OPERATION AND MAINTENANCE

MANUAL
SCRAPING MACHINE

Index of General Inspection Manual

1

SCRAPING MACHINE
Sr.
No.

Content/ Title

Page no.
From

To

OPERATION PHILOSOPHY

WIRE ROPE ,BRAKE

WORM GEAR BOX

TRAVELLING WHEEL, ROPE PULLEY

GEAR COUPLING AND FLOATING SHAFT

ROPE & BRAKE DRUM, STEEL STRUCTURE, RAIL TRACK

10

LUBRICATION

10

11

ELECTRICAL , MOTOR, CONTROL PANEL

11

13

REPAIR AND MAINTENANCE

13

14

10

INSPECTION CHECKLIST

14

15

INTRODUCTION
Scraping Machines are conventionally used to scrap fine sediments normally get deposited on the bed of
Settling Tanks.
Regular operation of the machine at calculated intervals to remove sediments before accumulation of thick
layer, shall ensure efficient performance and longer life of the machine and the parts prone to fast wearing.
Scraping machine is simple in construction and needs very little maintenance for trouble free operation.

OPERATION OF THE SCRAPING MACHINE

The Scraping Machine has four (4) distinct operations:
i)
ii)
iii)
iv)

Lowering of the Scraper beam

Forward movement of the machine (Scraping operation)
Raising of Scraper Beam
Return movement of the machine (Idle run)

OPERATION PHILOSOPHY OF THE SCRAPING MACHINE

3

Machine has two mode of operationManual Mode and Auto Mode.

Manual Mode is used for initial adjustment, setting etc. during commissioning. Manual Mode operation is
also necessary during maintenance of the machine.
Auto Mode shall always start from the parking position of the machine which is extreme end away from the
scale hopper, with scrapper beam in raised condition.
Control Panel with a built-in Push Button control Desk is located on the machine and local Control push
button unit (Local Control Post, LCP) is suitably located on the ground from where the machine is fully
visible. Selector Switch in the Control Panel can be set-in either to Manual Mode or Auto Mode.
In Manual Mode operation, the above mentioned four distinct movements can be effected by individual push
buttons (held-on type), located in the Control Desk on the machine.
In Auto Mode position of the selector switch the auto cycle operation of the machine can be effected by
START Push button Located in Control Desk on the machine as well as from LCP on the ground. The
Auto Mode shall have cyclic operation in the sequence mentioned below:
i)
ii)
iii)
iv)

Lowering of the Scraper beam

Forward movement of the machine (Scraping Operation)
Raising of Scraper beam
Return movement of the Machine (Idle run)

Machine thus will run in repeatitive auto-cycle untill stopped by a STOP Push Button in the Control Desk
on the machine or in the Local Control Post (LCP) on the ground or by the Emergency Stop Push Buttons
located suitably on the machine on either side and approachable from the ground.
Once machine is stopped while in AUTO MODE, to re-start, it gas to be brought to the Parking Position
with Selector Switch in Manual Mode and operating individual Push Buttons as required from the Control
Desk on the machine.
When the scales will be deposited in heaps in the pit for some ressons or other, the scales will be removed
gradually as follows:
a)

The machine has been provided with manual mode of operation.

b)

In the Manual Mode the machine should be moved only 100 mm (approx.) from the hopper, the
scraper beam should be lowered down in manual mode and the machine should be run in
forward motion to remove the scales into the hopper. The machine should be moved further for
every 100 mm to remove all the deposited scales as stated above.

c)

Only after all the scales are removed from the entire pit, the machine should be put into normal
operation.

SCHAMETIC DIAGRAM OF SCRAPING M/C:

Wire Rope:
Lubricate wire rope by grease at regular intervals and ensure that the rope is never dry.
Keep a watch on condition of wire rope. Kinks on the rope must be avoided and broken wires should be
nipped off. If number of broken wires in a pitch length exceeds 10% of total number of wires or if one
complete strand is broken or if wear on the surface wires of the rope exceeds 50% of the original section,
the wire rope must be replaced immediately.
To replace rejected wire rope, support the scraper beam at its highest position by some external fixtures,
remove the rope fasteners on the drums, open out other end of the rope from the scraper arm and pull out
the rope slowly. Replace all the ropes at one time, even if one of them could have been used for little more
time.
Stretch the new wire ropes on the ground avoiding twist and kink. Pull in one end of each rope through the
pulleys and fasten them on their respective drum. Wind the ropes on their drums over all the grooves and
fasten the other ends to the thimbles, which in turn are relocated to their original position in the scraper
arms.
Run the hoist mechanism by setting the selector switch in the control panel at Manual Mode, two-three
times and see that scraper beam is moving up and down in leveled condition. If required set the cams in the
commands switch to match extreme positions of the scraper beam.

