CAT Armored Face Conveyor AFC PF-6 1142 Armored Face Conveyor Operation & Maintenance Manual - PDF

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Operation Manual BUCYRUS- AFC PF-6 / 1142® Model - Armored Face Conveyor Doc. No.: 02-14-08

BUCYRUS ___________________________________________________ 2045 WEST PIKE STREET HOUSTON, PA 15342-1010

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________________________________________ Before starting to work preface

This manual is intended to provide basic operating information on BUCYRUS AFC systems. Additional information can be obtained by referring to the Parts Book supplied with your equipment, or by contacting your local BUCYRUS representative. The illustrations, descriptions and procedures contained in this manual pertain to the equipment as it was originally manufactured and delivered to your mine, and when the manual was approved for printing. BUCYRUS reserves the right to discontinue or revise machine models at any time, or change specifications, designs or procedures, without notice and without incurring obligations.

The equipment was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of manufacturing, this equipment was issued the appropriate approval numbers and nameplates indicating that it met the technical requirements of the appropriate agencies. Any change to the design or structure of this equipment, without the consent of BUCYRUS and these agencies, may void these approvals and render the equipment illegal or dangerous for use.

© BUCYRUS 2006

Strict compliance with all local and national laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment is necessary to ensure the personal safety of those working on, or around, this machine.

While this manual attempts to anticipate the most important operations and maintenance needs for this equipment, unforeseen circumstances may arise that have not been addressed in this manual. If any concerns or questions arise, please contact your BUCYRUS Service Representative immediately.

This work contains information protected under trade secret and other intellectual property laws, and is protected under the U. S. Copyright Act of 1976, as amended. This work is provided under license and the license is non-transferable.

Distribution and access is limited only to authorized personnel.

Disclosure, reproduction, distribution or unauthorized use may be a violation of federal and state laws and may subject the unauthorized user to criminal liability.

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_________________________________________________ Table of contents

TABLE OF CONTENTS ABOUT THIS MANUAL ......................................................................................... 1.0 about this manual ........................................................................................ 1.3 before starting work ..................................................................................... 1.3 new operating manual ................................................................................. 1.3 purpose of operating manual ....................................................................... 1.4 efficiency...................................................................................................... 1.4 service ......................................................................................................... 1.4 safety ........................................................................................................... 1.4 characters and symbols............................................................................... 1.4 YOUR SAFETY...................................................................................................... 2.0 your safety ................................................................................................... 2.3 state of the art.............................................................................................. 2.3 further operating manuals............................................................................ 2.3 installation and repair................................................................................... 2.4 operating conditions..................................................................................... 2.5 intended use ................................................................................................ 2.5 prerequisites for operation ........................................................................... 2.6 safety instructions ........................................................................................ 2.7 general......................................................................................................... 2.7 noise emission............................................................................................. 2.7 protective equipment ................................................................................... 2.7 symbol plates............................................................................................... 2.7 emergency stop ........................................................................................... 2.7 lock out ........................................................................................................ 2.7 cordon off working area ............................................................................... 2.7 ignition hazard ............................................................................................. 2.8 transport safety device................................................................................. 2.8 means of attachment ................................................................................... 2.8 mobile handling system ............................................................................... 2.8 environmental acceptability ......................................................................... 2.8 securing ....................................................................................................... 2.9 replacing components.................................................................................. 2.9 original parts ................................................................................................ 2.10 protective devices ........................................................................................ 2.10 handling of hydraulic fluids .......................................................................... 2.10 protective equipment hydraulic .................................................................... 2.10 maintenance and repair .............................................................................. 2.10 pressure relief valves................................................................................... 2.10 permissible hoses ........................................................................................ 2.11 laying hydraulic hoses ................................................................................. 2.12

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TABLE OF CONTENTS (Continued) overview of the safety instructions ............................................................... 2.14

INSTALLATION ..................................................................................................... 4.0 points to observe prior to installation ........................................................... 4.3 which tools are required for installation........................................................ 4.3 shutdown procedure .................................................................................... 4.4 notes on installation ..................................................................................... 4.4 overview of head end drive—1921 055 000 00 00....................................... 4.5 cross frame—5322 177 020 00 00............................................................... 4.6 tensionable drive frame—MEHS 65............................................................. 4.7 flange box .................................................................................................... 4.8 Flange plate—5322 166 610 00 00.............................................................. 4.9 directing bracket .......................................................................................... 4.10 stripper bracket—5322 177 520 00 00......................................................... 4.10 instructions for installation of the gear box................................................... 4.11 drive connection assembly—1958 515 140 00 00 ....................................... 4.12 pan line—return head/crusher ..................................................................... 4.13 cooling system—1946 004 170 00 00.......................................................... 4.14 how to assemble the chain .......................................................................... 4.16 adjusting chains........................................................................................... 4.17 installing the chain connector ...................................................................... 4.17 opening the block-type connector ................................................................ 4.18 flat-type connector ....................................................................................... 4.18 how to tension the chain assembly .............................................................. 4.19 fitting the chain locking device ..................................................................... 4.21 tensioning the conveyor chain ..................................................................... 4.22 sequencing the control of the conveyors ..................................................... 4.23 how to start-up the conveyor system ........................................................... 4.24

