Do

Document No. A171SS201

TO：P.T.
P.T. SIKO TECHNO

Mainte
tenance & Operation Man
anual
for
L
Ladle Tilting Machine

Name of Project
ct P3FH PROJECT
Name of Equipm
ment Ladle Tilting Machine
Quantity 1 set

October, 2017

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
10
10-1, Kitaminato-machi, Wakamatsu-ku, Kitakyushu-shi
shi
Fukuoka, 808-0027
808 Japan
TEL:+81(93)761
TEL:+81(93)761-3754 FAX:+81(93)761-5454
 CONTENTS

1. Main Specification ・・・・・ 1

2. Construction ・・・・・ 2~3

3. Preparation and Adjustment Before Operation ・・・・・ 3~9

4. Operation ・・・・・ 9~10

5. Precautions on Operation ・・・・・ 11

6. Maintenance and Inspection ・・・・・ 11~13

6.1 Daily Checking
6.2 Periodic Inspection

7. Disassembly and Reassembly ・・・・・ 14

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

1. Main Specification

1.1 Ladle Tilting Device

1.1.1 Ladle tilting machine frame

1) Quantity 1 set
2) Tilting angle max.98 degree
3) Construction Made by shape steel and steel plate

1.1.2 Hydraulic cylinder

1) Quantity 2 pc’s
2) Type Clevis mounting cylinder
3) Load 60 ton/pc
4) Stroke 1,400 mm
5) Bore diameter φ250 mm
6) Rod diameter φ140 mm
7) Up-Down speed Up:max.250mm/min, Down:max.750mm/min
8) Accessories Cushion, Bellows

1.1.3 Hydraulic oil pump unit

1) Quantity 1 set
2) Type Mounted 630 Liter tank
3) Pump capacity Operation: 24.5 Liter/min at 140kg/ cm2 (13.7MPa)
(Limit setting values 32.0 Liter/min: max. 55.0 Liter/min)
4) Motor power 18.5kW×4P×380V
5) Accessories Solenoid valve and Oil cooler (Radiator)

1.1.4 Operation valve set

1) Quantity 1 set
2) Type Manual adjusting type oil flow control
3) Accessories Emergency switching valve
4) Location Control room

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

2. Construction

Fig.1 Construction Drawing of Tilting Table and Stand

2.1 The ladle(1) mounted on the tilting table(2) is tilted by 2(two) hydraulic cylinder(4) to send hot
pig from the ladle to the runner(6).

2.2 As for the tilting speed of the ladle(1), when the flow control valve of the valve set incorporated
in the operation panel in the operation room is operated, the speed of the hydraulic
cylinders(4) is controlled properly to change the discharging amount of hot pig in the ladle.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

2.3 For prevention of falling-down of the ladle, a hook(3) is applied to the ladle(1) and the
tilting table (2) for binding and fixing with a handle(5).

3. Preparation and Adjustment Before Operation

3.1 Check the ladle tilting table for correct position.

3.2 Check for existence of foreign substances and obstacles on the ladle tilting table .

3.3 Check the runner for thorough cleaning and being free from obstacles.

3.4 Check the hook for prevention of ladle fall for perfect fixing.

3.5 Check the fixing nut (for conveyance) for oil pump unit motor part is released.

Fixed bolts for conveyance

Release fixing nut before operation
3.6 Piping circuit check
Be sure that on-site piping work has been made correctly in accordance with the hydraulic
diagram.

3.7 Flushing
After completion of on-site piping work, do not fail to perform sufficient flushing of the
pipeline.
Combining it with this manual refer to the hydraulic piping of the separate volume installation
manual.
In addition, please prepare the temporary pipe and the blank flange to use for the following
work in your company.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

3.7.1 Method of flushing

1) After completion of regular pipe arrangement for the device, remove the flexible hoses
which are connected to the actuator on the head side and the rod side, and connect these
flexible hoses of both sides with temporary piping. Fig.2

Fig. 2

2) Next, remove the pipes (from the flange part) which are connected to the valve set.
Fig.3

Fig. 3

2-1) After the pipes have been removed from the valve set, start flushing work in the
order of the following item[1], [2] and [3].