Brakes:

Ac Electromagnetic brakes used in the Scraping Machine are BCH make. They hardly require any
maintenance. In long use brake shoe lining shall wear out; never allow rivet heads to rub on the brake drum
surface. Till them the gab between drum surface & the brake lining face may be adjusted to compensate
wear and to maintain required torque / time.
-----------------------------------------------------------------------------------------------------------------------Size of
Brake

Torque Rating,
Continuous

kg.cm.
Intermittent

Compressed
length of spring, mm.

S-42

41.50
138.30
207.50

41.50
138.30

27

S-51
S-52

345.75
484.00

345.75

45

S-71
S-72

691.50
1037.25

691.50

52.4

----------------------------------------------------------------------------------------------------------------------These compressed lengths of the springs should be maintained by turning the torque screw nut. When the
brake is energized, the wear allowance for lining should be kept 1.5 mm (wear allowance is measured
between the stop nut and rocket block at top of outer shoe lever). When the lining wears out, the gap
increases and this should be adjusted by turning stop nut.
Adjustment of travel of the shoe should be done by turning the hexagonal nuts on which the inner shoe
rests. This adjustment is done to make travel of both shoes equal.

Worm Gear Boxes:

6

It is advisable to check the alignment of the gear box and motor at regular intervals by rotating the
mechanism from motor shaft by hand. To do so, release the brake manually.
Fit coupling, brake drum, on the gearbox shafts with light drive; heavy blows may damage the bearing and
should always be avoided.
Temperature of gearbox rises with the load and running. Maximum temperature of oil and/or body should
not exceed 93 degree C. If higher running temperature is observes, manufacturer should be consulted.
Oil filling in time is the main feature of maintaining a gearbox. Gears and bearings are lubricated by the
splash of oil from the trough.
It is also important the excess oil is not filled into the gearbox, because this may result in excessive
temperature rise due to churning.
First change of oil should be made after 500 hours of operation. Subsequent oil changes must be made
after every 3000 hours of operation. The intervals should not however exceed 1 year.
Cleanliness of oil is of prime importance and it is imperative to flush the gearbox with flushing oil before
filling the fresh oil.
Both worm shaft and output shaft are mounted on taper roller bearings and means of adjustment have been
provided under end covers. With the bearing covers tightened, there should be reasonable amount of play
in the bearings which can be ensured by easy rotation by hand without noise.
If gear case is dismantles for any reason, it is preferred that the oil seals are replaced by new ones and this
should be done carefully to avoid damage to the sealing lip.
Recommended lubricants for the gear box depending upon rubbing speed are as follows:
-----------------------------------------------------------------------------------------------------------------------RUBBING SPEED
OIL GRADE
M / Min.
B.P.
H.P.
600 900

Cabol 150 / Amocam 150 / Equivalent

Enklo 150

300 600

Cabol 220 / Amocam 200 / Equivalent

Enklo 220

150 300

Cabol 320 / Amocam 320 / Equivalent

Enklo 320

60 150

Cabol 460 / Amocam 320 / Equivalent

Enklo 460

0-

60

Engol 68 / Equivalent

Cyndol TC 680

------------------------------------------------------------------------------------------------------------------------

Worm Gear Boxes

7

Worm gear boxes generally perform satisfactorily for the service life of about 25000 hours. However, as a
guide to good continuous performance, following points may be kept in view for maintenance :
-----------------------------------------------------------------------------------------------------------------------Problem
Causes
Remedy
Gearbox is over heating

1. Over load.
2. Lubricant is short or too much
3. Incorrect grade of lubricant
4. Oil seal damaged

- Check actual loading.

- Fill to specified level.
- Use oil of correct grade.
- Replace.

