Underground Coal Mining Equipment

UNDERGROUND COAL MINING EQUIPMENT

ENGINEERED TO LAST

10 Lubrication Best Practices for Improved Equipment Reliability

Lubrication has a direct effect on equipment reliability. If you have a good lubrication strategy, you will improve your plant and equipment uptime. For any given plant, there are a number of important steps that, if implemented, will increase equipment reliability. The following 10 lubrication best practices can help achieve the optimal result in maintenance costs compared to production reliability.

1. Assessment/Benchmarking

In this process, you assess the things that you do right as well as the things you need to do better.

2. Organisation and Planning

This step is about ensuring that all lubrication tasks in the plant are completed at the right time with the right lubricant and the right quantity while using the right processes. For this, most companies use software to control and report the activity.

3.

Identification

To ensure that the right lubricant is added to a piece of equipment, a labelling system is needed. This is driven by the fact that in large plants, multiple types of lubricants are used. Lubricants are complex chemical compositions and are often very incompatible, so to avoid errors of mixing lubes and to support industry standards, particularly in the food-grade industry, a good labelling system is necessary.

4. Cleanliness Control

Oil contamination is a major source of component wear and equipment failure. Therefore, it is important that only clean lubricants are used in the equipment operation. Cleanliness-control centres ensure that the lubricant is stored safely, is clean and is transferred in a contamination-free environment. Best practices for cleanliness control include:

• O nly use fully sealed containers.

• F it air breathers to all containers to prevent the ingress of water and contaminants from the atmosphere.

• Filter all oil to get it very clean.

• O nly use contamination-free containers, i.e., containers that will not generate contaminants.

5. In-plant Dispensing

Open and dirty dispensing containers can be a source of contamination entering the machine. Dispensing equipment must be safe, clean and closed. It also should be efficient, easy to use and adapted to the applications being filled. Make sure the containers are well-identified so no mistakes occur, regardless of who uses them.

6. Grease Lubrication Tools

Adding grease to a machine accounts for the majority of lubrication jobs. Therefore, it’s essential to have tools that are efficient and practical. Grease guns should be colour-coded to ensure that the right lube gets in the right application. Colour-coded grease guns, with one colour for each different grease, can help in this regard.

7. Contamination Control

Controlling the contamination of oil inside the equipment is also critical. The international standard for measuring this is ISO 4406. Online and offline filtering systems are used to clean up the oil, while breathers or air conditioners are utilised to protect the lubricant.

8. Oil Analysis

Analysing the oil in an application is an important part of a lubrication strategy. By measuring against ISO 4406 standards, the oil can be kept at the right cleanliness levels. Additionally, chemical analysis of the oil will determine if it is fit for further use.

9. Environmental Control

If spilled, lubricants can contaminate the environment. Therefore, most maintenance strategies today work to prevent such contamination from occurring. This is also a key ingredient in world-class manufacturing standards.

10. Knowledge Management

Management of knowledge is becoming critical in industry today, particularly within the maintenance sphere. Maintenance workers must be skilled in the benefits of good lubrication practices. Additionally, with the growing awareness of the benefits of employing reliability-based maintenance strategies, the basic training of personnel should be raised to that of the reliability techniques employed by best-practice organisations.

CARTRIDGE GREASE

660AS ALEMLUBE TRIGGER ACTION

GREASE GUN

Free of external aluminium components, the 660AS, 660ASCB and 600AS are essential tools to use in underground coal mines.

• D evelops up to 8,500psi (586bar)

• D elivers up to 1.1g of grease per stroke

• 4 50g capacity

• S elf Priming Twin Lock System eliminates the possibility of dummy lubrication

• Ever-Flow System enables the gun to handle thick tacky greases even at low temperatures

• O ne hand operation, 4 jaw coupler and 30cm long flexible extension makes light work of arduous greasing applications

• M anufactured in Germany

600AS

ALEMLUBE LEVER ACTION

GREASE GUN

• D evelops up to 12,000psi (828bar)

• D elivers up to 1.6g of grease per stroke

• 4 50g capacity

• I ncludes extension locking knob with no tool required to adjust angle

• L arge diameter piston with long lever travel facilitates high volume greasing

• Twin Lock System eliminates the possibility of dummy lubrication

• Ever-Flow System enables the gun to handle thick tacky greases even at low temperatures