[1] Connect two pipelines (C1) and (B1) with temporary piping.
At this time, be sure to provide a blank flange to each of the pipelines(T1) and
(A1). Fig.4

Fig. 4

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

[2] Connect two pipelines of (C1) and (T1) with temporary piping.
At this time, never fail to provide a blank flange to each of (A1) and (B1).
Fig.5

Fig. 5

[3] Connect two pipelines of (C1) and (A1) with temporary piping.
At this time, make sure to provide a blank flange to each of (T1) and (B1).
Fig. 6

Fig. 6

3) After connection has been accomplished, operate the pump and start flushing of the
unit piping. At this time, open the flow adjusting valve to the extreme end.

4) After completion of flushing, remove all oil in the hydraulic unit tank and piping.
Clean up tank inside specifically by opening the inspection cover to remove foreign
materials thoroughly.

5) Should operation be started after insufficient flushing, faulty operation of change-over

valves or other troubles may be caused in the hydraulic equipment due to dirt, dust or
other foreign matters remained in the pipelines.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

3.8 Preparation for oil feeding

Check the oil tank inside for foreign matters such as dust, dirt, sand, sludge, waste close,
water and others as well as tank corrosion.
If foreign matter is found, remove it without delay and wipe the tank inner faces sufficiently with
clean sponge moistened with hydraulic fluid.
But be careful at this time not to use waste cloth for wiping, otherwise its fluff or dust may
remain in the tank.
Check the pipelines and their connections, oil tank manhole cover and other for bolts and nuts
which are loose or left not tightened.

3.9 Oil feeding

3.9.1 Oil tank feeding

Pour oil from a port provided in the upper surface of the tank.
Although a wire net is installed in the oil feed port, it is primarily intended to prevent coarse
foreign substances from falling into the tank, and not capable of filtering out fine
contamination particles contained in the hydraulic fluid.
Therefore, use the specified clean oil without fail.

3.9.2 Checking of oil level

Fill the tank with oil up to the specified level. (Min.:280L, Max.:630L)

3.9.3 Hydraulic cylinder feeding

Refueling to the rod said of hydraulic cylinder (1 Liter).

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

3.10 Adjustment of pressure control valve

Fully open relief valve (Low pressure operating) for adjustment of pump discharge pressure.
(for no-load starting).
Perform confirmation of the piping connection, oil leak from the piping, air venting from the
piping.
After confirmation, set it in predetermined hydraulic pump delivery pressure (13.7MPa).

★V-Series Variable Displacement Axial Pumps

Attention
If you loosen a pressure adjustment screw too much,
this screw can be detached and the working oil
leakage will be caused from the hole.
In case you reduce the pressure, keep the length of
the pressure adjustment screw within 13mm like the
attached picture.

3.11 Trial start of pump

3.11.1 Checking of centering between driven shaft of the pump and drive shaft of the motor.
Make an alignment of the coupling both motor and pump.
Concentricity tolerance ・・・・ less than 0.05mm
Coupling gap tolerance ・・・・ less than 0.1mm

3.11.2 Fill the case with hydraulic fluid prior to pump starting.
Prior to the pump operation, fill the pump housing with hydraulic oil from the case-drain
inlet, and then start to drive the pump.
How to fill the case drain
Remove the plug from the case-drain inlet indicated by the arrow mark, and fill the
hydraulic oil. After filling, plug it as it was.
Quantity of Oiling
V15(V23) 500cc
V38 900cc
V70(V50) 1800cc

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

3.11.3 Confirmation of revolution direction of the pump.

Before starting pump, be sure that motor is wire in the specified manner so that it turns in
correct direction to ensure specified revolution direction of the pump.

3.11.4 Starting
Don’t attempt to start the pump momentarily at full speed.
Repeat inching to increase speed gradually for satisfactory pump suction.
New or overhauled pump should be subjected to ample running-in at pressure
(about 10 kg/cm2) for sufficient-dispersion of the initial lubricat2ion.