Gear box Buzzes

1. Gear damaged
2. Bearing damaged
3. Inadequate oil
4. A foreign matter in the box

- Rectify gears.
- Replace by new one.
- Fill-in more oil.
- Remove it and change oil.

Unusual vibration

1. A foreign matter inside

2. Bearing damaged or worm out
3. Bolts loosened

- Remove it and change oil

- Replace.
- Tighten the bolts.

Leakage of oil

1. Oil seal damaged

- Replace.
2. Packing damaged
- Replace.
3. Drain plug loose
- Tighten the drain plug.
------------------------------------------------------------------------------------------------------------------------

Gear box description

Component

Type

Ratio

H / L Drive
Motor Drive
L / T Drive
Motor Drive

U500
AZ 37
U400
AZ 37

50/1 DOS
15/1 RB12
30/1 DOS
10/1 RB12

Wheels:

Travelling wheels are mounted on L-type bearing housing with anti-friction bearings. Extended end of the
driving shaft has a keyway for connecting it with the transmission shaft by means of a toothed coupling.
While inspecting the wheel see that the L-type bearing housing are properly fixed to the structure.
Rolling surface of the wheel should not have dents and wearing of flange should not exceed 40% of its
initial dimension. Wheels with worm out flange beyond 40% of its dimension should be replaced.
Wheels should not have any crack sign of pitting or excessive wear on the rolling surface, shall lead to
replacement of the wheel.
In case of uneven wear, the surface of the wheel should be remachined and hear treated.
Lubricate wheel bearings regularly.

Rope Pulleys:
Pulleys are mounted on self-lubricating polyacytal bush and therefore do not require any attention for
lubrication.
Check the condition of the pulley groove surface for dents and cracks. It is advisable to apply grease on the
surface of the groove occassionally.

Gearing Couplings & Floating shafts:

9

Gear couplings are introduced in between two units of a mechanism to provide flexible connection. Gear
coupling can negotiate maximum misalignment between two units without damaging the bearing or shaft of
the coupled units. In case two units are located far apart, floating shaft with half-rigid, half-gear couplings at
both ends of the shaft is employed to couple these units.
Check that bolts connecting the coupling halves are tight and the O rings are in good condition. Check the
fitting of the coupling on the shafts, presence of end play is within limit and condition of working surfaces of
gear teeth and wear of teeth.
Coupling should be rejected and replaced when the amount of wear of tooth is 30% of the initial tooth
thickness in case of hoist mechanism and 40% in case of travel mechanism.
Extensive tooth wear is the result of insufficient lubrication or excessive angular misalignment of mating
shafts and should be eliminated during inspection.
Grease should be injected through the port in the flange; amount of grease must be sufficient to keep the
teeth in wet condition.
To remove toothed bush from the shaft, use puller or any other suitable fixture. Fitting or removal of such
item by hammering is not allowed.

Rope Drums:
10

While inspecting the rope drum check the grooves, rope fastenings and tightness of the fixing bolts of
supporting pedestals.
During periodical inspection, bearing covers may be removed to check condition of bearings. When grease
dries up, the same should removed, bearings cleaned and then regreased with fresh lubricant.

Brake Drum:
In case of uneven wear or light cut marks developed in course of use, the drum should be redressed by
machining. In such cases after refitting the drum, the brake should be adjusted in line with the installation
procedure laid down in the manual. Due to wear when the drum diameter is reduced by 2 to 5 mm.
depending upon size of the drum, the same should be replaced.

Steel Structures:
Steel structures like bridge, hanger, scraper beam etc. must be regularly inspected & defects observed
repaired immediately.
See that there is no broken or bent member, cracks in and near the welds and that all load bearing
members are straight.
After repair the member should be painted to prevent corrosion and to maintain appearance.
The material used to replace or reinforce any damaged member should be identical to that of the original
member. For welding, use of electrode type should ensure mechanical properties equivalent to that of the
original member. After welding see that no crack has developed as a result of welding.
If during transportation, erection or operation warping or bending of structure takes place, all the defective
member must be straightened. Members with thickness less than 4 mm . can be straightened cold whereas
those with thickness more than 4 mm. should heated red before straightened. While straightened by
hammer, give back rest to avoid formation of local dents.
The Steel structure as a whole should be repainted at a regular interval.