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STORAGE AND TRANSPORT.............................................................................. 3.0 corrosion protection ..................................................................................... 3.3 no direct exposure to sunlight...................................................................... 3.3 moisture and dirt .......................................................................................... 3.3 short-term storage ....................................................................................... 3.3 long-term storage......................................................................................... 3.3 natural aging................................................................................................ 3.3 transport ...................................................................................................... 3.4 temperatures below freezing ....................................................................... 3.4 electrical and electronic components........................................................... 3.4 machine parts .............................................................................................. 3.4 pan grippers................................................................................................. 3.5

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TABLE OF CONTENTS (Continued)

test run of the conveyor ............................................................................... 4.25 test operation of the conveyor ..................................................................... 4.26 how to dismantle and withdraw the conveyor system .................................. 4.28 OPERATION .......................................................................................................... 5.0 operation...................................................................................................... 5.3 who is allowed to operate the conveyor....................................................... 5.3 when may conveyor be started.................................................................... 5.3 mechanical lockout of the tensionable drive frame ...................................... 5.4 instructions on the maintenance of the conveyor......................................... 5.5 shearer mechanical stop.............................................................................. 5.5 lubrication schedule ..................................................................................... 5.6 central lubrication system ............................................................................ 5.6 lubricating points.......................................................................................... 5.7 inspection of the system .............................................................................. 5.7 weekly ............................................................................................... 5.7 monthly ............................................................................................. 5.7 instructions on the maintenance of the hydraulic system............................. 5.8 maintenance of the hydraulic system........................................................... 5.8 daily .................................................................................................. 5.8 weekly ............................................................................................... 5.8 instructions on the replacement of wear parts ............................................. 5.9 sprocket drum.............................................................................................. 5.9 assembly ..................................................................................................... 5.9 tappet........................................................................................................... 5.9 chain sprocket bolt....................................................................................... 5.10 tightening torque .......................................................................................... 5.10 chain sprocket.............................................................................................. 5.10 chain stripper ............................................................................................... 5.11

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TABLE OF CONTENTS (Continued) TECHNICAL DATA................................................................................................ 6.0 technical data............................................................................................... 6.3 permissible power ratings ............................................................................ 6.4 marking of the tensionable drive frame........................................................ 6.5 tightening torques ........................................................................................ 6.6 permissible media........................................................................................ 6.7 stability test.................................................................................................. 6.7 certificate ..................................................................................................... 6.9 hydraulic fluid maintenance ......................................................................... 6.10 quality of the process water ......................................................................... 6.10 lubricating greases and pastes .................................................................... 6.11 FOR YOUR INFORMATION .................................................................................. 7.0 our service ................................................................................................... 7.3

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1

About this manual

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________________________________________ Before starting to work

About this manual This chapter contains important information, which will simplify work with this manual for you. In addition, it contains information about the structure of the manual and on the characters and symbols used.

Before starting work right operating manual If you use an operating manual which has not been written for your conveyor type, you will endanger yourself and others. Ensure that the data on the Gearbox correspond to those in the operating manual.

This operating manual belongs to: type BUCYRUS-ARMORED FACE CONVEYOR—PF-6 / 1142 Serial No.: AFC 165759 The operating manual is to be used only for this ARMORED FACE CONVEYOR (AFC). new operating manual An operating manual for the conveyor must always be available at the place of operation. Send for a new manual immediately if the present manual is no longer complete or has become illegible.

© BUCYRUS 2006

Who is this operating manual intended for?

This operating manual is intended for all persons working with or on the AFC. All persons working at the face, at the edge of the face or in the entry must have read this operating manual.

This includes persons: responsible for transport, developing the raise, carrying out erection / disassembly, operating the conveyor, eliminating faults, carrying out daily routine work at the face or in the entry, carrying out maintenance operations, carrying out repairs. supervisory persons: instructing and/or supervising the above activities.

