantry.
2) Wearing and damages
For maintenance and inspection items and periodic values, although specified the limitations,
however those important components concerning with the normal running and reliable performances
of shipunloader such as gears of reduction gearbox etc shall be provided the repair schedule within
the period before next inspection according to the degree of wearing, or replaced as soon as possible.
3) Loose of fasteners
Carefully check whether the fasteners such as bolt etc for connecting two driving components
together loose or not.
The fastened places such as motor, gearbox, frame and wheel shaft etc must be fully checked.
4) Motor brake, rail clamper
The motion of brake and rail clamper should be checked at least once a month, especially the fasteners,
wearings, and oil pipe connections.
5) Limit switch
The gantry travel brake and rail clamper have many limit switches, checked carefully and made the
confirmation for the position and reliability of each limit switch.
28 of 102
3.1.3 Disassembly and assembly
During disassembly and assembly, care to not forcibly knock to avoid damages to components. Now
some main components are described as below.
1)
Disassembly
(1) Wheel
Drive the gantry to stop position, properly setup the anchoring pin as required, windproof lashing rope
etc. According to the surface lifting point and position of frame to be lifted (special-purpose lifting
beam and accessories are normally not installed on the shipunloader), lift up the trolley to be
disassembled, remove the connecting bolts of frame with support, move the trolley outside the rail
with fork lift or other lifting equipment from side, and respectively remove the wheels, shaft sleeve,
retainer and shaft etc from the trolley disassembled.
(2) Motor and gearbox
Both the motor and gearbox can be disassembled one by one from the inside of rail through crane
or fork lift.
2) Assembly
Prior to assemble, carefully check the new components according to the requirements of
assembly diagram, and assemble according to the reverse order of disassembly. Care to no dust
or other sundries left.
3.1.4 Precautions (general precautions)
For the reassembled travel mechanism, firstly manually turn the well assembled wheels; assembled on
the trolley carrier only after rotated properly. During assemble the motor and gearbox, especially care
to the rotation direction of motor.
During test run, firstly carry out the no-load test run, then the loaded test run.
Maintenance and checklist and period
1) All components
(1) Whether the fastening bolts are loose or not
Fully understand the importance of fixing bolts. After initial running for one week, the bolts shall be
checked monthly for loose problems, if loosened, retightened, only the correct wrench should be
used for this purpose.
29 of 102
Maintenance period: weekly and monthly.

(2) lubrication oil
Add the oil correctly according to the lubrication schedule.
Maintenance period: once a week
2) Brake (including rail clamper), motor
(1) Brake (including rail clamper)
Brake bushing worn, surface temperature abnormal rise, and running non-uniform
Maintenance period: daily
(2) Motor
Carbon brush worn, whether there are any unusual noises in it
3) Gearbox
(1) Whether the oil volume and brand are correct or not
(2) Whether it is leaked or not
(3) Whether the temperature rise is abnormal or notIf the housing temperature is beyond 85,
check the inside of gearbox.
(4) Whether there is abnormal noise in it
(5) Whether the bolts are loose or not
(6) Whether the bearing temperature is beyond 85 or not.
4) Wheel
(1) Whether the wheel has any axial motionsIf there are any axial motions, the retainer or bearing
may be damaged.
(2) Whether the wheel tread is peeled or not, and whether there are any other damages.
3.1.5 Important precautions
The gantry travel mechanism has the total brake system (driving wheel motor brake, rail clamper) for
the braking of shipunloader, ensure the shipunloader to continue running under wind velocity <25m/s,
the braking force shall be designed according to the wind velocity 35m/s.
When the wind velocity is up to 20m/s, and an alarm given, immediately stop, and drive the
shipunloader to the specified stop position. Insert the anchoring plate into the anchoring pit on the
wharf (the anchoring is interlocked with the travel).
30 of 102
Note: During strong wind, off duty, weekend or long outage, the shipunloader shall be also
locked up with windproof lashing rope, with the front girder locked at the upward elevated
position of 80.
If there is windstorm alarm and wind velocity up to 55m/s, the windproof lashing rope and anchoring
device must be able to fix the shipunloader to the stop position.
3.2 Power cable reel a nd Control Cable Reel (D etail see d rawing:GSU0702.Usr.12 Po wer cable
reel )
Both the power and control cable take-up is the input of shipunloader power supply and control,
communication: from the wharf connection box, introduce 10KV electricity into this equipment through
the power cable, meanwhile send the detection signal of shipunloader to the wharf central control
room.
3.3 Dust spray system (Detail see drawing:GSU0702.Usr.24 dust spray system)
This machine has the water sprinkling dust suppression system for coal unloading: 1) sprinkle water
around the hopper; 2) sprinkled at the outlet of feeder; 3) sprinkled at the transfer point of wharf belt
conveyor.
3.3.1 Water sprinkling dust suppression system
The wharf is arranged with the water supply pipe, the water may be delivered to the water tank of
machine through hose, then pumped to the upper port of hopper, the receiving point of belt conveyor,
and discharging point of belt conveyor etc.
During water supply, the stop on water tank shall give the relevant signal and displayed in operator
cab.
Detail see OEM Instructions OEM
3.4 Hopper System (Detail see drawing:GSU0702.Usr.17 Hopper System)
3.4.1 Structure and performance of hopper system
1) Structure
31 of 102
Composes of wind shield, grille, hopper, lining plate, hinged strut, and vibrator etc.
The wind shield at both sides of hopper effectively reduces the influences of wind to dust formation
during unloading. The grille may sieve the size of materials, during non-working conditions, the grab
may be put above it. The lining plate is made of abrasion-resistant steel, bolted with hopper body,
after worn, it may be replaced. In order to control the level of materials in hopper, designed with
structures such as hinged strut, sensor support and jack etc. The opening of discharge door may be
adjusted according to different flow rate.
2) Performances
The materials shall enter the belt conveyor from the upper port of hopper, through grille and
discharge door.
The hopper system has the material level metering device, when the weight of materials in hopper
is less than 20%, the feeding belt conveyor stops; when the materials in hopper is up to 80%, it
shall give an alarm; when the materials in hopper is up to 100%, the loaded grab is unable to open
above the hopper.
1) Disassembly
(1) Grille
The grille may be disassembled respectively.
(2) Lining plate
Remove the sunk screws, that is, the lining plate may be taken out manually.
(3) Shaft sensor
When the hopper emptied, lift up the hopper at the lifting point beside the support with jack, remove
the pedestal bolts and connecting wires with amplifier, take out the shaft sensor.
2) Assembly
Assemble according to the reverse order of disassembly.
3) Precautions
(1) Properly fulfill the preparations for disassembly and assembly.
(2) Care to keep the disassembled components, not damaged.
32 of 102
3.4.3 Precautions for maintenance and protection
1) Check the loose of fasteners

Periodically check the connecting bolts for hinged strut of hopper, sensor support and other supports,
the bolts for connecting the wall vibrator and hopper, if found there are any loose positions, tightened
with proper wrench immediately.
The lining plate in hopper is easily worn, and replaced when the wearing quantity up to 50% the wall
thickness. However, even if the wearing quantity beyond 50%, it may be also used, the replacement
of lining plate depends on the actual situations.
Usually the grille plate and hopper etc shall be not damaged, if damaged by accidental collision,
repair immediately.
3.5 Discharge door and drive unit (Detail see drawing:GSU0702.Usr.17.07 Discharge Door)
3.5.1 Components and performances
1) The discharge door and drive consist of discharge door and hydraulic driving mechanism, and the
discharge door is a welded structure. The hydraulic cylinder drives the discharge door, operated along
the sliding way fixed on the structure to open and close the discharge door. When unloading, the
driver may control the flow rate of materials by adjusting the opening of discharge door. Usually
adjusted to a specified position according to the materials to be unloaded. The discharge door driving
mechanism is fixed on the frame.
2) The materials may reach the belt conveyor through the discharge door under the hopper. The correct
opening of discharge door may uniformly feed and reduce the impact and unbalanced feeding
problems.
3) The flow rate of materials is controlled by the driver, operated at operator cab or auxiliary operator cab,
the discharge door close is interlocked with the whole machine.
3.5.2 Precautions for repair and maintenance
1) Lubrication
The hydraulic cylinder shall be checked and lubricated according to the general requirements; the
33 of 102
other movable parts shall be lubricated with grease.

2) wearing and damages
If the wearing or deformation beyond the specified limitations, immediately repair or renew
3.6 Spillage-flap and drive unit (Detail see drawing:GSU0702.Erc.17.05 Spillage-flap)
3.6.1 Structure and performances of spillage-flap
The sea side of shipunloader hopper is equipped with spillage-flap for recovering the fallen coal and
materials scattered between the ship and wharf. The spillage-flap may realize the inclination action
through hydraulic system. During working of shipunloader and hoisting the cleaner, the spillage-flap
inclines downward to form -10 with level surface; during clean out the spillage-flap, the spillage-flap
inclines upward to form +81 with level surface. The spillage-flap may fulfill the individual actions at
working or non-working positions, and interlocked with main trolley operation through limit switch.
1) Main components
This system composes of hydraulic power station and cylinders..
1) Hydraulic oil
The hydraulic oil shall be replaced periodically, usually about half a year, when renew the oil, the
used oil must be drained out completely. When added with new oil, care to the properties and brand
of oils.
1) Disassembly
Firstly dismantle the oil pipeline, and then respectively remove the other units.
2) Assembly
Prior to assemble, all parts must be cleaned out, and added with appropriate grease, and
assemble according to the reverse order of disassembly.
34 of 102
3.7 Operator Cab (Detail see drawing:GSU0702.Usr.04 Operator Cab)
3.7.1 Structure and performances
The operator cab operating mechanism is arranged under the left of shipunloader boom girder (seen from
land side to sea side), located at the same side of elevator. Control the operator cab to move forward and
backward along boom on H-rail through the whole driver. Under working conditions, the operator may drive
the operator cab to the correct position to operate. At the land side stop position, an operator cab
anchoring device is arranged. When the shipunloader stop or during long period outage, stop the operator
cab at the anchored position, and lockup the anchoring pin, the anchoring device is interlocked with the
operator cab operating mechanism. A fall-proof device ensures the operator cab not fallen during the
operator cab wheel shaft broken.
1) Components
The operator cab assembly composes of driver and operator cab.
The driver composes of AC frequency-varying motor with brake, reductor, gear transmission, half-serrated
coupling, and drive wheel etc.
The operator cab is the place for operator working, with combined console, control box, instrument cabinet,
air conditioner, LCD monitor, communication equipment, extinguisher, window curtain, foldable chairs etc
in it, and rain wiper, sun shade, reflector etc outside. Three sides of operator cab has the fixed windows,
the front floor of operator cab has the visible glass. The entrance and exit of operator cab walkway are
arranged with security door, which has the detection limit, interlocked with operator cab operating
mechanism. The outside of operator cab has a straight ladder to emergency exit platform outside the
girder through the walkway platform of operator cab.
The driver is integrated firmly with operator cab through the connecting bolt and buffer.
All mechanisms of shipunloader may be operated in operator cab through control buttons and operating
handles, monitor the unloading area and trolley operation area in real time through industrial TV.
2) Main operating parameters and performances of operator cab
Travel speed: 20m/min
Track gauge: 2050mm
Travel rail size: I steel 25b
Power: 0.75kw x 4
35 of 102
3.7.2 Description of operator cab
The distance of operator cab travel to sea side (from the center of sea side rail) is 28m, and the max. travel
land distance-22m. Both the front and rear ultimate positions of operator cab are equipped with the limit
switches and buffers. During non-working conditions (stop), locked up with anchor pins, and interlocked
with operator cab. When the front girder luffing, interlocked with operator cab.
1) Lubrication
See attached table for lubrication of gearbox.
All the coupling, bearing, and travel wheel shall be periodically lubricated with grease.
2) Fastened bolt locking check
The drive chassis and operator cab may be bolted, prior to test run, carefully check and tightly
fastened with correct wrench; after one cycle operation, check whether all bolts, and nuts are
loosened or not.
3) Cleaning of outer window glass of operator cab
(1) The glass at both sides may be wiped on the platform; when clean the front glass, stop the
operator cab at the cleaning platform of rear girder for cleaning purpose.
(2) During cleaning, the safety belt must be worn according to the relevant requirements, and pay
much attention to the safety.
3.8 Electric cable-hanging unit (Detail see drawing:GSU0702.Usr.04 Oper ator Cab)
The towing trolley is a device for hanging the control communication cable and trolley power cable. The
control communication cable and trolley power cable are connected to operator cab and connected with
the wiring box in it from the electrical room, through cable trough, rear end of towing rail, and trolley. One
end of electric cable-hanging unit is fixed with the rear protruded end of towing rail, the other end is fixed
with the universal joint of operator cab, two elastic rubber bands are connected between towing trolleys,
and connected with one wire rope; the length of elastic rubber band< the length of wire rope<the length of
cable to reduce and prevent the direct tension of towing trolley during startup and running. Both ends of
36 of 102
each trolley shall be arranged with travel buffers to reduce the mutual collision during trolley startup and
running. Each towing trolley composes of four travel wheels, four horizontal wheels and cable carrier,
travels on the lower wing brim of H-rail. The towing trolley is driven by operator cab, the drag link trolley
itself has no power.
1) lubrication
Casually fill the grease into the travel wheel.
2) Fastening
Check whether the bolt connections loose or not, if loose, immediately fastened.
Check whether the buckle at the fixing end of rubber band and wire rope loose or not, if loose,
fastened immediately.
Frequently check the wearing of travel wheel, and horizontal wheel etc, check the fixing of rubber
band and rope and buckle damages, check whether the travel buffers damaged or not. Those
seriously worn and damaged components must be replaced as soon as possible.
Frequently check whether the cable and cable trolley mutually interferenced and worn, if found any
problems, repair immediately.
3.9 Hoist,Close and trolley device (Detail see drawing:GSU0702.Usr.08 Hoist,Close and trolley device)
The hoist, close and trolley device are the most important mechanisms of shipunloader, which are
responsible for the grab hoist, close and trolley operation, and fulfill all three-in-one works of differential
system, so it is very important to master its operation rules, strengthen the inspection and maintenance.
This device mainly composes of inverter AC motor, drum tooth coupler, disc brake, differential reduction
gearbox, low speed axis brake, reel, rolling bearing seat and base frame etc, arranged in the machine
room.
The ends of four 40 ropes are respectively fixed on four reels through rope hold-down plates. In which,
two ropes exit wound to sea side, the other two ropes exit wound to land side. Two ropes wound to sea
side are respectively connected to one end of the grab bearing beam and end of one close rope through
redirecting pulley block on front girder, and main trolley close and hoist pulley block through quick buckles.
The ends of another two ropes wound to land side respectively connect with another end of grab bearing
37 of 102
beam and end of another closing rope through the redirecting pulley block on rear girder, and main trolley
close, and hoist pulley block through quick buckles.
This device drives four reels through motor driven reductor to realize the grab hoist, close and trolley
operation etc. Not only make the individual motion, but also realize the complex motion, and realize
3-in-one motion combination.
This device still has the pulse encoder, speed measuring and overspeed switch etc to detect and control
every position of grab, and the position of trolley operated. Its main technical data are as below:
1) Motor
Two 500kw AC motors, one 315kw AC motor are respectively connected with reductor to input the hoist,
close and trolley traction powers.
2) High speed axis brake
The high speed axis of gearbox is equipped with brake disc, and disc brake. When the electric hydraulic
pusher disc brake power failed, the compression spring shall tightly clamp the brake disc through gripper,
the brake stops. When powered on, under the function of electric pusher, open the clamp plier, release the
brake, so, when powered off or power failed due to other causes, the clamp plier may rapidly clamp the
brake disc securely, the brake is normally closed type.
3) Reel
The reel is made of Q345B steel plate through weld, anneal and machining, a single-link and single-layer
wound reel. The reel shall be maintained the standby coil and safety coil as required. Four ends of four
ropes are respectively fixed at one end of single rope groove with clamping plate, exit under the reel; two
ropes are wound to sea side, the other two ropes are wound to land side. One end of reel is connected to
output shaft key of reductor through reel coupler, another end of reel is supported on the rolling bearing
seat.
4) Rope
This mechanism adopt the different left-handed and right-handed ropes, wound on the reel with different
requirements, the right-hand close reel adopts the left-handed rope, the left-handed up and down reel may
adopt the right-handed rope, moreover, the required length for each rope is also different.
5) High speed coupler
The motor is connected with gearbox input shaft through the brake disc drum tooth coupler. The shaft end
of motor is installed in the outer-gear semi-coupler; the inner-gear coupling band is connected to the
semi-coupler of gearbox input shaft through bolts and brake disc, which may not only transfer high torque,
38 of 102
but also easier for adjustment and disassembly.