Rail Track:
Long travel rail track should be regularly inspected.
Top of rail should be smooth to avoid shock during movement of the machine.
Longitudinal gradient of the track should be within 1 in 1000 but cumulatively should not exceed 10 mm.
No foreign material should be allowed to remain on the track rail and the rail fixings should be firm and none
missing.

Lubrication General Guidance:

11

Scraping machine is normally provided with individual point lubrication system.

Individual lubrication is done by hand lubricating gun and grease nipples.
Effectiveness of lubrication depends primerialy on quality of lubricant used and timely application. Trace of
water, alkali, acid or metallic or abrasive particles in grease aggravate working condition of parts subject to
friction and wear.

Lubricate the units in compliance with Table below:

Lubrication
Points

Frequency of Lubrication
and Lubricant

Frequency of
Washing

Anti-friction
Bearing (ball
and roller)

Once a week for every high

speed bearing; once a month
for low speed bearings.

Every 4-6 months.

a) With grease
lubrication

Sovarex grease L-1/Equivalent

Mobilux grease No. 2/Equivalent

b) With oil
lubrication

Sovarex grease L-2/Equivalent

DTE oil light / heavy / Equivalent
DTE oil heavy

Enclosed gear
pair

Check oil level two times a

week. Add as per consumption.
DTE oil heavy.

Remarks

For temp. upto 60 C

For temp. above 60 C
to 85 C.
Upto 110 C.
Upto temp. + 60 C.
Temp. upto + 100 C
Every 6 months.

For normal temp.

Upto 60 C

Lubrication General Guidance

----------------------------------------------------------------------------------------------------------------------------------------------Lubrication
Points

Frequency of Lubrication
and Lubricant

Frequency of
Washing

Remarks

Gear coupling

Every month : DTE oil extra

Heavy / Equivalent

Every 3-4 months.

For normal temp.

upto 60 C.

Steel wire rope

Twice a month.
Mobilux grease No. 2/Equivalent

When lubricant
dries up.

Worm and Worm

Wheel.

Every month DTE oil Heavy.

Every 6 months.

For normal temp.

Upto + 70 C

----------------------------------------------------------------------------------------------------------------------------------------------NOTE: All grades and trade marks used for lubricants are IOC make, unless otherwise specified.

Electrical Equipment:
12

The machine is suitable for auto operation of the full cycle, repeating one after the other until it is stopped by
pressing any one STOP push buttons located in the control desk and on sides of the machine.
For initial installation and adjustment of the machine, set the selector switch in manual mode position and
operate hoist and travel mechanisms by individual push buttons for each motion to bring the bridge /
skimmer / scraper beam to their desired extreme positions and set the limit switches and command
switches as per circuit diagram. Now run the machine for one full cycle according to sequence of operation.
See that the limit switches operate according to switching sequence in cycle. Switching sequence of the
mechanisms in a cycle will be:LOWERING
(of scraper beam)

FORWARD

HOISTING
(of the scraper beam)

BACKWARD

Trial run with selector switch in AUTO position should ensure sequential operation with Pause in
between two operations as per setting of timers in the panel. Adjust timers during trial run or during regular
operation in case it is felt that pause between two operations is either too short or too long.

MOTORS
Squirrel cage motors do not require practically any maintenance. It is however advisable to service the
motor once in a year or once in two years.
Keep motors clean from dust and accumulation of any foreign matter on them. Check the fixing bolts of the
motor occasionally and ensure that all bolts are fully tight and the motor is held in position firmly.

Component

Type

Kw / HP

H / L Drive
L / T Drive

1 LB 3046-4
1 LB 3070-8/4

1.5 / 2
3.0 / 4

CONTROL PANEL
For trouble free performance of electrical control panel and operating push button switches, it is necessary
to check from time to time the followings:-

Supply voltage is within the prescribed limits and frequency of supply also does not cross the
permissible limits.
No connection between supply lines and panel and between panel and motor etc. is loose
resulting drop of voltage.
In case of dashpot type overload relays, oil level does not fall below marked lever.
Fuses used in power and control circuits are of recommended type and size.
Panel door is always closed.
Isolater switch is in off position whenever the machine is not in use.