• M anufactured in Germany

440A

SAMOA

400G

GREASE GUN

TRIGGER ACTION

• D elivers up to 1.1g per stroke

• D evelops up to 3,500psi (241bar) grease pressure

• B arrel manufactured from 1mm thick cold draw precision seamless tube

• R olled large pitch thread will not wear prematurely

• I ncludes a 150mm long flexible extension and a heavy duty 4 jaw coupler

• Suits a 400g cartridge or bulk grease

DRUM GREASE

9611HS ALEMLUBE 20KG GREASE KIT

• S pool valve air motor design requires minimum maintenance and results in fewer pump failures

• 5 0:1 ratio grease pump develops grease pressures up to 7,500psi (517bar)

• Delivery rates of up to 0.9 kg/min

• S ingle shot or continuous flow hand piece provides greater lubrication options

• M ostly all that is required to undertake repairs is 5 minutes and a screwdriver facilitating substantial savings in labour costs and downtime

• Q uiet operation cuts noise levels by up to 30%

• Free of external aluminium components

• Manufactured in the USA

424170S SAMOA 20KG GREASE KIT

• 5 5:1 ratio air motor develops grease pressures up to 7,700psi (550 bar)

• M aximum free flow delivery of 540g/min (at 100psi)

• W ill handle high viscosity, tacky grease up to NLGI2

• K it comprises a 55:1 ratio pump plus drum cover, follower plate, carry handle, 2 metres of hose, z swizel and control valve

• I ntegral foot valve filter protects the pump tube from contamination

• Fully serviceable with individual spare parts and service kits readily available

• Quiet operation due to exhaust muffler: 92 dB

• Delivery rates of up to 0.8 kg/min

• Manufactured in Spain

GREASING

66880SN

ALEMLUBE GREASE CONTROL VALVE

• S tandard duty steel & non aluminium construction

• Made of steel so ideal for underground coal use

• Rigid extension with 3 jaw coupler

• Inlet: 1/4" BSP(f)

• Maximum pressure rating: 7,000psi (483bar)

• Robust design

• Manufactured in China

6320-3

ALEMITE GREASE CONTROL VALVE

• H eavy duty grease control valve capable of continuous flow or preset measured shots

• 1/4" NPT(f) inlet thread

• USA’s industry standard grease control valve

• Manufactured in the USA

HP-N-350S

COXREELS 3/8" SPRING REWIND GREASE HOSE REEL

• C omplete with 15m x 3/8" ID R2 hose and adjustable hose stop

• FRAS compliant hose assembly

• N o external aluminium components

• G uide arm adjusts to wall, floor, vehicle and overhead positions

• M ulti-position lock ratchet mechanism secures hose at desired length

• R olled edges & ribbed discs provide strength & safety

• 1" solid steel axle & lubricated precision bearings for smooth rotation drum pump

• S wivel rating: 4,000psi (276bar)

• Weight: 32kg

• Manufactured in the USA

ACCESSORIES

14513

ALEMLUBE

GREASE GUN COUPLER

• I ndustrial quality 4 jaw coupler for standard hydraulic grease nipples

• 1/8" BSP(f) thread

• 12mm spanner slot assists during coupler replacement

• E asy on, easy off

• M anufactured and designed for heavy duty industrial applications

• 14 514: as above but 3 jaw coupler

331107

ALEMITE GREASE SWIVEL

• 1/4" NPT (m) x 1/4" NPT (m)

• S wivel rating: 10,000psi (690bar)

• M anufactured in the USA

14512

ALEMLUBE QUICK RELEASE

GREASE GUN COUPLER

• Works with all grease gun types - pneumatic, manual & battery

• 1/8" BSP(f) thread

• M aximum working pressure of 10,000psi (690 bar)

• 4 hardened spring steel jaws resilient under high pressure

• 9 0mm long

• 14511: as above but 1/8" NPT(f) thread

ALEMLUBE

GREASE GUN FLEXES

• I ndustrial quality, genuinely high pressure, high flexibility grease gun flex

• M inimum burst pressure of 14,500psi (1,000bar)

• Polyamide hose maximises product life

• M ade in Germany

• 14 551: 30cm; 14552: 45cm; 14553: 70cm

OIL

9668S

ALEMLUBE

5:1 RATIO

OIL TANK PUMP

• N o external aluminium

• F low rates of up to 28L/min

• C apable of pumping medium weight oils over longer distances through hose reels

• Q uiet operation cuts noise levels by up to 30%

• M ostly all that is required to undertake repairs is 5 minutes and a screwdriver facilitating substantial savings in labour costs & downtime