6) Encoder, cam limit, speed measurement, overspeed switch and differential limit switch
The encoder and cam limit are installed on the output shaft at the other end of gearbox, according to the
rotary speed of motor, the PLC control system shall be used for detecting the grab up and down, close and
trolley position, realize the semi-automatic control for grab working cycles, and interlock with boommachinery etc. Both the speed measurement and overspeed shall be realized through PLC. The
differential limit switch is installed on the hoist reel shaftcontrol the height of grab through sprocket
driving.
The rope trough bounce detector is also installed under the reel to interlock with reel.
1) Lubrication
The electric lubrication equipment is arranged at the reduction gearbox, reel bearing and other
rotation places.
The special lubrication equipment of gearbox must be started firstly before four reels started. The
electric lubricaiton for reel bearing and other rotations may be started according to the maintenance
demands.
When replace the gearbox oil, drain out all used oil. Those oils or greases with different performances
and specifications cannot be mixed together.
2) Wearing or damages
Care to the brake clamp friction pieces worn, gear face fatigue of gearbox, wearing and abnormal
damages, and bearing damages etc. While periodic check and maintenance, repair or renew
immediately according to the actual wearing or damages.
3) Abnormal temperature rise
Care to ensure no abnormal temperature rise of brake, gearbox, motor and bearings etc, if found any
abnormal temperature rise problems, the work may continue only after found the causes and
remedied.
4) Loosening of fasteners
The anchor bolts of motor, brake, gearbox, and bearing seat etc and rope clamping bolts etc shall be
not loosened, no weld opening of welding line on the limit shearing block.
39 of 102
5) Brake
The functions of brake must be carefully checked every two weeks. The gap between brake disc
and clamping friction piece shall be kept 0.51.0mm.
6) Limit switch and pulse encoder
Because this machine adopts the mechanical differential compensation trolley mode, the main
trolley adopts the rope traction, combined with the hoist, close and trolley operations. So, prior to
work, firstly confirm the position of each limit switch and pulse encoder displayed, and then begin to
operate again.
During disassembly and assembly, care not to collide any components. See accompanied documents
for motor, brake and gearbox.
1) Brake disc
Unscrew the anchor bolt of motor, remove the gear coupler bolt, move the motor backward about
100mm, slightly knock the brake disc with copper hammer, and then remove it
2) Reel
Disconnect the bolt for connecting the bearing seat and steel structure. Remove the anchor bolts of
motor and move the motor away. Remove the anchors of gearbox, move the gearbox to the motor
side until there is enough space for removing the low speed coupler of reel.
3) Bearing in seat
Firstly remove the blind connection bolts of bearing seat, loosen the fastening bolts for upper and
lower bearing seats of reel bearing pedestal, remove the upper bearing seat and bearing.
4) Assembly
Prior to assemble, clean the bearing and coupler etc, especially prevent the intrusion of dust and
sundries; during assembly, add the appropriate quantity of grease, assemble according to the
reverse order of disassembly.
3.9.4 Precautions
Maintenance and check period:

1) Whether the fastening bolts are loose or not
40 of 102
Frequently check the tightness of bolts, especially one week after initial running and monthly later,
all bolts must be checked carefully, and retightened; the correct wrench for this purpose must be
used.
2) Lubrication
Usually the lubricating oil for gearbox, and hydraulic pusher is replaced every six months.
Three months after initial running, all lubricating oil in gearbox must be replaced, and
replaced every six months later.
3) Rolling bearing
Include the bearings of motor, gearbox and in the rolling bearing seat etc.
(1) Whether found any abnormal temperature rises
Upper limit of bearing temperature rise: 40 above the ambient temperature
(2) Whether there are any abnormal noises
4) Rope
Whether the rope end clamp plate loosened or not
Whether there are excessive torn and wire broken
5) Limit switch, encoder

Whether the pulse encoder, and limit switch function properly and locate at the correct positions
3.10 Boom-Machinery (Detail see drawing:GSU0702.Usr.07 Boom-Machinery)
This device drives the rope through inverter AC motor, drum tooth coupler, gearbox, reel coupling, and reel,
and realize the boom hoist and inclination through pulley system.
41 of 102
At both ends of reel block, the rope clamp plate may be used for fix both ends of rope on the reel. The
ropes are continuous by two redirecting pulleys of sea side trapezoidal frame through boom hoist pulley
block and pulley block at both sides, the rope between both redirecting pulleys is fixed with clamp block to
let it only move in the long trough welded on the trapezoidal frame, not only balance the pulling force at
both sides of wire rope, but also protect against all ropes bounced when the rope at single side suddenly
broken during boom hoist. The sea side trapezoidal frame hoist and inclination pulley block has the rope
limit device to prevent the mechanism continuing work after the girder put to level position; or the safety
hook of girder not released, the boom machinery beginning to work and cause the accidents. A rope trough
bounce detector is also installed under the reel and interlocked with reel. When the rope at one side
broken, but the rope at other side not loosened or damaged, the boom may be hoisted by the rope at one
side to the nearest position for overhaul.
Under normal working conditions, hoist and inclination duration (single stroke) : <8min
Main components:
1) Motor
Model:1LG4313-6AA50-Z
Power: 90kw
Rotary speed: 988rpm
See specification of motor for its components and description.
2) Gearbox, manufactured by SEW

Model: M4PSF90E
Transmission ratio: 140.28
3) High speed axis spider elastic coupler
The motor shaft is connected with gearbox shaft through coupling, the brake disc is connected with
gearbox input shaft end through hinged bolts.
4) High speed axis brake
When the electric hydraulic pusher brake power failed, the spring in clamp driver may tightly clamp
the brake disc through the pusher, and plier, and then the brake stopped. When powered on, due to
the electric hydraulic pusher function, the clamp plier and open the brake. So, when found the power
failed or powered off due to other causes, the clamp plier shall rapidly clamp the brake disc tightly,
and stop the boom hoist seperately.
42 of 102
5) Reel
The reel set composes of both left and right symmetrical single reels connected with high strength
bolts through the flange. The reel is made of steel plate, manufactured through weld and annealing
treatment etc. The reel has the standby clamping rope and safety coil as required. One end of reel is
connected to the output shaft of gearbox through reel coupling; another end of reel is supported on
the rolling bearing seat.
6) Low speed axis disc brake
This brake is installed on the end of right reel, consists of brake disc, electric hydraulic disc brake,
hydraulic pump station, and pedestal etc. During daily working, this brake may unlock the clamp plier
to delay the stop through electric control system and hydraulic pump station, ensure the stability and
safety of boom hoist; under the accidental cases, this brake may individually stop the operation of
boom hoist, ensure the high safety.
7) Overspeed switch
When the drive motor is beyond the normal rotary speed, the overspeed switch shall realize the
effective control.
8) Cam limit switch
Synchronized with the reel, control the deceleration (acceleration) and stop etc during the boom
hoisting
1) Lubrication
When replace the oil of motor, brake, gearbox, coupler and bearing etc, drained off all used oil.
Those lubricating oils or greases with different performances and specifications cannot be mixed
together.
Care to the wearing of brake clamp plier; reductor gear face fatigued, damaged and abnormal cases;
the early damaged of bearing etc, all these important components must be also repaired or renewed
immediately according to the actual damages during the periodic check and maintenance.
3) Abnormal temperature rise
For all brake, gearbox, motor and bearings, care whether there are any abnormal temperature rise.
43 of 102
If found any abnormal temperature rise, find the causes, continue to work only after these problems
remedied.
4) Fastener loose
Frequently check the connection of fasteners, if any problems found, tightened immediately.
5) Brake
The action of brake must be carefully checked every two weeks. The gap between the brake disc
and clamp friction piece shall be kept 0.51.0mm.
6) Overspeed switch and master switch
Irregularly check whether the installed position moved or not.
During disassembly and assembly, keep no damages to each component.

See the relevant documents for motor, brake, and reductor.
1) Disassembly
(1) High speed disc brake
Just remove the anchor bolt, main spring, pin shaft, and lever.
(2) Low speed disc brake
Remove the oil pipe and disc brake anchor bolts, just then the brake may be individually removed.
(3) Reel
Remove the through-rod bolts of reel coupling connected with reel and gearbox output shaft;
Remove the cam limit switch and bearing seat anchor bolts, just then the reel may be taken out.
(4) Reel bearing
Firstly remove the bearing cap connecting bolts, remove the bearing cap, then the connecting bolts
of end rings, just then the bearing may be removed.
2) Assembly
During assembly, clean the bearing and machined pieces, dried to prevent the entry of dust and
foreign matters, assemble according to the reverse order of disassembly, and fill the appropriate
quantity of grease etc.
44 of 102
3.10.4 Precautions
Maintenance and check items and period

1) All components
(1) Whether the fixing bolts are loosened or not
Care whether the bolts loosened or not, especially the first cycle, and check all bolts once a month,
retightened. The correct wrench must be used for this purpose.
Maintenance period: daily and monthly
(2) Lubrication
All the motor, brake, gearbox, coupler, bearing seat, and cam limit switch drive etc must be correctly
lubricated according to the schedule of lubrication.
2) Motor
(1) Check the emission of heat, whether the bearing has the abnormal emission of heat.
(2) Whether the inner of motor has any abnormal noise
(3) Check the wearing of carbon brush etc.
3) Gearbox
(1) Measure the oil quantity with oil leveler.
(2) Whether the oil temperature is rose or not
If the housing temperature is beyond the ambient temperature 40, it interior check must be carried
out.
(3) Check whether there are any abnormal noise in it.
4) Gear coupler
(1) Tightening of through rod bolts at both sides of inner gear.
(2) Meshing and wearing of inner and outer gears.
(3) The central deviation of coupler is less than 0.03mm, and angle deviation <15.
Maintenance period: monthly.
5) Bearing
(1) Whether there is abnormal temperature rise
45 of 102
The temperature rise of bearing cannot be beyond the ambient temperature 40.
(2) Whether there is abnormal noise;
(3) Whether the fixing bolts are loosened or not;
6) Master limit switch
(1) Lubrication of gear
(2) Whether function correctly or not
Maintenance period: monthly
7) Disc brake
(1) Gap between the brake clamp and brake disc is 0.5~1.0mm;
(2) Check the worn of brake friction piece;
(3) Check the heat emission;
Maintenance period: 2 weeks
3.11 Rope system
The rope system consists of hoist, close, main trolley traction rope system, trolley rope system and
boom hoist rope system.
3.11.1 Rope system (Detail see drawing:GSU0702.Usr.20 Rope system)
1) Components of hoist close traction spinning