3.12 Air venting

Air, if included, in the hydraulic circuits may not only hamper to attain the specified
performance, but cause trouble in operation of the control valve, from which noise or
vibration may be resulted to shorten service life of the hydraulic equipment.
Accordingly, thorough air removal from the hydraulic circuit is the absolute necessity.
If pump discharge pressure is unnecessarily high at the time of air removal, hydraulic fluid or
air may spout out to cause danger, or air may be dissolved in the hydraulic fluid, and for
complete removal of the dissolved air it is necessary to discharge the whole hydraulic fluid
containing air.
Therefore, keep the discharge pressure at lowest required level (10 to 30 kg/m2).

3.13 Supplement of hydraulic fluid

Since hydraulic circuits have become full with fluid due. to air removing operation, fluid level
in the tank lower.
Supplement hydraulic fluid in the tank strictly to the specified level.

3.14 Manual operation

Manually operate solenoid valves to move hydraulic cylinders up and down or to and fro.
Check the respective actuators at this time to see that they are operating normally.

3.15 Automatic operation

Before stating automatic cyclic operation perform idle run with hydraulic power source turned
off to check that the respective solenoid valve and electric detector are wired correctly.
Then wipe off fluid leakage, finally tighten piping connections and the automatic operation.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

3.16 Record of trial running condition

During trial run close attention should be kept on the operating pressure, actuator speed,
change of oil tank level, running noise, etc.
It is recommended to make a record of condition of the trial run, because it is useful for
checking change in performance of the hydraulic equipment.

4. Operation

The ladle tilting device consists of a stationary

frame stand, tilting frame stand, hydraulic
cylinder , hydraulic pump and valve set.
These equipments are operated by valves on
the valve set incorporated on the valve stand
in the operation room.
For operation, press the operation pushbutton
on the operation panel in the operation room
and the motor starts.
After confirmation of pump pressure, depress
the ladle tilting pushbutton and tilt the ladle.
The tilting speed becomes slow by turning
clockwise the rising speed adjusting knob built
in the valve set and becomes fast by turning the knob counterclockwise.
The lowering speed after completion of tilting becomes slow by turning counterclockwise the
lowering speed adjusting knob and becomes fast by turning the knob clockwise.
For the counter plan at electric failure in pouring work, the hot pig accident beyond the tilting
device is prevented by operation of the handle of the manually operated valve (built in the
valve set) immediately after the outbreak of electrical failure, because the handle operation
promptly returns the working oil in the hydraulic cylinders to the hydraulic unit and lowers the
hydraulic cylinders.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

5. Precautions on Operation

5.1 Avoid application of the load over capacity.

Overload operation gives a good reason to harmful wear, deformation, damage, etc. of the
parts, sometimes resulting in a serious accident.

5.2 Provide positive maintenance and inspection.

Detection and repair of the malfunctioning part its early stage according to careful
maintenance and inspection brings safe operation and secures a long service life of the
device.

6. Maintenance and Inspection

Maintenance and periodic inspection of the hydraulic equipment including daily checking are
very important not only to keep the equipment in the normal condition, but for improvement of
operation reliability , trouble finding at the earliest stage and ensuring long service life.
＊Never fail to make sure to turn off the power before conducting maintenance and inspection.

6.1 Daily checking

The following should be checked by operator during daily operation.
For effective checking, it is recommended to prepare a daily operation record book to enter
points noted during operation.