• 9 669-BS suits 205L drums

8828SN

ALEMLUBE

20L GEAR OIL

DRUM PUMP

• D elivers 110mL of lubricant on the down stroke

• I deal for the topping up of engines, differentials, oil and gear boxes

• D rain back nozzle holster ensures that excess oil ends up back in the drum

• Free of external aluminium components

• H igh quality manufacturing and smooth pump action ensures efficiency and a long service life

• D esigned to be used in 20L drums

• 8 878SN as above but for 60L drums

10028

ALEMLUBE

HEAVY DUTY

20L GEAR OIL

DRUM PUMP

• H eavy duty fully serviceable drum pump delivers 170mL on the downstroke

• N on-drip nozzle & drain back holster ensure a clean, safe workshop

• H eight adjustable bung adaptor & two extra adaptors to suit local & international 20L drums

• 1.8m long rubber assembly ensures a long service life

• I deal for use with engine, hydraulic, gear, diff and synthetic oils

201S

ALEMLUBE

OIL ROTARY

DRUM PUMP

• C an syphon in both directions

• D elivers up to 20L/min or 0.33L per rotation

• S uitable for the transfer of oil diesel fuel

• S uits 60L & 205L drums and bulk tanks

• C omes complete with 1.1m of hose

• 2 " BSP bung adaptor

• M anufactured in China

SOI700S ALEMLUBE

S SERIES OIL HOSE REEL

• Working pressure of up to 2,000psi (138bar)

• 1/ 2 " BSP(f) inlet/outlet

• S upplied with 10m x 12mm ID hose and lead in hose

• N o external aluminium components

• F RAS compliant hose assembly

• Impact resistant UV stabilised covers for maximum durability

• A utomatic and positive latching mechanism

• H igh flow swivel and fluid path

• A djustable hose stop for convenient lead length positioning

• D etachable steel mounting bracket enables 180° hose reel rotation

• C an be wall, ceiling or floor mounted

• N et weight of 15.6kg

COXREELS

1/2" SPRING REWIND

OIL HOSE REEL

• S upplied complete with 15m x 1/2" ID R1 hose

• N o external aluminium components

• F RAS compliant hose assembly

• S wivel rated to 2,500psi (172bar)

• S olid one piece, heavy gauge 6mm steel base & support post for maximum stability

• 24mm solid steel axle & lubricated precision bearings facilitate smooth rotation

• S uitable for air, water and oil applications

• Weight of 31kg

SAMOA

3/4" SPRING REWIND

OIL HOSE REEL

• H eavy duty full metal double pedestal construction

• No external aluminium components

• FRAS compliant hose assembly

• Hose capacity: 15m x 19mm ID

• 1,500psi (103bar) hose pressure rating

• 3 /4"(f) inlet; 3/4"(f) outlet threads

• Manufactured using 4mm gauge steel

• E poxy coated for increased wear resistance

• Weight of 38kg

• Suitable for air, water & fuel

AIR & WATER

SA400SN

ALEMLUBE S SERIES AIR HOSE REEL

• 15m x 12mm ID hybrid polymer hose

• Working pressure of 300psi (20bar)

• 1/2" BSP(f) inlet & outlet

• H ybrid polymer hose is more flexible, easier to handle & longer lasting

• Impact resistant UV stabilised covers for maximum durability

• A utomatic & positive latching mechanism

• A djustable spring tension

• C an be wall, ceiling or floor mounted

SH-N-450S

COXREELS 1/2" SPRING REWIND AIR HOSE REEL

• C omplete with 15m x 1/2" ID air line hose

• S wivel rating: 300psi (21bar)

• Weight: 27kg

• M anufactured in USA

AWP1215

ALEMLUBE AIR & WATER HOSE REEL

• M aximum working pressure of 220psi (15bar)

• I ncludes 15m x 12mm ID hose & a 0.9m lead in hose

• C onstructed in high impact polypropylene

• S upplied with fitted high quality polyurethane hose & integral mounting bracket

• Powder coated integral wall/ceiling mounting bracket won’t corrode or distort

• D imensions of 435mm (H) x 235mm (W) x 500mm (D)

• M anufactured in Italy

552164

SAMOA

1/2" DIAPHRAGM PUMP

• F low rates of up to 50L/min

• Polypropylene body & TPE diaphragms

• A ir pressure operating range of 22 to 102psi (1.5 to 7bar)

• D elivery per stroke approximately 0.1L

• F luid inlet & outlet connections: 1/2" BSP(f)

• A ir inlet connection: 3/8" NPSM(f)