Four ropes of hoist, close and trolley traction (3-in-1) shall be led- out under four hoist and close
reels, in which, two rope are respectively fixed on grab after redirected by front girder sea side end
pulley block and main trolley pulley block through sea side upper cross-beam pulley block; the other
two ropes are respectively fixed on the grab after redirected through rear girder land side end pulley
block and main trolley pulley block. The shaft of redirecting pulley block at the land side end of front
and rear girder is installed with overload protector, which tests the load through a shaft sensor.
When the grab is overload or overloaded by operators maloperations, the overload protector shall
give an alarm signal.
The joint actions of hoist, close and trolley operations in rope system may be realized through the
mechanical differentials.
2) Hoist, close and traction rope during non-working (as boom elevated) period
46 of 102
When the boom is under hoist and inclination conditions, both the main trolley and rear cantenary
trolley shall be driven to the specified position of rear girder, the front cantenary trolley is on the front
girder, the main trolley is locked by the anchoring pin. During the boom hoisting of hoist, close and
traction ropes, the rope length is slightly varied, but basically give no influences to the boom hoist
actions. In order to prevent the rope trough bounce on pulley caused by varying of rope length, an
arc abrasion-resistant lining is installed under the sea side upper cross beam, and guide arc guide
plate is also mounted at the interim pulley.
Each pulley is equipped with rope trough bounce resistant device to prevent the rope trough bounce
caused by rope slack and overtight, and bounce during the operation.
After put into operation for a period, the rope length may be varied, if found that the stroke cannot
meet with the requirements, adjust at the fixed position of rope.
3.11.2 Trolley rope system (Detail see drawing: GSU0702.Usr.20.01A/B/C Trolley rope system)
1Components of trolley rope system

The trolley rope system has total six ropes, two ropes connect the main trolley and front trolley together, let
the ratio of speed between the main trolley and front trolley 2:1, both ends of this rope are respectively
connected with both rope connectors at the front of main trolley, and its middle passing through the pulley
of front trolley and redirecting pulley at the end of rear girder; two ropes connect the main trolley and rear
trolley together, which let the ratio of speed between the main trolley and rear trolley 2:1, both ends of this
rope are respectively connected with both rope ends behind the main trolley, and its middle passing
through the pulley of rear trolley and redirecting pulley at the end of front girder; two ropes connect the
front trolley and rear trolley together, let the speed ratio between the front trolley and rear trolley 1:1, both
ends of this rope are respectively connected with both rope ends of front trolley, and its middle passing
through the pulley at the ends of front and rear girder and the redirecting pulley of rear trolley. After
operated for a period, the length of rope connected with front and rear trolleys shall be varied, which may
be adjusted by counterweighted take-up.
2) Hoist, close and traction rope during non-working conditions (as boom elevated)
Under the hoist and inclination status of boom, because the main trolley is locked by anchor pin, the front
trolley is on the front girder, the rear trolley is at the specified position of rear girder. So, during boom hoist
of traction rope, the length of rope may be varied. In order to solve this problem, the tail of rear girder is
arranged with the trolley rope take-up compensation system. When the boom machinery begin to work, the
47 of 102
take-up shall compensate the length of rope.
3.11.3 Boom Hoist Rope System (Detail see drawing: GSU0702.Usr.20.02 Boom Hoist Rope System)
One end of two ropes for boom hoist is fixed on one end of reel, the other end is wound out under the
boom reel, through pulley block at one side of trapezoid frame top, and pulley block at the same side of
front girder, with one end fixed on the front girder. All the pulleys are equipped with rope guard to prevent
the rope bounced out of the trough. After operated for a specified period, the rope must be adjusted to let
both ropes suffered the balanced forces.
The maintenance scope includes all pulley blocks such as hoist, close and traction trolley, cantenary
trolley traction and boom hoist etc, pedestal connection, and rope etc.
1) Lubrication
All greases for lubrication points must be selected as requirements.
All pulleys and ropes must be lubricated frequently.
2) Fasteners
For connections through fasteners such as bolt etc, it is very important to check the loose problems,
one week after the first operation, each pulley pedestal must be carried out the fastening check, later
check at least once a month. If find any problems, immediately tightened with correct wrench.
When wearing and deformation are beyond the limitations, repair or renew as soon as possible.
When the pulley rope trough worn beyond 20% the wall thickness, replaced, the wearing or broken
of rope shall be replaced as required.
4) Shaft sensor
The shaft sensor is a key component for overload protection, not permit to knock and dismantle
without authorization.
48 of 102
3.12 Tension equipment (Detail see drawing: GSU0702.Usr. 20.01.01 Tension equipment)
3.12.1 Structure and working principle
The cantenary trolley rope take-up is arranged on the rear girder. The take-up consists of
counterweight, moving pulley, and chassis etc. the rope wound with main trolley according to the
stroke proportion shall be led out from the rear cantenary trolley pulley, fixed on the front cantenary
trolley chassis after passed the moving pulley on the rope take-up and redirecting pulley at the end
of front girder.
During the start and brake of main trolley and cantenary trolley, due to the influences of mass forces
and resistance etc, the tension of rope (sag of rope) varied, which give influences to the stable
running of trolley and forces on steel structure. The take-up may automatically compensate to
ensure the stable running of cantenary trolley.
1) Description of service conditions
(1) Working status
Working status, automatic compensation of rope tension
1) General precautions
(1) Lubrication
The oils for lubricating the pulley, roller, and hinged points with different specifications and
characteristics cannot be mixed together
(2) Abrasion and damages
Casually check the wearing of pulley etc. Renew immediately after worn to the specified extent.
(3) Tightness of fastening parts
For bolt connection parts, the connection between the piston rod end and nuts must be frequently
checked to avoid any loose problems.
2) Precautions for main components
(1) Pulley
a) Whether the pulley rotates freely
b) Whether the bearing has the heat emission, with temperature rise not beyond the ambient
temperature 40
49 of 102
c) Whether the screws on the end cover are loosened or not, whether the rope groove are worn
seriously.
3.13 Replacement of main ropes
The replacement of ropes may be realized through all drive reels
3.13.1 Hoist rope, close rope
The individual replacement of hoist and close ropes may be realized by driving a single reel.
Now take the replacement of new rope on close reel as an example to introduce the method of
replacing the rope:
1) Stop the main trolley at the position for replacing the rope of rear girder, and anchor the main trolley,
the grab is in open status and put on the wharf, release the closing rope to be replaced, remove the rope
at the end of grab.
2) Fix the rope replacing pulley at the specified position with hook on the repairing travel trolley.
3) Open the trolley drive brakes of four reels, meanwhile remove any one of both universal coupling. The
insert pin of rope replacing mechanism shall be used for locking another reel not required to replace the
rope. Startup the close motor, drive the reel under the speed for replacing rope, slowly put down the used
rope, after the whole rope in the trough completely put down, then open the rope clamp block on the reel,
connect the old rope with the fine rope in reel of special rope changing mechanism behind four reels, (the
fine rope must firstly wound through the rope changing pulley on the repairing travel trolley, the fine rope
length is approximate to the rope to be changed), and then start the rope changing mechanism to put the
old rope on the ground.
5) Remove the old rope; connect the new rope with one end of fine rope. The closing motor shall slowly
rotate along the rope retracting direction, let the new rope wound on the reel, fix the rope ends with
clamp plate, the other end is connected with grab.
6)
Note: At beginning, the tension of rope may be too high, just then, aid with fork lift or other lifting tools,
care to safety.
7)
Similarly, replace another one closing rope and two hoisting ropes.
50 of 102
3.13.2 Boom hoist rope
1) The boom is at the horizontal position.

2) Remove the boom hoist rope fixing device on girder.
3) Take-up the rope to the trapezoid frame through reel.
4) Then reversely rotate the reel to put the rope on the ground surface.
5) Remove the rope clamp plate at another end of reel, release the safety rope. The end of rope is
connected with the guide rope, (with enough length), continue release the former rope to the wharf.
6) Then connect the guide rope with new rope through front girder and tower pulley, after all are
ready, start the rope retracting and drive the reel, drive the new rope with guide rope.
7) After all new ropes wound on the upper reel, fix the rope end with clamp plate. The reel may wind
another end of rope to the trapezoid frame. Then wound on the pulley of girder, and fix its ends.
8)Note: at beginning, the tension of rope may be too high, just then, aid with fork lift or other lifting
tools, but the safety must be cared.
3.13.3 Precautions
1) After the clamping plate removed, the rope sag seriously due to the weight, and the preventive
measures must be provided.
2) Care to protect the rope, not touch the flame, not worn on the sharp parts.
3) Carefully replace the rope with drive reel, firstly turn the reel twice, contine only after checked
correctly; recheck, and turn twice again, particularly care as the final point reached.
4) When the ropes are put into place, the length adjustment should be carried out.
5) Only after the tests for limit switches of hoist, close and boom hoist etc met with the requirements,
the loaded run may begin.
3.14
Maintenance crane of machinery house (Detail see drawing:GSU0702.Usr.09 Machinery G.A)
The maintenance crane is an indoor type, which is mainly responsible for repairing of all components or
hoisting of materials in the machine room, the outdoor crane is mainly responsible for hoisting the
components to be renewed or repaired.
51 of 102
3.14.1 Structure and properties of indoor maint enance crane
This is a single-beam crane, with 10t electric hoist trolley etc, the gantry moves vertically along the rail
beam in the machine room, the indoor maintenance crane may be used for repairing the shipunloader
components for hoist, close and traction etc.
Main performances
Lifting weight: 10t
Hoisted height: ~40m
The maintenance crane may be used for repairing the hoist, close and traction mechanisms, boom
machinery, electric equipment etc. of shipunloader.
3.14.2
Precautions for repair and maintenance
1) lubrication
The oils for lubricating the pulley, wheel, and all bearings with different characteristics and performances
cant be mixed together.
2) Fastener locking
Particularly check the fixing end of hoist rope. Prior to use, check it carefully.
3) Rope
It is very important to check the rope wearing, damage, and broken. Prior to use each time, carefully
check.
3.15 Main-trolley (Detail see drawing: GSU0702.Usr.03 Main-trolley)
The main trolley composes of wheel, horizontal wheel, frame, pulley shaft seat, pulley, idler roller and
anchoring pin etc. By retractable coordination of hoist and close rope, let the trolley reciprocating motion
along travel rail on front girder and rear girder; or let the grab make close up and down movement; or let
the grab make the close up and down and forward/backward movement.
For four pulleys on main trolley, two are hoist pulley blocks, another two are wide-groove close pulley block
for quick disengaging of rope joint, which respectively has a set of individual fixed shaft and bearing seat,
supported on the split type pulley seat. All shafts have the oil holes for lubricating the pulley and wheel
52 of 102
bearings, with the multi-point central lubrication system, easily refill the oil. The adjustable horizontal wheel
is connected to the frame through fastening bolts, and equipped with blocking device. The relevant
cantenary trolley pulley pedestal is welded on the trolley frame, the main trolley is equipped with hydraulic
travel buffers at four corners, the main trolley still has the maintenance platform, convenient for repair and
maintenance.
Main technical data:
Track gauge:4100mm
Wheel gauge: 4420mm
Wheel diameter:500mm
Horizontal wheel diameter:420mm
The external lifting device can be used for disassembly and assembly purposes. Moreover, it may be also
realized by driving the main trolley to the anchored stop position, putting the grab on the hopper grille,
properly inserting the anchoring pin, the outdoor maintenance crane may be used as the lifting equipment
for disassembly and assembly purposes.
1) Disassembly
(1) pulley
Remove the strut in pulley shaft seat, take out the upper bearing seat, then the hoist and close pulley block
may be disassembled.
(2) wheel
Lift up one corner of trolley frame with jack (~10t), remove the bolts for fixing the wheel bearing seat, then
the wheel shaft may be removed. During knock, care to protect the baffle bolt holes and lubrication nozzle
etc.
(3) Horizontal wheel assembly
Just remove the connection bolts.
2) Assembly
Refer to relevant drawings and technical documents. All machined components and purchased
components must be cleaned and dried before assembly. During assemble the bearing, fill the appropriate
quantity of grease. Assembled according to the reverse order of disassembly. After assembled, the rotating
components should be turned manually, then the next procedure may begin.
53 of 102
General requirements:
1) lubrication
The greases with different performances and specifications must be not mixed. All pulley, wheel, horizontal
wheel, and idler roller etc .must be lubricated and checked as required.
2) wearing and damages
The wearings of pulley, wheel, horizontal wheel, and idler roller etc. must be repaired and replaced as
soon as possible.
3) fastener locking check
The bolt connections must be frequently checked for the slack. Carefully check the pulley bearing seat,
wheel and trolley horizontal wheel connections at least once a month.
4) Check of main components:
(1) pulley
Check the pulley working status, lubrication and wearing, when the rope groove worn up to 30%,
the the pulley must be replaced.
Check the heat emission of bearing and working status, and pedestal slack etc.
(2) Wheel checklist
Wheel operation status, wearing, lubrication, and heat emission of bearing etc.
3) check the rope connection
Check whether the rope connections are broken, reduced, and loosened etc.
3.16 Cantenary trolley (Detail see drawing:GSU0702.Usr.15 Front cantenary trolley, GSU0702.Usr.18
Backword cantenary trolley)
This machine has total two cantenary trolleys, respectively arranged at the sea and land sides of
main trolley. The motion of main trolley may drive the rope traction, and the centenary trolley may
move along the trolley rail on girder, form the rope system with main trolley. It composes of wheel
54 of 102
block, reverse roller, frame, pulley block, traction rope redirecting pulley block and idler roller etc.
The traction cantenary trolley pulley blocks are respectively welded on the pedestal, all the
lubricating nozzles of pulley, wheel, and idler shaft may adopt the multi-point central lubrication. The
adjustable reverse roller may be connected with frame through fastening bolts to prevent the
accidents of cantenary trolley.
Main technical data:
Track gauge: 4100mm
Wheel gauge: 800mm
Wheel diameter: 200mm
During disassembly and assembly, release the take-up, stop the main trolley at the anchored
position, put the grab on the hopper grille, the outside lifting equipment may be used for disassembly
and assembly purpose.
Note: during disassembly and assembly, the repair staff must tie the safety belt properly.
1) Disassembly
(1) Pulley
When disassemble the pulley on cantenary trolley, only remove the respective shaft baffle plates,
after the pulley block lifted, disassemble the shaft end baffle, remove the pulley shaft with
introduction shaft (or copper hammer), and remove the bearings from both sides of pulley with
special tools. During disassembly, care to protect the shaft end nozzle and bolt holes.
(2) Wheel
Lift up the cantenary trolley frame with 5T jack, disassemble the shaft end baffle and wheel shaft,
during disassembly, care to protect the shaft end nozzle and bolt holes.
(3) Reverse roller
Disassemble the connection bolts.
2) Assembly
All machined components and purchased parts etc must be firstly cleaned and dried. When
assemble the bearing, fill the appropriate quantity of grease. Assemble according to the reverse
order of disassembly.
55 of 102
1) General requirements
(1) The grease with different performances and specifications cannot be mixed together. All the
bearing, pulley, wheel, reverse roller and idler roller etc must be lubricated and checked as soon as
possible.
(2) Wearing and damages
The wearing and damages of all components such as pulley, reverse roller and idler roller etc shall
be repaired or renewed as necessary.
(3) Fastener locking check
The connections of fasteners such as pulley block shaft end baffle, wheel, and reverse roller etc
must be checked at least once a month.
2) Check the main components
(1) Pulley
If the pulley rope groove worn up to 30%, the pulley must be renewed, the bearing running status
and heat emission must be checked monthly
(2) Wheel
The wheel running conditions, wearing, lubrication, and heat emission of bearing etc may be
checked monthly.
3) Check the rope joint
Check whether the rope joint has any problems such as broken, reduced, and loose etc.
3.17 Safety Hook (Detail see drawing:GSU0702.Usr.05 Safety Hook)
The safety hook composes of support, hook, and hydraulic system etc. Both the support and base
frame mounted on sea side trapezoidal frame may be connected together with high strength bolts.
When the shipunloader is under non-working conditions, the boom elevated into 80 with level, held
the pin shaft of boom with safety hook. Only after the hook pin disengaged, the boom may be inclined
to level position. All these actions shall be detected by stop.
56 of 102
Main performances
Rated stroke: 120mm
1) Boom and safety hook locking pin: (during the boom pin shaft entering into hook)
During the boom elevated, when the boom entered the upper limit deceleration area, the
deceleration of boom slowly rises. The safety hook shall be lifted up in advance, when the boom pin
shaft entered into the hook groove, until the limit ram knocked the stop limit switch, the boom stops
the elevation motion, and put down the safety hook. Restart the boom machinery to lower the boom,
and then let the pin shaft enter into hook, the hook limitation displays correctly, the hoist rope
loosened and locates under the rope loosening status.
2) Disengaging pin between boom pin shaft and safety hook: (during the boom pin shaft disengaged
from the hook)
The lowering of boom is as below:
Start the boom hoist mechanism to slowly rise the boom deceleration until the limit ram knocked the
stop limit switch, the boom stops elevation motion, lift up the safety hook. Restart the boom
machinery, lower the boom, and lower the boom again. Just then the safety hook recovered to
normal position. When the boom is horizontal, the rope is under relaxation status.
Note: both processes mentioned above are automatically carried out. However, during maintenance,
carefully observe and check whether there are any displacements or limit failed problems, if there
are any problems, immediately adjust or replace.
1) Lubrication
Forbid to mix lubricating oils and greases with different specification and characteristics.
All hinged points should be lubricated once a month
2) Check the position of limit switches
The limit switch position and sensibility must be checked, if any problems found, eliminate
immediately.
57 of 102
3.18 Grab assembly (Detail see drawing: GSU0702.Usr.02 grab assembly)