Daily Checking Item Standard

1 Oil leakage at hydraulic unit and piping
2 Smooth performance of hydraulic cylinder
3 Smooth performance of hook handle for prevention
of ladle fall
4 Abnormal heating of bearing
5 Abnormal noise during operation
6 Hydraulic fluid level in oil tank (Proper or Not) To be checked with oil level gauge
It is normal if the level is kept
between two lines (L,H Level)
7 Temperature and viscosity of hydraulic fluid In accordance with viscosity-
(Proper or Not) Temperature curve of the
hydraulic fluid
8 Contamination and whitening of hydraulic fluid State at the time of trial run
9 Reading of pressure gauge when hydraulic pump is 0 kg/cm2
at rest

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

Daily Checking Item Standard

10 Discharge pressure of hydraulic pump Data of trial run
1) Operating pressure
2) Reading of pressure gauge
(too Excessive or Not)
11 Abnormal noise from hydraulic system
12 Suction pressure of hydraulic pump: To be checked with indicator of
when too low・・blocking of pump suction line or suction filter
clogging of suction filter (clean or replace whit new
filter); or tank oil temperature too low
13 Line filters (Clogged or Not; if clogged, clean or To be checked with indicator
replace with new one)
14 Oil leakage from pipe joints of machines or
equipment
15 Hydraulic cylinder operation
1) Operating speed (as Specified or Not)
2) Smoothness

6.2 Periodic inspection

Periodic inspection of the hydraulic equipment is classified into monthly checking and quarterly
checking.

6.2.1 Monthly checking: to be performed by maintenance personnel during or after normal

operation to keep quantitative records, based on which maintenance plan is made.

[1] Monthly checking item

1) Analysis of daily checking records
2) Fluid level in oil tank
3) Sampling test of hydraulic fluid
4) Hydraulic cylinder operation
(1) Operation speed
(2) Operating pressure

5) Hydraulic fluid leakage from piping joint of the machines or equipment

6) Operation check of machines and equipments which are scarcely used usually (such as
equipment for emergency use).
7) Checking for surface injury of hook.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

6.2.2 Quarterly checking: to be performed to replace or repair parts of the hydraulic equipment
based on analysis results of records of daily and monthly checking’s.

[1] Quarterly checking item and Maintenance work

1) Analysis of monthly checking records
Determine part or equipment to be replaced or overhauled based on the analysis
results and perform replacement or overhauling as necessary.

2) Execution of monthly checking (all time)

3) Checking of air breather contamination degree and cleaning thereof as necessary.
4) Checking of chain coupling condition and grease replacement
5) Checking of centering between driven shaft and prime move shaft
・Centering allowance: less than 0.05 mm
・Eccentricity allowance: less than 0.1 mm

6) Checking of tightness of fixtures and set bolts

7) Checking of electric wiring condition and operating condition of relays and solenoids.
8) Checking of operating accuracy of pressure gauge, thermometer and other instruments
9) Checking of flexible hoses ( for surface crack, distortion, etc. )
10) Checking of wearing state of bushing

6.2.3 Comprehensive inspection

Comprehensive inspection should be carried out for the purpose to check change of
performance of not only the individual hydraulic units but the entire hydraulic equipment for
determination of part to be repaired or replaced and prevention of equipment trouble.
Perform the comprehensive inspection once a year without fail.

[1] Comprehensive inspection item

1) Analysis of quarterly checking records

2) Execution of quarterly checking ( all times )

3) Analysis of hydraulic oil

4) Cleaning of oil tank inside

(Discharge oil in the tank and clean its inside with washing oil)

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group
 Page.

7. Disassembly and Reassembly

Fig.7 Tilting frame stand assembly Fig.8 Hydraulic cylinder assembly

7.1 Disassembly of hydraulic cylinder

7.1.1 For detachment of hydraulic cylinder(3) from tilting frame stand(1) and bracket(2).

1) First stop operation of the hydraulic pump. Remove the flexible hoses(7) at the head and
rod sides of the hydraulic cylinder(3), the keep plate(5) and the pin(6).
Next, apply a wire rope to the tilting frame stand(1) and lift it up temporarily by crane.
Then disconnect the end plate(4) and the hydraulic cylinder(3) sideways.

2) For disassembly and reassembly of the hydraulic cylinder proper, refer to User’s Manual of
hydraulic cylinder.

3) Pay attention in handling of the hydraulic cylinder(3).

7.2 Reassembly of hydraulic cylinder

7.2.1 Execute reassembly in the reverse order of disassembly.

MM Nagata Coal Tech Co., Ltd.

Resource Processing Engineering Division
Technical Group