For maintenance of the control panel follow the circuit diagram of the machine. During maintenance / repair
of the panel, deviation from the circuit diagram is not permitted. Any modification in the circuit if found
necessary to improve performance of any drive should first be brought to the notice of the equipment
supplier and them carried out with designers consent.

Sequence of Operation:
The following switching sequence of electrical equipment is carried out at the time of starting the machine.

13

a)
b)
c)
d)
e)

Switch on the main breaker or fuse-switch unit.

Push the CONTROL-ON button to energise the contactors.
Set the Selector Switches to the required mode of operation.
Press the START push button to run the machine in auto cycle.
At the end of operation, stop the machine by pressing the STOP push button and switch off all the
preliminary switches as stated above while leaving the machine at the parking place.

Safety Rules:
a) During working of the machine, do not open electrical panel etc. for inspection or repair.
b) Wire ropes should be inspected at regular intervals.
c) To prevent possibility of using the faulty machine, put a placard reading OUT OF ORDER on the
maching.
d) Limit Switches should be inspected at regular intervals.

Routing Check for Electrical Installation:

The following tests should be conducted periodically for trouble free functioning of the electrical installation:
a)
b)
c)
d)

Insulation test for all electrical equipment.

Resistance of earthing arrangement of all equipment.
Routine check of all bought out equipment as specified in the manufacturers manual.
Condition of all electrical connections which are liable to losen themselves due to vibration.

Operation and Maintenance Personnel:

Operation of the machine is to be entrusted only to persons specially trained for the job, who have been
examined and approved by the plant.
Persons operating the machine (operator, mechanic and supervisor) must be given written instructions
about their duties.
Supervision of the machine should be assigned to qualified and experienced technical person who will be
responsible for proper maintenance, inspection, servicing and safe operation of the machine.
The supervisor must do through inspection regularly and briefly note the inspection results in a record book.
Inspection should be done more frequently if wire rope develops any defect like wire breakage, signs of
wear etc.
Person taking charge of the machine is responsible for its condition and must report about all defects to the
supervisor for necessary repair.

Duties of the Operator:

Before starting the machine, the operator should do the followings:

14

a) Make himself familiar with the condition of the machine by going through the entries made in the
shift record book.
b) Inspect the mechanisms, specially brakes, other electrical equipment, wire rope etc.
c) Check and if necessary, lubricate points in the mechanism.
On starting the machine any defect is detected, the operator should not run the machine and report the
same to the supervisor.
The machine should only be started after eliminating all the defects & a corresponding entry is recorded to
that effect in the record book.

The machine should not be operated if:

a)
b)
c)
d)

Rope has broken strands, kinks, loops or excessive number of broken wires.
Brakes do not work properly and rivets touch the brake drum surface.
Bolts or nuts are missing in the couplings.
Gear box, bearing pedestals, brakes, motors etc. are not properly installed and liable to be displaced
when the mechanisms are in operation.
e) Wiring on the machine or any trailing cable is damaged or earthing wire is broken.
f) Command switch / limit switch is not functioning properly.
g) Any abnormal sound arises during operation.

The operator is not allowed to:

a) Repair the mechanisms and electrical equipment by himself, inspect or repair the festoon cable
arrangement or replace the safety fuses.
b) Leave tools and other loose parts on the machine.
c) Jam any contactor or interfere with the working of brake, limit switch and other electrical protection
equipment.

Service and Repair:

Scraping machine should be serviced at regular interval to maintain good condition for the machine.
Servicing of the machine includes inspection and minor adjustments and alignments.
Servicing may be carried out by the authorized mechanics and electricians of the department during any
interval when the machine is not working.

MAINTENANCE
15

It is advisable to make check up of machine almost regularly.

Do not allow any fastener to remain lose or missing.
Check condition of oil in the gearboxes at an interval of one month.
Regular check up must detect the wear and damage of any component and condition of mechanical
assemblies. White carrying out such inspection careful attention must be given to the following details:a)
b)
c)
d)
e)
f)
g)
h)
i)

The condition of runner wheels, amount of wear on the tread and flange.
Condition of the gear teeth and meshing of the pair.
Condition of shafts and bearings.
Run-out of shafts connected by couplings; overall alignment of two coupled units.
Condition of rope pulley surfaces.
Condition of Wire Rope.
Amount of wear of brake shoe linings.
Condition of lubrication points.
Condition of steel structure.