Each shipunloader has 25m3 coal grab.
In which, one of grabs has the 40mm closing rope, the closing rope on grab may be connected to
the closing rope on shipunloader through a quick coupling, the piriform coupling of rope shall be
made by specialized persons.
See operating instructions for grab disassembly, assembly, and maintenance.
3.19 Stairs & platforms, walkway and elevator
3.19.1 Stairs & platforms (Detail see drawing:GSU0702.Usr.14 Stairs & platforms)
The main pathways on shipunloader are inclined ladder and platform, in general, the inclined ladder is not
more than 55, with reversing or junction platforms at the corners. If the places uneasy to install the
inclined ladder, a straight ladder may be used.
Along the whole travel length of operator cab, at the operator cab travel rail side, under the front and rear
girder platform, an operator escape platform is arranged, once the operator cab has any accidental faults
during operation, the operator may easily reach the escape platform through the straight ladder, and safely
reach the girder platform from the straight ladder.
3.19.2 Elevator (Detail see drawing:GSU0702.Usr.13 Elevator)
A rated load 400kg rope drive elevator is installed beside the land side column , the elevator has totaled
the following stop layers:
z
Landing platform
Hopper platform
Operator cab platform
Machine room platform
If the elevator has any accidental faults, the passengers may climb the exit door from the direct ladder in
the shed, finally reach the wharf, or announce for rescuing through first-aid telephone in cab.
3.19.3 Precautions
Frequently check whether the welding line of ladder platform torn or not, whether the grille plate and pedal
58 of 102
connecting bolts are loose or not. After long outage of shipunloader or elevator disassembled or
assembled, firstly make the no-load operation, while observe the running status, the loaded running may
begin only after the transmission mechanism fully lubricated.
3.20 Steel Structure (Detail see drawing: GSU0702.Usr.01 Steel Structure)
The metal structure must have the adequate strength and rigidity, the whole member must be smooth, with
specified forces, all struts and brace rod may adopt the pipe structure, with the advantages of beautiful
appearance, low wind resistance, and no wind vibration.
The door frame is a welded box structure and welded with rear girder to ensure adequate overall rigidity of
crane, reduce the horizontal swing of crane as starting and stopping the fully-loaded trolley, comfortable for
operators operations.
Both the front and rear girders are a double box bear with rectangular cross section, the upper part of both
front and rear girders are connected in parallel with two hinged points, the upper hinged points is used as
the rotating hinge during the inclination of front girder, its middle part has the pressure block for bearing the
forces above and below the girder, the lower hinged point is used as the support for girder repairing.
3.20.1 Fastening bolt connection locking check
In the main structure, the high strength fastening bolts at the connections of trapezoidal frame with sea
side gantry, sea/land gantry flange, gantry and travel pedestal etc. must be checked frequently for its
locking status. Prior to test run, fastened with correct torque wrench, after operated for one month, 10%
random check, if loosened, all should be checked.
3.20.2 Lubricating of hinged shaft connection
The drawbar hinged shaft connection may adopt the self-lubricating bearing, monthly fill a specified
quantity of grease, both the front and rear girder hinged points should be lubricated once a week.
59 of 102
Part III: Maintenance Documentation
60 of 102
CONTENTS
NO.
Title
Page
Equipment maintenance and protection
62
Check of equipment
62
Faults and remedies
78
Lubrication
83
61 of 102
1Equipment maintenance and protection

The machine maintenance divides into daily (per shift maintenance and periodic maintenance.
1.1 Daily (per shift) maintenance and protection()
Clean and check, fill grease to all points to be greased, carry out the cyclic check for all mechanical parts
and hydraulic system, and eliminate all faults or hidden troubles. Record the daily work and handover
properly, any important problems must be reflected and handled as soon as possible, forbid to operate the
equipment with any troubles.
1.2 Weekly maintenance and protection
Based on daily (per shift) maintenance works, care to observe the driving components and hydraulic
components weekly, and adjust as necessary, adjust the rubber tape machine and all baffles.
1.3 Monthly maintenance and protection
Based on daily (per shift) maintenance works, monthly check oil quality in gearbox, check the locking of all
pin shafts, wearing, check the loose of fasteners, clean or replace all filter cartridges, check whether the
structure, drawbar, cable sheath damaged or not.
1.4 Prepare the major, medium and minor repair schedules
The responsible person of equipment must also prepare the minor, medium and major overhaul plans
according to the actual running conditions of equipment, help the operator and maintenance staff to
strengthen the daily cyclic check, adjust and handle all problems found during working.
2. Check of equipment
Periodically check the equipment and rail foundation etc according to the table below.
Repair interval
Check / repair for relevant assemblies

No.
M1
M3
M6
M12
General rules
z
Check the gear and bearing noise and fastened properly or not
Check the leak of hydraulic and lubrication pipeline
Fasten/replace some loose or missed screws
Record the cracks on the structural pieces
Clean wiring box
Check whether the connection bolts mated properly
62 of 102
No.
Repair interval
See the documents provided by the supplier in annex for repair
Gantry travel mechanism
2.1
Gearbox
2.2
2.3
Check the abnormal noise
Check whether the connecting bolts are mated correctly or not
Check the oil level of gear, if necessary, refill the oil
Check the leak of gear
Replace the oil of gear
Clean the gearbox base
Check the shaft and gear conditions
Flexible coupling
z
Check the fixing of protective cover
Check the flexible components (if necessary, replace)
Check linearity ( if necessary, calibrate correctly)
Drum brake
z
Check the open/close conditions. If necessary, readjust the brake
Check the connection between brake lining and drum. If necessary, replace
the lining
2.4
2.5
Check the correct mated screw connection
Check the adjustment of brake torque, if necessary, readjust
Check the hinged point of lever mechanism
Electrohydraulic pusher
z
Check the cable connection and installation
Check the pusher oil sealing
Check the air gap, if necessary, readjust
Intermediate driving pieces
Check the contamination and wearing
63 of 102
No.
2.6
if necessary, replace bearing and gear ring
Check the lubrication of meshing, if necessary, relubricate
Repair interval
Travel wheels
z
Check the service conditions and wearing
Check abnormal noise
Check the rotation (block)
Check the power transmission (sliding)
Check the lubrication (central lubrication system)
Check the diameter of travel wheel, if necessary, turning again or replace
Check the travel wheel shaft and radial gap of bearing, if necessary, replace
the bearing and bearing seat
2.7
2.8
2.9
2.10
Rail cleaner
z
If necessary, adjust the elements of cleaner
if necessary, replace the elements of cleaner
Hydraulic travel buffers

z
Check the stroke of piston
Check the oil leak
Storm anchorage and locking device

z
Check the service conditions (contamination)
Check the functions of limit switch, immediately replace any defected switches
Check the locking elements, if necessary, replace
Rail clamper
z
Check the service conditions (contamination) and wearing
Fulfill the functional tests
If necessary, replace the clamp
If necessary, replace the bearing
Check the lubrication of hinged points and bearing
64 of 102
No.
2.10.1
Repair interval
Lubricate the roller
Check the service conditions and wearing of rail cleaner
Hydraulic cylinder and hydraulic power station for rail clamper and locking bolt
z
Check the hose and pipe connections, and hydraulic cylinder leak and seal
mating
2.10.2
2.11
2.12
2.13
2.14
Rail clamper position switch

z
Check the fixing of rail clamper
Check the functions
Limit switch
z
Check the functions of limit switch
Check the service conditions
Emergency limit switch

z
Check its functions
Check cable connection and installation
Collision-prevention limit switch

z
Check its functions
Central lubrication system

z
If necessary, fully fill the grease tank
Refer to the description of supplier
3.
Hopper discharging system
3.1
Hopper
3.1.1
Abrasion-proof lining plate

z
Check the correct mating and wearing of abrasion-proof lining plate, if

necessary, replace
65 of 102
No.
Check the wearing of fixing screw head of abrasion-proof lining plate
3.1.2
Repair interval
Overload protection
z
Check the possible damages of connection cable
3.2
Vibration feeder
3.2.1
Path of vibration feeder

z
Clean
Check the correct mating of abrasion-resistant lining plate and wearing, if
necessary, replace
3.2.2
3.2.3
3.2.4
Driver
Check the correct mating of connection bolts
Check the oil level, if necessary, refill the oil
Check the leakage
Replace the oil
Spring
z
Check the broken spring, if necessary, replace
Check the free swing
Check the height of large block
Material door
z
3.2.5
6h
Lubricate the door supporting point
Hydraulic cylinder and hydraulic power station for rail clamper and locking pin
z
Check the hose and pipe connection, hydraulic cylinder leakage and close
mating
3.3
Double path chute
3.3.1
Chute
z
66 of 102
No.
Clean the chute
Check the service conditions and functions
Check the wearing
Check the bearing lubrication, if necessary, lubricate the bearing
See article 3.2.5 for hydraulic system
3.3.2
3.3.3
3.3.4
Flap
Guide chute
z
Check the service conditions of sealing batten, if necessary, replace
Check the functions of seal batten, if possible, readjust
Idler roller of rolling working table

z
Check the sliding of working idler (block), if necessary, replace
Check the abnormal noise, if necessary, replace
Check the contamination, if necessary, clean
Vibratory motor
z
Check the service conditions and functions
Check the contamination, if necessary, clean
Coal baffle and hopper door
5.1
Coal baffle
5.2
Repair interval
Check the stacking of materials, if necessary, remove
Check bearing
Check the connection with steel structure
Check the service conditions and functions of loaded sensor
Hopper door
z
67 of 102
No.
5.3
Repair interval
Check the abnormal noise and bearing
Hydraulic cylinder and hydraulic power station

z
Check the hose and pipeline connection, check the leakage and sealing
mating of hydraulic cylinder
6.1
Water sprinkling system

z
Check the tightness of all valve fittings, pipeline and hose connections
Check whether all nozzles function properly or not
Water pump
z
Relubricate the bearing
2500h
Replace the grease of bearing
10000h
Movable operator cab