• M aximum dry suction head: 6m

• M aximum wet suction head: 8m

• Weight: 2.2kg

363054S

SAMOA 3/4" HIGH VOLUME OIL CONTROL VALVE

• 100% aluminium free & suitable for underground coal use

• M aximum working pressure of 1,450psi (100 bar)

• H igh volume oil control valve with 3/4" BSP(f) threaded inlet

• F low rates of up to 70L/min

• F lexible hose extension with semi-automatic non-drip nozzle

• S uitable for use with synthetic & mineral based lubricants, gear oil, hydraulic oil & fluids, ATF and antifreeze solutions

• Weight of 3.4kg

551164

SAMOA

1" DIAPHRAGM PUMP

• F low rates of up to 100L/min

• Polypropylene body & TPE diaphragms

• A ir pressure operating range of 22 to 102psi (1.5 to 7bar)

• D elivery per stroke approximately 0.25L

• F luid inlet & outlet connections: 1" BSP(f)

• A ir inlet connection: 3/8" NPSM(f)

• M aximum dry suction head: 4.5m

• M aximum wet suction head: 7m

• Weight: 2.2kg

ALP0821

ALEMLUBE

LUBE POD

• D imensions with all doors shut:

Overall length 3,000mm, Height 1,650mm Width 2,200mm

• Weight: Dry 4,000kg / Loaded 5,500kg (maximum)

• Tank & storage capacities:

Waste oil (exchangeable pod) 1,000L

Hydraulic oil (exchangeable pod) 1,000L

Gear oil 320 grade 205L

Gear oil 460 grade 205L

Grease 20kg

• A ir supply: Minimum 80psi, Maximum 120psi

• C onnection Minsup type “S”

• H ose reel reach: Oil & Grease – 15m / Waste oil – 10m

FUEL

8080-GS

ALEMITE LARGE CAPACITY OIL, FUEL AND AIR HOSE REEL

• Sealed spring cassette

• FRAS compliant hose assembly

• Suitable for use with air, water, oil and fuel

• Sealed and plated bearings

• 1,000psi (60bar) hose pressure rating

• Supplied complete with 15m x 1" ID hose

• L ifetime warranty on the hose guide assembly and latch pawl spring

• Weight: 2.2kg

8080-FS

ALEMITE HEAVY DUTY OIL AND AIR HOSE REEL

• C orrosion resistant, easy to install and incredibly durable

• L ifetime warranty on the hose guide assembly and latch pawl spring

• FRAS compliant hose assembly

• 25m x 19mm ID capacity reel

• Sealed spring cassette

• Sealed and plated bearings

1175-6-50S

COXREELS

HAND REWIND HOSE REEL

• Working pressures of up to 3,000psi (207bar)

• 1" NPT(f) inlet/outlet

• FRAS compliant hose assembly

• All metal construction

• Hand rewind hose reel with long handled lock pin

• Can store and retrieve up 15m x 25mm ID hose

• Hose not included

Head Office

22 Green Street

Brookvale NSW 2100

Phone: 02 9938 2999

Fax: 02 9938 6605

New South Wales / ACT 8 Grevillea Street

Eastern Creek NSW 2766

Phone: 02 9677 1555

Fax: 02 9675 1155

1125-5-50S

COXREELS

HAND REWIND HOSE REEL

• L ow profile hose connector ensures smooth even hose wraps

• FRAS compliant hose assembly

• Can store and retrieve up to 30m x 25mm ID hose

• Maximum working pressure of 3,000psi (207bar)

• Suitable for air, water, oil or fuel transfer

• Capable of storing and retrieving 15m x 19mm ID hose

Workshop Equipment Head Office

57-61 Smeaton Ave

Dandenong VIC 3175

Phone: 03 8768 8011

Fax: 03 8787 8266

Victoria / Tasmania 57-61 Smeaton Ave

Dandenong VIC 3175

Phone: 03 8787 8288

Fax: 03 8787 8266

www.alemlube.com.au

info@alemlube.com.au

Queensland / PNG

75 Kabi Circuit

Deception Bay QLD 4508

Phone: 07 3204 9166

Fax: 07 3204 1224

South Australia / NT 3 Nucera Court

Greenfields SA 5107

Phone: 08 8241 7111

Fax: 08 8241 7011

www.alemlube.co.nz

info@alemlube.co.nz

Western Australia

9 Kalinga Way

Landsdale WA 6065

Phone: 08 9302 4199

Fax: 08 9303 2095

New Zealand Unit 1/43

William Pickering Drive

Albany Auckland NZ

Phone: 64 9 447 1007

Fax: 64 9 447 1008