Periodical repairs and maintenance are divided into the

following three categories;

1.

LIGHT MAINTENANCE

Inspection of different assembles, tightening of fasteners and

minor adjustments.

2.

MEDIUM MAINTENANCE

Opening and checking of all the sub-assemblies, replacement

of worn out bushes & dressing of all pins, repair of brakes,
repair of steel structure joints and platform and painting where
required.

3.

CAPITAL MAINTENANCE

Checking of all the details of sub-assemblies, replacement of

wheels, couplings, gear, pulleys and other worn out parts,
complete repair of metal structure, checking the mechanism for
geometrical installation.

Check Points in case of any Operation Problems:

A.

IF MOTOR DOES NOT START

a) Failure of respective Limit Switches interlocked in Control Circuit.

16

b) Single phasing.
c) Check Brake operation for its smooth release.
d) Check up overload relay.
B.

BRAKES NOT FUNCTIONING PROPERLY

a)
b)
c)
d)
e)
f)

Plunger / Spring jammed.

Stroke adjustment to be set right.
Coil to checked.
Adjustment nuts to be checked.
Brake liners worn out.
Setting of torque adjustment spring to be checked up.

General Operational Check Points:

A.
B.
a)
b)
c)
d)
e)
f)
g)
h)
C.

If power is not reaching the under voltage contactor, ensure that the main fuses are okay and
also check up the Control Transformer. Further ensure that the Carbon Brushes are properly set
on the slip ring arrangement.
POWER IS THERE, BUT ANY ONE OR MORE OPERATION (S) IS NOT WORKING
Single phasing or loose contact.
Fuse to be checked up.
Systematic check up of the control circuit to be done.
Limit Switched incorporated in the control circuit to be checked up.
Overload relay has tripped or some defect in the overload relay, or current setting to be checked.
Cable connection and condition to be checked up.
Check the limit switch contacts.
Cam setting of command switches to be checked.
If skewing is observed in Travel motion then check the rail alignment, brake setting of the travel
motor, wheel tread condition and also the condition of the track rail.

17

General Inspection Checklist for

Scraper
S
r.
Part Name
n
o

Parameter
to
be Standard
checked
Sound

bearing

Once in each shift

Operator

10 Secs

inform
maintenance

Once in each shift

Operator

10 Secs

inform
maintenance

Once in each shift

Operator

10 Secs

inform
maintenance

Once in each shift

Operator

15 secs

Fill grease

Check

Once in a month

Operator

15 min

Check

As & when required

Operator

60 min

inform
maintenance

Hear

Vibration

Feel

No Vibration

Between min &

See
max level

Tools

Tightness

Match marks
for nuts & See
Bolts

Once in a month

Operator

30 secs

Tightness

Comply
with
Check
match marks

Spanner

Once in a month

Operator

2 min

Clean & dry

Clean & dry

See

Fortnightly

Operator

30 secs

Hear

Once in each shift

Operator

10 Secs

Temperature < 60 deg C

Feel

Once in each shift

Operator

10 Secs

Sound

Hear

Once in each shift

Operator

10 Secs

Feel

Once in each shift

Operator

10 Secs

See

Once in each shift

Operator

5 secs

Fortnightly

Operator

2 mins

Foundation bolts

&

Action
in
case
of
abnormality

Feel

Sound
6

abnormal

Gap

Coupling

Responsibility Time

Temperature < 60 deg C

Oil level in Gear

Level
box

Foundation
frame

No
noise

Frequency

Method

Motor bearing CE

Motor bearing FE

No abnormal

noise

Wipe, blow
No deposit
wipe
dust

Normal

Temperature < 60 deg C

Working
on

when

Motor fan

Working

Motor fins

clean

10

Motor cover

fixed

See

Monthly

Operator

30 secs

11

Electrical
connection

Loose contact No
Loose
/
Gland contact / No See
missing
Gland missing

Monthly

Operator

30 secs

12

Ammeter

Current

Once in each shift

Operator

15 secs

properly fixed

Green zone

See

18

19