z
Manually relubricate the lubrication points E4 and E6
Check the service conditions and wearing of drive idle wheel
Check the service conditions and wearing of drive gear
Check the service conditions and wearing of travel wheels bearing
Check the service conditions of walkway, if necessary, clean
Check the linearity and wearing of flexible coupling
Check the leak of transmission device
Check the driver abnormal noise and brake functions
Replace the oil of transmission device
Working elevator
Grab
z
Lubricate the hinge, rope pulley, rope guide rolling shaft and rope sprue gate
Check the fixing and connection of rope, if necessary, replace the damaged
and worn rope

z
Check the worn components such as pin shaft, bearing etc, if necessary,
replace
10
Grab hoist, close and trolley traversing device
68 of 102
No.
10.1
Repair interval
Rope guide, rope pulley and rope

z
Check the fixing of rope on hoist and close winch and grab
Check the possible damages, broken, erosion or wearing of rope connection
Check the lubrication of rope pulley bearing (central lubrication equipment)
Check the wearing of rope pulley bearing (remove the rope)
Check the lubrication of rope (central lubrication equipment)
Check the broken wire of rope and repaired, count the wire broken, if
necessary, replace the rope

z
Check the correctness of diameter of rope pulley and profile of trough, or if
necessary, replace the rope pulley
Replace the grease in rope pulley bearing
10.2
Hoist, close and traversing winch
10.2.1
Rope reel
10.2.2
10.2.3
10.2.4
Check the lubrication of bearing seat (central lubrication equipment)
Check the wrapping of rope
Check the damages and wearing on reel surface
Drum coupling
z
Check the linearity of shaft
Retighten all screws with the given tightening torque
Check the wearing of coupling
Relubricate the coupling
Flexible coupling
z
Check the linearity (if necessary, correct)
Gearbox
z
Clean the ventilation filter
Relubricate the labyrinth seal
Check the oil level of dip rod
69 of 102
No.
10.2.5
Repair interval
Replace the oil
Check the service conditions of main shaft and gear
Disc brake
z
Check the open and close conditions, if necessary, readjust the brake
Check the service conditions of brake lining and brake disc, if necessary,
replace the brake lining
10.2.6
10.2.7
10.2.8
Check the properly aligned screw connection
Check the setting torque of brake, if necessary, readjust
Check the hinged point of mechanical lever
z
Check the oil seal tightness of pusher
Check the air gap, if necessary, readjust
Overload protection
z
Check the damages of connection cable
Check the possible damages and wearing of speed controller and limit switch
Check the abnormal noise (if necessary, relubricate the bearing)
Speed controller and limit switch

z
10.2.9
Motor
z
10.3
Central lubrication equipment

z
If necessary, fully filled the grease into the oil tank
See the description of manufacturer
11
Not used
12
Boom hoisting mechanism
12.1
Rope guide, rope pulley and rope

z
Check the fixing of rope on winch and rope balancer
Check the possible damages, broken, erosion or wearing of rope connection
70 of 102
No.
Check the rope pulley bearing lubrication
Check the rope lubrication
Check the broken wire of rope and repaired, count the wire broken, if
Repair interval
necessary, replace the rope

z
Check the functions of limit switch on the rope balancer
Check the correctness of diameter of rope pulley and profile of trough, or if
Replace the grease filled into the rope pulley bearing
12.2
Boom hoist winch
12.2.1
Rope reel
z
Check the lubrication of bearing seat (central lubrication equipment)
Check the rope and winding
Replace the oil for gear transmission device of limit switch
Every 2000h
M
D
W
1
12.2.2
12.2.3
12.2.4
Check the possible damages and wearings on the reel surface
Drum coupling
z
Check the axial linearity
Retighten all screws with the specified fastening pitch
Check the wearing of coupling
Relubricate the coupling
Flexible coupling
z
Check the linearity (if necessary, correct)
Gearbox
z
Clean the ventilation filter
Relubricate the labyrinth seal
71 of 102
No.
12.2.5
Repair interval
Check the oil level of dip rod
Replace the oil
Check the service conditions of shaft and gear
Disc brake
z
12.2.6
12.2.7
Check the setting torque of brake, if necessary, readjust
Check the hinged point of mechanical lever
z
Check the oil seal tightness of pusher
Check the air gap, readjust as necessary
Disc brake (acted on the safe brake of reel)

z
Check the gap between the brake lining to brake disc, if necessary, adjust
Check the parallelism between the brake lining and brake disc, if necessary,
12.2.8
Acceleration controller and limit switch

Check the possible damages and wearing of acceleration controller and limit
switch
12.2.9
Motor
z
12.3
Check abnormal noise (if necessary, relubricate the bearing)
Safety hook (security hook)
72 of 102
No.
Repair interval
Check the hose and pipe connection, the leakage of cylinder and mating of
seals
12.4
Lubricate the safety hook bearing
Hinged point
z
Check the abnormal noise ( if necessary, replace the damaged bearing)
13
Main trolley
13.1
Rope pulley
z
Check the abnormal noise and heat emission
Lubrication of bearing
Check the diameter of rope pulley and profile of rope trough, let it correct; if
Monthly or every 250h

z
13.2
13.3
13.4
Main trolley travel wheels

z
Check the diameter of wheel
Check the wearing of wheel bearing
Lubricate the bearing of wheel
Horizontal guide roller of main trolley

z
Check the distance between the guide roller and rail, if necessary, adjust
Check the wearing of bearing
Lubrication of bearing
Rope
z
13.5
Check the take-up of trolley traction rope and connected rope
Travel buffers
z
14
Towing trolley
14.1
Rope pulley
73 of 102
No.
Check the abnormal noise and heat emission
Lubricate the bearing
Check the correctness of diameter of rope pulley and profile of rope trough; if
Repair interval

14.2
14.3
14.4
Travel wheels of towing trolley

z
Check the diameter of wheel
Check the wearing of wheel bearing
Lubricate the bearing of wheel
Replace the bearing grease
Horizontal guide roller of towing trolley

z
Check the distance between the guide roller and rail, if necessary, adjust
Check the wearing of bearing
Lubricate the bearing
Replace the bearing grease
Rope
Check the broken wire of rope and remedied, calculate the broken wires, if
necessary, replace
Check the fixing of rope
14.5
Travel buffers
15
Hydraulic equipment
Check the electrical connections and correct combination and erosion of
wiring and cylinder on valve fittings
15.1
Motor
z
Check the lubrication of bearing
Clean the wiring box
74 of 102
No.
15.2
Repair interval
Check wiring box and bolt
Check the tightness of connection
Pump
z
Check the tightness (oil seepage), if necessary, replace the seal
Observe the working pressure (reading of pressure gauge), if worn, replace
the pump (working pressure insufficient)
15.3
15.4
Oil tank
z
Check the oil level, if necessary, fully filled the working oil
Drain out the condensate
Check the air filter (contamination), if necessary, clean the air filter
Working oil
z
Control the oil temperature with thermometer for controlling the electrical
temperature, compared with the measured values
Check the service conditions (oil blackened, turbid, pasty), if necessary,

replace the oil
15.5
Working oil analysis
Replace the oil
Working pressure drop

z
Read the working pressure (pressure gauge), if necessary, adjust the working
pressure
z
15.6
15.7
Check the tightness
Solenoid valve
z
Check the tightness (oil leakage), if necessary, replace the seals
Check the cable connection
Oil filter
z
If necessary, replace the components of filter
75 of 102
No.
15.8
15.9
Repair interval
Pipeline/accessories/pipe clamp
z
Check the tightness (oil seepage), tighten the fittings, if necessary, replace
Check the fixing of pipe
Hose
z
Check the tightness (oil seepage), tighten the fittings, if necessary, replace the
leaked or damaged hose
15.10
15.11
16
Check the fixing of hose
Replace the hose after used at most six years
Hydraulic hoist disc brake

z
Check the open and close, if necessary, adjust the brake
Check the brake lining conditions, if necessary, replace the lining of brake
Hydraulic cylinder
z
Check the tightness (oil seepage), if necessary, replace the seal
Check the freedom of movement
Check the fixing of hydraulic cylinder
Lubricate the hinged points
Clean
Central lubrication system

z
If necessary, fully filled the oil tank of pump
Check the tightness of lubrication oil pipe
Check the block of lubrication oil pipe
17
Auxiliary crane of machine room
171
Safety of equipment
172
At most after six years
Check the brake
Emergency shutoff switch of crane
Accessories of crane
z
Check the loading hook
Check the rope and rope fixing
Rope guide
76 of 102
No.
Repair interval
Check the wearing of drive components and lubrication
Replace the hoist gearbox oil
Oiling of rope
173
Check the wearing of travel wheels
174
Check the current of power cable
77 of 102
3. Faults and remedies

The faults of equipment shall be remedied according to the methods specified in table below.
Table 2
Component
Fault
Causes and possible results
Remedies
The diameter of both driving wheels is

unequal, the linear speed of gantry is not
Replace the wheel
equal, which causes the gantry tilted
Properly mating the motor and brake,

Transmission system deviation too high
Traveling
mechanism
gear
Rail seized
Structural deformation
Correct the deformation
Adjust the rail, and ensure its span,
Rail error too high
linearity and elevation up to standard
Rail top with oily dirt or frost
Gear
repair the transmission shaft, keys and
teeth
broken
Bounced during working, and further caused

the mechanism damaged
Gear worn
Eliminate the oily dirt or frost
Replace the gear
Abnormal noise and bounce when the gear
The gear thickness is beyond the
rotation
specified value, replace the gear
Gear
Crack on gear
rib/rim and hub
Key
Gear damaged
Replace the gear
damaged,
the
bounced
gear
on
Renew the key to ensure the gear
Key broken
securely installed on the shaft
shaft
Cracks on the
Replace the shaft
shaft
Shaft
Shaft bent
Journal worn
Correct the linearity <0.5mm/m
78 of 102
Keyway
damaged
Component
Fault
Crack
Clean the trough or replace the shaft
The torque cant be transferred
in
again
Remedies
the
Renew.
semi-coupling
Coupler
The bolt holes in
Bounced during the mechanism working,
Rebroach and assemble the bolts, if
coupling worn
cutoff the bolts
seriously damaged, replace
Run out during running, cut off the bolt
Renew
The
tooth
of
coupling worn or
broken
Apart from makeup the wearings, cut a

Keyway worn
new keyway at the place 90 away from

the former one
Gear circular pitch error too high or running
Periodic flutter
clearance too high caused the vibration
Serious
noise,
Usually caused by unalignment of gearbox
caused
the
high speed axis with motor shaft or gear tooth
Repair and adjust the alignment or
gearbox
surface uneven worn, with sharp edges at
repair the gear teeth
vibration
tooth tip
Housing,
especially
Reductor
Replace the gear
the
bearing
temperature too
high
Bearing poor installed or rolling ball broken, or

retainer broken, journal seized, tooth worn,
Replace the bearing, repair the gear,
lack
and replace the lubricating oil
of
lubricating
oil,
poor
lubrication,
lubricating oil got bad

Replace the seal ring, after the former
Lubricating
oil
leaked along the

split face.
Seal
ring
damaged,
gearbox
housing
deformed, connecting bolts loosened
housing cleaned, apply the hydraulic

seal ring, repair the gearbox housing,
scrape the split face, open the oil sump,
and fasten the bolts
The
whole
The fixing bolts of gearbox loosened, input or
79 of 102
Adjust
the
alignment
of
gearbox
gearbox
output shaft are misaligned with motor, poor
transmission shaft, fasten the gearbox
shocked
rigidity of support
bolts,
reinforce
the
support
and
increase the rigidity
Component
Fault
Remedies
Check
The turning joint in lever system blocked
whether
there
are
any
mechanical block and lubricate the

turning joint
After
off,
powered
unable
to
stop as soon as
possible,
slip
distance
too
Lubricate the working face of brake wheel
Brake bushing worn
Clean the brake wheel and brake

bushing with kerosene
Replace the brake bushing
high
Check the pusher or other electrical
Hydraulic pusher cant be operated easily
components, check whether the oils of

pusher used properly or not
Brake bushing and brake wheel seized
Clean the brake wheel and brake

bushing with kerosene
Check
Brake
Unable to open
Turning joint seized
whether
mechanical
there
seizure
are
any
problems
and
lubricate the turning join

Whether the pusher oil used correctly
Hydraulic pusher is unable to operate easily
or not, whether the pusher impeller and

electrical system function properly or
not
Brake
bushing
burnt or worn
Brake
During stop, the brake bushing is not stopped

or disengaged uniformly, which cause the
local friction heat emission
bushing
easily
Repair and adjust
Adjust the nuts not tightened
disengaged
Tighten the nuts according to the

adjusted position
Check the lubricating oil quantity in

Lack of lubrication oil or poor installation
Bearing
bearing and ensure to maintain the

specified volume
temperature too
high
After cleaned, fill new lubricating oil into
Oily dirt in bearing
Bearing
Working noise of
the bearing
Poor assembly, cause the bearing seized
80 of 102
Check the quality of bearing assembly.
bearing too high
Component
Bearing components damaged
Fault
Renew the bearing
The whole motor

is overheated
Overloaded due to working beyond the ratings
Remedies
Reduce the working duration
When the voltage reduced, reduce the

Stator
core
locally overheat
Works under low pressure, the core steel
load.
sheet locally short-circuit
problems
Remove
the
caused
burr
the
or
other
short-circuit,
applied with insulation paint

Rotor
Neutral point of winding end or parallel
temperature
winding poor contact
external defects
Poor connection between the winding and slip
Check the connection between the
ring
winding and slip ring
Check all welded ends, eliminate the
rose, stator has

high
current
impact,
the
motor
reach
cant
the
full
Poor contact of electric brush
Check and adjust the electric brush
speed rated load

Rotor
temperature
rose, stator has
high
current
impact,
the
motor
reach
Check
Poor contact in rotor circuit
cant
the
the
connecting
wires
of
contactor or controller rotor circuit, and

poor connection of contact, remedy.
Check the resistance, if broken, replace
full
speed rated load
Motor
Motor
Unaligned between motor shaft and gearbox
Align the motor and gearbox, ensure
shaft
high concentricity
working
shock
Motor
not
good
working
conditions
in
Bearing worn
Check, repair or replace the bearing
Rotor deformed
Check and adjust
Rolling bearing worn
Replace the bearing
Key damaged
Remedy or replace the key
81 of 102
Component
Fault
Remedies
Reduce the movable contact pressure
Coil overloaded
Coil
or replace the controller
high
temperature
Moving part of magnetic conductor cant
Eliminate the causes of moving part of
contact with the static part
magnet not in good conditions
Reduce
Coil overloaded
Magnetic
the
pressure
of
movable
contactor spring
conductor
working
surface
contaminated
Eliminate the contamination
High noise
Magnet bent
Adjust the position of magnet
AC contactor
and relay
The magnet automatic regulating system

seized
The distance between the moving and static

Cant
operate
parts of magnet too high
Eliminate the additional abrasion
Shorten the distance
easily
The lower part on the chassis is not aligned
As powered off,
the
magnet
The pressure on the contactor is uneven
Adjust the pressure of contactor spring
cant be fallen
Contactor
overheat
burnt
or
The pressure between the contactor dynamic

and static pieces is inadequate
82 of 102
Adjust the pressure of contactor spring
Contactor contaminated
Component
Fault
Eliminate the dirt or replace the slip

piece of contactor
Remedies
System pressure
Pressure regulating screw not screwed tightly
zero
7DT casually powered on or valve disc seized
regulating screw
The inside of overflow valve plugged
Electromagnetic overflow valve or oil pump
overflow valve
damaged
Check, and adjust the pressure
Check and clean the electromagnetic
Replace the components damaged

Check, and adjust the pressure
Hydraulic
System pressure
Pressure regulating screw not screwed tightly
system
too low
Oil temperature too high
regulating screw
Oil mixed with water etc or viscosity too low
High leak of components
radiator
Oil not in easy flow conditions
Stop to cool down or add a heat
Replace the oil or increase the degree
of oil viscosity
Oil cylinder no
actions
Running speed too high, cause the casual lock
Clean, repair or replace
Fill oil, replace the filter
Inch to the reverse direction, then slow
of bursting valve
the speed
Working pressure too low
Properly increase the system pressure
Throttle valve opening too small or balancing
Adjust, clean or replace the relevant
valve, diverter valve failed or damaged

Noise too high
components
System entered with air
Add the oil, and exhaust the air
Pump suction inlet fasteners loosened
Fasten
Overflow valve setting pressure lower than pump
Adjust
Oil pump failed
Repair, replace
4. Lubrication
4.1 Introduction
See schedule of shipunloader oils (greases) for equipment lubricating points, brands of all lubrication
oils, lubrication cycle and time limit for replacing the oil, care to filter the oil during replacing, especially
the working oil of hydraulic system, which must be filled into oil tank after filtered. The hydraulic system
has the suction filter, oil returning filter, which frequently cleaned with gasoline (about monthly), when
83 of 102
the pressure oil filter blocked, it may give an alarm, just then stop to clean or replace the filter cartridge,
when clean the filter, the housing may be removed by removed only one screw, take out the cartridge,
clean and dry, if the cartridge damaged, renew.
A summary of all relevant information and instructions regarding lubricants (oil and
grease) scheduling of the installed components is listed in the following lubrication
schedule below.
For special instruction use the relevant OEM of the supplier as per Section 10 of this
Equipment Manual.
4.2 List of Lubrications
List of oils (greases) for shipunloader

Applications
Recommended
oils (greases)
Quantity Time
Replacement interval
Firstly
Foru-reel gearbox,
Oil,ISO
PDR40-00
gear oil
Vg460,
300L/set
As
required
replace the
Replaced
oil
once a year
after
operated for
later
500-800h
Firstly
Inclination
drive
gearbox
SEW, M4PSF90E
Oil,ISO
Vg460,
gear oil
208L/set
As
required
replace the
Replaced
oil
once a year
after
operated for
later
500-800h
Firstly
Traveling gearbox
Oil,ISO
KF107DV180M4
gear oil
Vg460,
10L/set
As
required
replace the
Replaced
oil
once a year
after
operated for
later
500-800h
Grease, Shell
Centralized
0#(winter) &
lubrication
2#(summer)
300Kg/set
Weekly
Lithium
Replaced
Rail
Camper
Device
OIL, Mobil
DTE-25,ISO VG46
60L/set
As
required
One month
once a year
for the early
according
days
to
the
season
Three
Hydraulic System
OIL, Mobil
DTE-25,ISO VG46
800L/set
As
required
months
the
days
84 of 102
for
early
Replaced
once a year
later
Part IV: Manufacturers specials OEM

(installation instructions of original equipment manufacturer)
85 of 102
CONTENTS
NO.
Title
1.
Rail-clamper Instruction Manual
Hydraulic System Instruction Manual
Spraying & Lubrication Instruction Manual
10
Vibration feeder Instruction Manual
11
Scale sensor Instruction Manual
12
Elevator Instruction Manual
Note: The data aboved please see the details of respective OEM
installation instruction.
86 of 102
Part V:Machine Drawings
87 of 102
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
0-1
GSU0702.Erc.ListA
B-CHA-M-BV-8000
List of drawing
A0
0-2
GSU0702.Erc.ListB
B-CHA-M-BV-8001
List of drawing
A0
GSU0702.Erc.00
B-CHA-M-BV-1001
General Arrangement
A0
GSU0702.Erc-1(1/2)
B-CHA-M-BV-1002
A0
GSU0702.Erc-1(2/2)
B-CHA-M-BV-1003
A0
GSU0702.Erc.01
B-CHA-M-BV-8002
Steel Structure
A1
GSU0702.Erc.01.01
B-CHA-M-BV-8003
Front girder
A1
GSU0702.Erc.01.02 A
B-CHA-M-BV-8004
Front Tension Bar
A2
GSU0702.Erc.01.03
B-CHA-M-BV-8005
Main Hinge
A1
GSU0702.Erc.01.04
B-CHA-M-BV-8006
Pylon
A2
GSU0702.Erc.01.04.03
B-CHA-M-BV-8007
Maintenance Hoist
A2
10
GSU0702.Erc.01.05 A
B-CHA-M-BV-8008
Back Tension Bar
A2
11
GSU0702.Erc.01.08
B-CHA-M-BV-8009
End Grider
A1
12
GSU0702.Erc.01.09A
B-CHA-M-BV-8010
Frame
A0
13
GSU0702.Erc.01.09B
B-CHA-M-BV-8011
Frame
A0
14
GSU0702.Erc.01.09-1
B-CHA-M-BV-8028
W.S.Sill Beam
A2
15
GSU0702.Erc.01.09-2
B-CHA-M-BV-8038
Underside W.S Legs
A2
16
GSU0702.Erc.01.09-3
B-CHA-M-BV-8041
L.S.Sill Beam
A2
17
GSU0702.Erc.01.09-4
B-CHA-M-BV-8042
Fixed Tie Links I
A2
18
GSU0702.Erc.01.09-5
B-CHA-M-BV-8043
Horizontal Beam I
A2
19
GSU0702.Erc.01.09-6
B-CHA-M-BV-8044
Upside W.S.Legs
A2
20
GSU0702.Erc.01.09-7
B-CHA-M-BV-8045
Underside L.S.Legs
A2
21
GSU0702.Erc.01.09-8
B-CHA-M-BV-8046
Upside L.S.Legs
A2
22
GSU0702.Erc.01.09-9
B-CHA-M-BV-8047
Fixed Tie Links II
A1
88 of 102
Drawing
Description Format
Rev.

Sequences
Sequences
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
Drawing
Quantity
23
GSU0702.Erc.01.09-10
B-CHA-M-BV-8029
Horizontal Beam of W.S
A2
24
GSU0702.Erc.01.9-11 A
B-CHA-M-BV-8030
Horizontal Beam II
A1
25
GSU0702.Erc.01.09-12
B-CHA-M-BV-8031
Horizontal Beam of L.S
A2
26
GSU0702.Erc.01.09-13
B-CHA-M-BV-8032
Fixed Tie Links III
A2
27
GSU0702.Erc.01.09-14
B-CHA-M-BV-8033
Support
A2
28
GSU0702.Erc.01.09-15
B-CHA-M-BV-8034
Anchor Support
A2
29
GSU0702.Erc.01.09-17
B-CHA-M-BV-8035
Short Fixed Tie Link
A2
30
GSU0702.Erc.01.09-18
B-CHA-M-BV-8036
Horizontal Beam
A1
31
GSU0702.Erc.01.09-19
B-CHA-M-BV-8037
Landside Portal
A1
32
GSU0702.Erc.01.09-20A
B-CHA-M-BV-8039
Belt system support
A0
33
GSU0702.Erc.01.09-20B
B-CHA-M-BV-8040
Belt system support
A1
34
GSU0702.Erc.01.10
B-CHA-M-BV-8048
Fixed Tie Links assemble
A2
35
GSU0702.Erc.01.09.01
B-CHA-M-BV-8012
Waterside Portal
A1
36
GSU0702.Erc.01.02B
B-CHA-M-BV-8013
Front Tension Bar
A2
37
GSU0702.Erc.01.05B
B-CHA-M-BV-8014
Back Tension Bar
A2
38
GSU0702.Erc.01.9-11B
B-CHA-M-BV-8015
Horizontal Beam II
A1
39
GSU0702.Erc.01.9-20C
B-CHA-M-BV-8016
Belt system support
A1
40
GSU0702.Erc.01.09-21
B-CHA-M-BV-8017
Horizontal Beam
A2
41-50
No Use
51
GSU0702.Erc.02
B-CHA-M-BV-8049
grab assembly
A2
52
GSU0702.Erc.03
B-CHA-M-BV-8050
Main-trolley
A1
53
GSU0702.Erc.03-1
B-CHA-M-BV-8058
Anchor
A2
89 of 102
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
Drawing
Quantity
54
GSU0702.Erc.03.05
B-CHA-M-BV-8051
Platforms
A2
55
GSU0702.Erc.03.05-1
B-CHA-M-BV-8052
Platform_I
A2
56
GSU0702.Erc.03.01
B-CHA-M-BV-8053
Main-trolley Assembly
A2
57
GSU0702.Erc.03.05-2
B-CHA-M-BV-8054
Ladder
A2
58
GSU0702.Erc.03.05-3
B-CHA-M-BV-8055
platform II
A2
59
GSU0702.Erc.03.05-4
B-CHA-M-BV-8056
support
A2
60
No Use
61
GSU0702.Erc.04 A
B-CHA-M-BV-8059
Operator Cab
A1
62
GSU0702.Erc.04-3
B-CHA-M-BV-8067
Operator Cab Structure
A0
63
GSU0702.Erc.04.02
B-CHA-M-BV-8060
Locking unit
A3
64
GSU0702.Erc.04.04
B-CHA-M-BV-8061
Running limit switch
A1
65
GSU0702.Erc.04 B
B-CHA-M-BV-8062
Operator Cab
A1
66
GSU0702.Erc.04.01
B-CHA-M-BV-8063
Operator cab hanger
A1
66-68
No Use
69
GSU0702.Erc.05 B
B-CHA-M-BV-8066
Safety Hook
A1
70
GSU0702.Erc.05 A
B-CHA-M-BV-8068
Safety Hook
A1
71
GSU0702.Erc.06
B-CHA-M-BV-8069
Boom-Hoist-CAB
A1
72
GSU0702.Erc.07A
B-CHA-M-BV-8070
Boom-Machinery
A1
73
GSU0702.Erc.07-9
B-CHA-M-BV-8080
A3
74
GSU0702.Erc.07.01
B-CHA-M-BV-8071
Roller Assembly
A2
75
GSU0702.Erc.07.02
B-CHA-M-BV-8072
Anti-ropeskiping
A2
76
GSU0702.Erc.07.03
B-CHA-M-BV-8073
Camming Limitator
A2
90 of 102
Fix-Block2
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
B-CHA-M-BV-8075
Boom-Machinery
A1
77
No Use
78
GSU0702.Erc.07B
79-82
Descriptio n
Format
Drawing
Quantity
No Use
83
GSU0702.Erc.08A
B-CHA-M-BV-8081
Hoist, Close and trolley device
A0
84
GSU0702.Erc.08-6
B-CHA-M-BV-8093
Wedge
A3
85
GSU0702.Erc.08-8
B-CHA-M-BV-8094
Limit Switch Support
A2
86
GSU0702.Erc.08.01
B-CHA-M-BV-8082
Drift shaft
A1
87
GSU0702.Erc.08.02
B-CHA-M-BV-8083
Drum
A2
88
GSU0702.Erc.08.04
B-CHA-M-BV-8084
Support
A1
89
GSU0702.Erc.08.05
B-CHA-M-BV-8085
Safty-Device I
A2
90
GSU0702.Erc.08.06
B-CHA-M-BV-8086
Safty-Device II
A2
91
GSU0702.Erc.08.07
B-CHA-M-BV-8087
Safty-Device III
A1
92
GSU0702.Erc.08B
B-CHA-M-BV-8088
Hoist, Close and trolley device
A0
93-96
No Use
97
GSU0702.Erc.09(1/3)
B-CHA-M-BV-8095
Machinery G.A
A1
98
GSU0702.Erc.09(2/3)
B-CHA-M-BV-8096
Machinery G.A
A1
99
GSU0702.Erc.09(3/3)
B-CHA-M-BV-8097
Machinery G.A
A1
100
GSU0702.Erc.09-1A
B-CHA-M-BV-8132
Distance wall
A3
101
GSU0702.Erc.09-1B
B-CHA-M-BV-8133
Distance wall
A3
102
GSU0702.Erc.09-2
B-CHA-M-BV-8136
Inclined ladder
A2
103
GSU0702.Erc.09-3
B-CHA-M-BV-8137
Grider
A2
104
GSU0702.Erc.09-4
B-CHA-M-BV-8138
A2
105
GSU0702.Erc.09-7
B-CHA-M-BV-8139
A3
106
GSU0702.Erc.09-8
B-CHA-M-BV-8140
A3
91 of 102
Walkway 1
Maintenance flat roof
Ladder used by maintenace
flat roof
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
107
GSU0702.Erc.09-9
B-CHA-M-BV-8141
108
GSU0702.Erc.09-10
109
Drawing
Descriptio n
Format
Upright ladder
A3
B-CHA-M-BV-8134
Roller(Or)
A3
GSU0702.Erc.09-11
B-CHA-M-BV-8135
Handle of the Machinery
A1
110
GSU0702.Erc.09.01A
B-CHA-M-BV-8098
Machinery Structure
A1
111
GSU0702.Erc.09.01B
B-CHA-M-BV-8099
Machinery Structure
A2
112
GSU0702.Erc.09.01-1A
B-CHA-M-BV-8100
The water side wall
A1
113
GSU0702.Erc.09.01-1B
B-CHA-M-BV-8101
The water side wall
A2
114
GSU0702.Erc.09.01-2A
B-CHA-M-BV-8102
The land side wall
A1
115
GSU0702.Erc.09.01-2B
B-CHA-M-BV-8103
The land side wall
A2
116
GSU0702.Erc.09.01-3A
B-CHA-M-BV-8104
The right side wall
A1
117
GSU0702.Erc.09.01-3B
B-CHA-M-BV-8105
The right side wall
A2
118
GSU0702.Erc.09.01-4A
B-CHA-M-BV-8106
The left side wall
A1
119
GSU0702.Erc.09.01-4B
B-CHA-M-BV-8107
The left side wall
A2
120
GSU0702.Erc.09.02
B-CHA-M-BV-8108
Ventilator I
A3
121
GSU0702.Erc.09.03
B-CHA-M-BV-8109
Luffing rope gate
A3
122
GSU0702.Erc.09.04
B-CHA-M-BV-8110
Hoist rope gate
A3
123
GSU0702.Erc.09.05
B-CHA-M-BV-8111
Ventilator II
A3
124
GSU0702.Erc.09.06
B-CHA-M-BV-8112
Wall indoor
A3
125
GSU0702.Erc.09.07
B-CHA-M-BV-8113
Walkway 2
A2
126
GSU0702.Erc.09.08
B-CHA-M-BV-8114
Walkway 3
A3
127
GSU0702.Erc.09.09
B-CHA-M-BV-8115
Inclined flat roof1
A3
92 of 102
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
128
GSU0702.Erc.09.10
B-CHA-M-BV-8116
129
GSU0702.Erc.09.11A
B-CHA-M-BV-8117
130
GSU0702.Erc.09.11B
B-CHA-M-BV-8118
131
GSU0702.Erc.09.11C
B-CHA-M-BV-8119
132
GSU0702.Erc.09.11D
B-CHA-M-BV-8120
133
GSU0702.Erc.09.11.01
B-CHA-M-BV-8121
134
GSU0702.Erc.09.01-6A
B-CHA-M-BV-8122
135
GSU0702.Erc.09.01-6B
136-143
Descriptio n
Inclined flat roof2
Format
Drawing
Quantity
A3
A0
A0
A1
A1
Cover
A2
Inclined angle iron
A1
B-CHA-M-BV-8123
Inclined angle iron
A1
UNDERFRAME OF
M.R&E.R
UNDERFRAME OF
M.R&E.R
UNDERFRAME OF
M.R&E.R
UNDERFRAME OF
M.R&E.R
No Use
144
GSU0702.Erc.11
B-CHA-M-BV-8142
NAME PLATE
A1
145
GSU0702.Erc.11-1
B-CHA-M-BV-8145
data plate
A3
146
GSU0702.Erc.11.01
B-CHA-M-BV-8143
name plate for chec
A1
147
GSU0702.Erc.11.02
B-CHA-M-BV-8144
capacity plate
A1
148
GSU0702.Erc.12
B-CHA-M-BV-8146
Power cable reel
A1
149
GSU0702.Erc.15
B-CHA-M-BV-8147
Front cantenary trolley
A2
150
GSU0702.Erc.15.04
B-CHA-M-BV-8148
Protect wheel
A3
151
GSU0702.Erc.16(1/2)
B-CHA-M-BV-8149
GANTRY
A0
152
GSU0702.Erc.16(1/2)
B-CHA-M-BV-8149
GANTRY
A0
153
GSU0702.Erc.16-1
B-CHA-M-BV-8166
Upper beam
A1
154
GSU0702.Erc.16-14
B-CHA-M-BV-8167
GROUNDING DEVICE
A3
155
GSU0702.Erc.16-15
B-CHA-M-BV-8168
anchor device
A1
156
GSU0702.Erc.16-16
B-CHA-M-BV-8169
RAIL CAMP ASSEMBLY
A2
93 of 102
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
157
GSU0702.Erc.16.03
B-CHA-M-BV-8151
158
GSU0702.Erc.16.04
B-CHA-M-BV-8152
159
GSU0702.Erc.16.05
B-CHA-M-BV-8153
160
GSU0702.Erc.16.FWI
161
GSU0702.Erc.16.FWII
162-171
Descriptio n
Buffer
Format
Drawing
Quantity
A3
SAFTY DEVICE
A0
STORM TIE
A1
B-CHA-M-BV-8154
Four wheel Assembly(I)
A1
B-CHA-M-BV-8155
Four wheel Assembly(II)
A1
No Use
172
GSU0702.Erc.17
B-CHA-M-BV-8170
Hopper System
A0
173
GSU0702.Erc.17-1
B-CHA-M-BV-8196
Shell
A2
174
GSU0702.Erc.17-2
B-CHA-M-BV-8197
Support I
A0
175
GSU0702.Erc.17-3
B-CHA-M-BV-8198
Base
A0
176
GSU0702.Erc.17-4
B-CHA-M-BV-8199
Feeder
A3
177
GSU0702.Erc.17.01
B-CHA-M-BV-8171
Dust prot walls(right)
A0
178
GSU0702.Erc.17.02
B-CHA-M-BV-8172
Dust Prot Gate
A0
179
GSU0702.Erc.17.03
B-CHA-M-BV-8173
Dust Prot Gate(Left)
A0
180
GSU0702.Erc.17.04
B-CHA-M-BV-8174
Support II
A0
181
GSU0702.Erc.17.05
B-CHA-M-BV-8175
Spillage-flap
A0
182
GSU0702.Erc.17.06A
B-CHA-M-BV-8176
Hopper
A0
183
GSU0702.Erc.17.06B
B-CHA-M-BV-8177
Hopper
A0
184
GSU0702.Erc.17.06C
B-CHA-M-BV-8178
Hopper
A0
185
GSU0702.Erc.17.06D
B-CHA-M-BV-8179
Hopper
A1
186
GSU0702.Erc.17.06E
B-CHA-M-BV-8180
Hopper
A0
94 of 102
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
Drawing
Quantity
187
GSU0702.Erc.17.06-2
B-CHA-M-BV-8181
Base I,II
A0
188
GSU0702.Erc.17.07
B-CHA-M-BV-8182
Discharge Door
A0
189
GSU0702.Erc.17.08
B-CHA-M-BV-8183
Chute&Support
A0
190
GSU0702.Erc.17.08-2
B-CHA-M-BV-8184
Conveyor Steel Structure
A0
191
GSU0702.Erc.17.09
B-CHA-M-BV-8185
A1
A2
A1
192-201
Anti-vibration-suppor
No Use
202
GSU0702.Erc.18
B-CHA-M-BV-8200
203
GSU0702.Erc.19A
B-CHA-M-BV-8201
204
GSU0702.Erc.19.01
B-CHA-M-BV-8202
Movable Block
A3
205
GSU0702.Erc.19.02
B-CHA-M-BV-8203
Landside Pulley
A3
206
GSU0702.Erc.19.03
B-CHA-M-BV-8204
Seaside Pulley
A3
207
GSU0702.Erc.19.04
B-CHA-M-BV-8205
Upside Pulley
A3
208
GSU0702.Erc.20
B-CHA-M-BV-8206
Rope system
A1
209
GSU0702.Erc.20-1
B-CHA-M-BV-8214
Rope guide support
A2
210
GSU0702.Erc.20.01A
B-CHA-M-BV-8207
Trolley rope system
A1
211
GSU0702.Erc.20.02
B-CHA-M-BV-8208
Boom Hoist Rope System
A1
212
GSU0702.Erc.19B
B-CHA-M-BV-8209
A1
213
GSU0702.Erc.20.01B
B-CHA-M-BV-8210
Trolley rope system
A1
214
GSU0702.Erc.20.01C
B-CHA-M-BV-8211
Trolley rope system
A1
215-216
Backword cantenary trolley

Cab Safeguard
Cab Safeguard
No Use
217
GSU0702.Erc.22
B-CHA-M-BV-8215
Limits for ship-unloader
A2
218
GSU0702.Erc.22-1A
B-CHA-M-BV-8216
Limits for trolley
A2
219
GSU0702.Erc.22-1B
B-CHA-M-BV-8217
Limits for trolley
A2
95 of 102
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
220-223
Rev.
Descriptio n
Format
Drawing
Quantity
No Use
224
GSU0702.Erc.23
B-CHA-M-BV-8222
Assistant cab
A2
225
GSU0702.Erc.24(1/5)
B-CHA-M-BV-8223
dust spray system
A1
226
GSU0702.Erc.24(2/5)
B-CHA-M-BV-8224
dust spray system
A1
227
GSU0702.Erc.24(3/5)
B-CHA-M-BV-8225
dust spray system
A2
228
GSU0702.Erc.24(4/5)
B-CHA-M-BV-8226
dust spray system
A2
229
GSU0702.Erc.24(5/5)
B-CHA-M-BV-8227
dust spray system
A1
230-234
No Use
235
GSU0702.Erc.26(1/2)
B-CHA-M-BV-8233
Hydraulics System
A0
236
GSU0702.Erc.26(2/2)
B-CHA-M-BV-8234
Hydraulics System
A0
237-239
No Use
240
GSU0702.Erc.27
B-CHA-M-BV-8238
Control cable reel
A1
241
GSU0702.Erc.14
B-CHA -M-BV -8239
Stairs & platforms
A0
242
GSU0702.Erc.14.01 A
B-CHA -M-BV -8240
243
GSU0702.Erc.14.01 B
B-CHA -M-BV -8241
244
GSU0702.Erc.14.01 B
B-CHA -M-BV -8242
245
GSU0702.Erc.14.01-1
B-CHA -M-BV -8243
Stairs I
A2
246
GSU0702.Erc.14.01-2
B-CHA -M-BV -8244
Platform I
A1
247
GSU0702.Erc.14.01-3
B-CHA -M-BV -8245
Stairs II
A2
248
GSU0702.Erc.14.01-4
B-CHA -M-BV -8246
Platform II
A2
249
GSU0702.Erc.14.01-5
B-CHA -M-BV -8247
Platform III
A2
250
GSU0702.Erc.14.01-6
B-CHA -M-BV -8248
Stairs III
A2
251
GSU0702.Erc.14.01-7
B-CHA -M-BV -8249
Platform IV
A2
252
GSU0702.Erc.14.01-8
B-CHA -M-BV -8250
Stairs IV
A2
96 of 102

Platform
Platform
Platform
A1
A1
A2
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
253
GSU0702.Erc.14.01-9
B-CHA -M-BV -8251
Platform V
A2
254
GSU0702.Erc.14.01-10
B-CHA -M-BV -8252
Platform VI
A2
255
GSU0702.Erc.14.01-11
B-CHA -M-BV -8253
Platform VII
A2
256
GSU0702.Erc.14.01-12
B-CHA -M-BV -8254
Stairs V
A2
257
GSU0702.Erc.14.01-13
B-CHA -M-BV -8255
Stairs VI
A2
258
GSU0702.Erc.14.01-14
B-CHA -M-BV -8256
Stairs VII
A2
259
GSU0702.Erc.14.01-15
B-CHA -M-BV -8257
Stairs VIII
A2
260
GSU0702.Erc.14.01-16
B-CHA -M-BV -8258
Platform VIII
A2
261
GSU0702.Erc.14.01-17
B-CHA -M-BV -8259
Ladder
A2
262
GSU0702.Erc.14.01-18
B-CHA -M-BV -8260
Platform IX
A1
263
GSU0702.Erc.14.01-19
B-CHA -M-BV -8261
Stairs IX
A2
264
GSU0702.Erc.14.01-20
B-CHA -M-BV -8262
Platform X
A2
265
GSU0702.Erc.14.01-21
B-CHA -M-BV -8263
Stairs X
A2
266
GSU0702.Erc.14.01-22
B-CHA -M-BV -8264
Platform XI
A1
267
GSU0702.Erc.14.01-23
B-CHA -M-BV -8265
Stairs support
A1
268
GSU0702.Erc.14.01-24
B-CHA -M-BV -8266
Stairs XI
A2
269
GSU0702.Erc.14.01-25
B-CHA -M-BV -8267
Platform XII
A3
270
GSU0702.Erc.14.01-26
B-CHA -M-BV -8268
Stairs XII
A2
271
GSU0702.Erc.14.01-27
B-CHA -M-BV -8269
Platform XIII
A2
272
GSU0702.Erc.14.01.01
B-CHA -M-BV -8270
Spring Door
A2
273
GSU0702.Erc.14.02A
B-CHA -M-BV -8271
274
GSU0702.Erc.14.02B
B-CHA -M-BV -8272
275
GSU0702.Erc.14.02-1
B-CHA -M-BV -8273
97 of 102

Girders
Girders
Platforms of Front Girders
A0
A3
A0
Drawing
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
276
GSU0702.Erc.14.02-2
B-CHA -M-BV -8274
277
GSU0702.Erc.14.02-3
B-CHA -M-BV -8275
278
GSU0702.Erc.14.02-4
B-CHA -M-BV -8276
279
GSU0702.Erc.14.02-5
B-CHA -M-BV -8277
Ladder
A2
280
GSU0702.Erc.14.02-6
B-CHA -M-BV -8278
Stairs I
A2
281
GSU0702.Erc.14.02-7
B-CHA -M-BV -8279
Stairs II
A2
282
GSU0702.Erc.14.02-8
B-CHA -M-BV -8280
Stairs III
A2
283
GSU0702.Erc.14.02-9
B-CHA -M-BV -8281
Transition platform I
A2
284
GSU0702.Erc.14.02-10
B-CHA -M-BV -8282
Transition platform II
A2
285
GSU0702.Erc.14.02-11
B-CHA -M-BV -8283
Stairs IV
A2
286
GSU0702.Erc.14.03
B-CHA -M-BV -8284
287
GSU0702.Erc.14.03-1
B-CHA -M-BV -8285
Stairs I
A2
288
GSU0702.Erc.14.03-2
B-CHA -M-BV -8286
Stairs II
A2
289
GSU0702.Erc.14.03-3
B-CHA -M-BV -8287
Stairs III
A2
290
GSU0702.Erc.14.03-4
B-CHA -M-BV -8288
Platform
A3
291
GSU0702.Erc.14.04
B-CHA -M-BV -8289
Stairs & Platforms of Pylon
A0
292
GSU0702.Erc.14.04-1
B-CHA -M-BV -8290
Platform I
A1
293
GSU0702.Erc.14.04-2
B-CHA -M-BV -8291
Platform II
A1
294
GSU0702.Erc.14.04-3
B-CHA -M-BV -8292
Stairs I
A2
295
GSU0702.Erc.14.04-4
B-CHA -M-BV -8293
Platform III
A2
296
GSU0702.Erc.14.04-5
B-CHA -M-BV -8294
Ladder
A2
297
GSU0702.Erc.14.04-6
B-CHA -M-BV -8295
Platform IV
A2
298
GSU0702.Erc.14.04-7
B-CHA -M-BV -8296
Stairs II
A2
98 of 102
Platforms of Rear Girders
Format
Front Section of
Emergency Passway
Rear Section of
Emergency Passway

Machinery House
A0
A0
A0
A0
Drawing
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
299
GSU0702.Erc.14.04-8
B-CHA -M-BV -8297
Stairs III
A2
300
GSU0702.Erc.14.04-9
B-CHA -M-BV -8298
Stairs IV
A2
301
GSU0702.Erc.14.05
B-CHA -M-BV -8299
302
GSU0702.Erc.14.05-1
B-CHA -M-BV -8300
Ladders I
A3
303
GSU0702.Erc.14.05-2
B-CHA -M-BV -8301
Platform I
A2
304
GSU0702.Erc.14.05-3
B-CHA -M-BV -8302
Maintenance platform
A3
305
GSU0702.Erc.14.05-4
B-CHA -M-BV -8303
Stairs I
A2
306
GSU0702.Erc.14.05-5
B-CHA -M-BV -8304
Stairs II
A2
307
GSU0702.Erc.14.05-6
B-CHA -M-BV -8305
Connection Platform
A2
308
GSU0702.Erc.14.05-7
B-CHA -M-BV -8306
Stairs III
A2
309
GSU0702.Erc.14.05-8
B-CHA -M-BV -8307
Ladder II
A3
310
GSU0702.Erc.14.05-9
B-CHA -M-BV -8308
Transition platform
A3
311
GSU0702.Erc.14.05-10
B-CHA -M-BV -8309
Platform II
A2
312
GSU0702.Erc.14.05-11
B-CHA -M-BV -8310
Ladder III
A3
313-327
Stairs & platforms of

Hopper
A0
No Use
328
GSU0702.Erc.25
B-CHA -M-BV -8326
329
GSU0702.Erc.25-1
B-CHA -M-BV -8327
330
GSU0702.Erc.25-2
B-CHA -M-BV -8328
331
GSU0702.Erc.25-3
B-CHA -M-BV -8329
332
GSU0702.Erc.25-4
B-CHA -M-BV -8330
333
GSU0702.Erc.25-5
B-CHA -M-BV -8331
334
GSU0702.Erc.25-6
B-CHA -M-BV -8332
99 of 102
Lubrication Systems
General Arrangement
M.TROLLEY LUB.SYS.
B.H.HINGE AND
ROLLERS LUB.SYS.
WIRE ROPE LUB.SYS.
MECHINARY HOUSE
LUB.SYS.
DIFFERENTIAL TRUNK
LUB.SYS.
L.S.C.TROLLEY
LUB.SYS
A1
A2
A2
A1
A2
A1
A2
Drawing
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
335
GSU0702.Erc.25-7
B-CHA -M-BV -8333
336
GSU0702.Erc.25-8
B-CHA -M-BV -8334
337-340
Rev.
Descriptio n
G.Traveller Lub.SYS.
W.S.C.TROLLEY
LUB.SYS.
Format
A1
A2
No Use
341
GSU0702.Erc.21(1/5)
B-CHA -M-BV -8347
tie down seat
A3
342
GSU0702.Erc.21(2/5)
B-CHA -M-BV -8348
tie down bolt
A3
343
GSU0702.Erc.21(3/5)
B-CHA -M-BV -8349
anchor seat
A3
344
GSU0702.Erc.21(4/5)
B-CHA -M-BV -8350
anchor bolt
A3
345
GSU0702.Erc.21(5/5)
B-CHA -M-BV -8351
buffer stop
A3
346
GSU0702.Erc.21-1
B-CHA -M-BV -8352
buffer stop bolt
A3
347
GSU0702.Erc.21-2
B-CHA -M-BV -8353
pre-set plate
A3
348
GSU0702.Erc.21-3
B-CHA -M-BV -8354
pre-set plate
A3
349
GSU0702.Erc.21-4
B-CHA -M-BV -8355
pre-set plate
A3
350
GSU0702.Erc.21-5
B-CHA -M-BV -8356
cable surpport
A2
351
GSU0702.Erc.21-6
B-CHA -M-BV -8357
cable surpport
A2
352
GSU0702.Erc.21-7
B-CHA -M-BV -8358
cable surpport
A2
353
GSU0702.Erc.21-8
B-CHA -M-BV -8359
power cable box surport
A2
354
GSU0702.Erc.21-9
B-CHA -M-BV -8360
control cable box surport
A2
355
GSU0702.Erc.21-10
B-CHA -M-BV -8361
RAIL
A1
356
GSU0702.Erc.21-11A
B-CHA -M-BV -8362
cable surpport
341
GSU0702.Erc.21(1/5)
B-CHA -M-BV -8347
tie down seat
A3
342
GSU0702.Erc.21(2/5)
B-CHA -M-BV -8348
tie down bolt
A3
343
GSU0702.Erc.21(3/5)
B-CHA -M-BV -8349
anchor seat
A3
344
GSU0702.Erc.21(4/5)
B-CHA -M-BV -8350
anchor bolt
A3
100 of 102
A2
Drawing
Quantity
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
Descriptio n
Format
Drawing
Quantity
345
GSU0702.Erc.21(5/5)
B-CHA -M-BV -8351
buffer stop
A3
346
GSU0702.Erc.21-1
B-CHA -M-BV -8352
buffer stop bolt
A3
347
GSU0702.Erc.21-2
B-CHA -M-BV -8353
pre-set plate
A3
348
GSU0702.Erc.21-3
B-CHA -M-BV -8354
pre-set plate
A3
349
GSU0702.Erc.21-4
B-CHA -M-BV -8355
pre-set plate
A3
350
GSU0702.Erc.21-5
B-CHA -M-BV -8356
cable surpport
A2
351
GSU0702.Erc.21-6
B-CHA -M-BV -8357
cable surpport
A2
352
GSU0702.Erc.21-7
B-CHA -M-BV -8358
cable surpport
A2
353
GSU0702.Erc.21-8
B-CHA -M-BV -8359
A2
354
GSU0702.Erc.21-9
B-CHA -M-BV -8360
A2
355
GSU0702.Erc.21-10
B-CHA -M-BV -8361
RAIL
A1
356
GSU0702.Erc.21-11A
B-CHA -M-BV -8362
cable surpport
A2
357
GSU0702.Erc.21-11B
B-CHA -M-BV -8363
cable surpport
A2
358
GSU0702.Erc.21-11C
B-CHA -M-BV -8364
cable surpport
A2
359
GSU0702.Erc.21-12
B-CHA -M-BV -8365
A2
360
GSU0702.Erc.21-13
B-CHA -M-BV -8366
A2
361
GSU0702.Erc.21-14
B-CHA -M-BV -8367
RAIL
A1
362
GSU0702.Erc.21.01
B-CHA -M-BV -8368
power cable guider
A2
363
GSU0702.Erc.21.02
B-CHA -M-BV -8369
control cable guider
A2
Elevator
A2
TJB-Y0000
A2
TJB-DG
A2
TJB-BZ
364-367
No Use
368
GSU0702.Erc.13
B-CHA -M-BV -8375
369
GSU0702.Erc.13-1
B-CHA -M-BV -8376
370
GSU0702.Erc.13-2
B-CHA -M-BV -8377
101 of 102
the
Guide-installation
drawing
layout drawing
Item
CHEC
SUMITOMO
No.
Drawing No.
Drawing No.
Rev.
371
GSU0702.Erc.13.01
B-CHA -M-BV -8378
372
GSU0702.Erc.13.01-1
B-CHA -M-BV -8379
373
GSU0702.Erc.13.01-2
B-CHA -M-BV -8380
374
GSU0702.Erc.13.01-3
375
Descriptio n
the
Format
frame-installation
Drawing
Quantity
A2
TJB-JD
Base
A2
TJB-JD-01
Short Support
A2
TJB-JD-02
B-CHA -M-BV -8381
Layout of Well
A2
TJB-JD-03
GSU0702.Erc.13.01-4
B-CHA -M-BV -8382
A2
TJB-JD-04
376
GSU0702.Erc.13.01-5
B-CHA -M-BV -8383
Frame
A2
TJB-JD-05
377
GSU0702.Erc.13.01-6
B-CHA -M-BV -8384
Ladder
A2
TJB-JD-06
378
GSU0702.Erc.13.01-7
B-CHA -M-BV -8385
A2
TJB-JD-07
379
GSU0702.Erc.13.01-8
B-CHA -M-BV -8386
A1
TJB-JD-08
102 of 102
drawing
Layout
of
Emergency
Ladder
Walking
Bench
Protective Fence
Machine Room
&

Volume 1 Instruction Manual For Ship Unloader Stacker&reclaimer Coal Handling System Final PDF

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Volume 1 Instruction Manual For Ship Unloader Stacker&reclaimer Coal Handling System Final PDF

Transféré par

Droits d'auteur :

Formats disponibles

P.T.

CENTRAL JAVA POWER

PO TITLE: SHIP UNLOADER, STACKER & RECLAIMER,

CHINA HUADIAN CORPORATION

CHEC China Huadian Engineering Co., Ltd

APPROVED FOR CONSTRUCTION

COAL HANDLING SYSTEM INSTRUCTION MANUAL

Coal Handling System Instruction Manual

Coal Handling System General Description

Ship Unloader Erection & Commissioning

Ship Unloader Operation & Maintenance

Ship Unloader Erection & Commissioning

Ship Unloader Operation & Maintenance

Grab Instruction Manual

Motor Instruction Manual

Gearbox Instruction Manual

Brake Instruction Manual

Rail-Clamper Instruction Manual

Hydraulic system Instruction Manual

Spraying&lubricating Instruction Manual

Maintenance Crane Instruction Manual

3.1.1 Mechanical Part

3.1.2 Electrical Part

IM0401-3.1.3-10 Cable reel Instruction Manual

IM0401-3.1.3-11 Vibration feeder Instruction Manual

IM0401-3.1.3-12 Scale sensor Instruction Manual

IM0401-3.1.3-13 Elevator Instruction Manual

IM0401-3.1.3-14 PLC Instruction Manual

COAL HANDLING SYSTEM INSTRUCTION MANUAL

3.4.2 Electrical Part

3.4.3 OEM Manual

IM0401-3.1.3-15 Inverter Instruction Manual

IM0401-3.1.3-16 Transformer Instruction Manual

IM0401-3.1.3-17 MV Switchgear Instruction Manual

Conveyor Instruction Manual

Steel Cord Conveyor Belt Vulcanization

Multi-plied Conveyor Belt Vulcanization

Pipe Conveyor Erection & Commissioning

Pipe Conveyor Operation & Maintenance

Pipe Conveyor Belt Vulcanization

Stacker&Reclaimer Erection &

Stacker&Reclaimer Operation &

Stacker&Reclaimer Erection &

Stacker&Reclaimer Operation &

Slewing bearing Instruction Manual

Motor Instruction Manual

Gearbox Instruction Manual

Hydraulic Coupling Instruction Manual

Brake Instruction Manual

Rail-Clamper Instruction Manual

Hydraulic system Instruction Manual

Spraying&lubricating Instruction Manual

Stacker & Reclaimer /

3.4.1 Mechanical Part

COAL HANDLING SYSTEM INSTRUCTION MANUAL

Planet gearbox Instruction Manual

IM0401-3.4.3-10 Cable reel Instruction Manual

IM0401-3.4.3-11 Belt scale Instruction Manual

IM0401-3.4.3-12 PLC Instruction Manual

IM0401-3.4.3-13 Inverter Instruction Manual

IM0401-3.4.3-14 Transformer Instruction Manual

IM0401-3.4.3-15 MV Switchgear Instruction Manual