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Before starting to work _________________________________________ efficiency This operating manual is intended to help you work efficiently and safely with our product. It contains important information on all the activities related to the AFC. Read this operating manual completely and carefully. In particular, pay attention to the safety instructions.

Note the appearance and meaning of the safety and warning symbols. service If any points are not clear, please contact our Service Department. You will find our Service address in chapter 7 ”For your information”. safety Pay particular attention to the chapter ”Your Safety”. It contains important information drawing your attention to possible sources of danger.

Observe the information and follow the instructions contained in this operating manual. characters and symbols

These points contain information on dangerous situations.

Possible consequences are: Very serious injury or even death.

This symbol draws attention to dangerous situations. Possible consequences are: Light to moderately serious injuries and machine damage.

Points in the text marked with this symbol draw attention to harmful situations. Possible consequences are: Damage to the conveyor or damage in the immediate vicinity.

Points in the text marked with this symbol contain useful tips and information intended to facilitate work for you. They do not warn about harmful or dangerous situations.

Items in lists are marked with bullets.

—

Points in sub-lists are marked with an arrow at the start of the line.

Points in the text marked in this way describe individual work steps.

Follow these instructions step-by-step. They will help you carry out your work faster and, more importantly, safer.

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Points in the text marked with this symbol draw your attention to immediately impending danger. Possible consequences are: very serious injury or even death.

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Your safety

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_______________________________________________________________ _________________________________________________ Your safety your safety

This chapter contains important information for your safety.

Please read this chapter particularly carefully. The safety instructions and behavioral rules are intended to protect you from any dangerous situations and to help you carry out your work as safely as possible.

state of the art The AFC has been manufactured to the state-of-the-art and in accordance with recognized safety engineering regulations. You and others can nevertheless be exposed to dangerous situations e.g. as a result of environmental influences, machine damage or operator errors.

Do not make any alterations or modifications, which could impair the safety of the AFC. All modifications and changes must be approved by BUCYRUS. In addition to this operating manual, please be sure to also observe the relevant regulations and accident prevention ordinance applicable in your country.

Observe the safety and accident prevention regulations: of the mine, © BUCYRUS 2006

of the Mines Inspector and of the mining supervisory authorities further operating manuals Please read also the operating manuals of the components required for operation, e.g. electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

Personnel

The conveyor may only be operated by qualified, trained personnel. training The conveyor is only allowed to be operated by qualified

personnel who can provide proof of having been trained on the control system installed.

Reading of the operating manual, especially the chapter on safety, shall constitute a part of this training.

You must have an adequate knowledge of the mechanics, hydraulics and control engineering and must be able to prove this knowledge. .

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Your safety __________________________________________________ Installation and repair In general, installation and repair work shall be preformed only by persons who have been adequately trained for the special operating conditions requirements.

Installation and repair of the safety devices (pressure relief valves, extinguishers, etc.) the electrical equipment (control units, signalling devices, etc.) the hydraulic system

© BUCYRUS 2006

shall only be carried out by BUCYRUS service engineers or by specially trained personnel of the mining company.

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_________________________________________________ Your safety

Operating conditions Intended use The conveyor has been exclusively designed and manufactured for use as a conveyor unit in entries. Employ the conveyor only for its intended use!

Intended uses include: the haulage of coal and debris between face conveyor and belt conveyor systems.

Unauthorized use Uses which are not expressly defined as intended are unauthorized uses and are not allowed to be performed with the conveyor.

Such unauthorized uses include: the transport of persons the transport of objects of any kind such as e.g. single props, boards, spare parts, etc..

© BUCYRUS 2006

BUCYRUS accepts no liability for any damage resulting from any such unauthorized use.

Surrounding area conditions Suitable measures must be taken by the operator to combat the explosion hazards due to firedamp or the ignition of dust which might occur in a mine.

These include: adequate and consistent ventilation water spraying systems.

 If the mine gas concentration in the free cross section of the consistently ventilated areas of the face exceeds a certain percentage of the lower explosion limit (LEL) as defined in the respective national laws the M2 equipment has to be de-energized.

It may only be restarted by an authorized person.

The atmosphere in the mine has to be monitored in the hazardous locations to permit disconnecting the power supply of all pieces of equipment except of those which are relevant for the safety and suitable for use in explosive atmospheres. The M2 equipment has to be stopped at once and secured to prevent a restart if firedamp protection facilities are found to be damaged.

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Your safety __________________________________________________ Prerequisites for operation Putting the conveyor into service is prohibited until the complete system into which this conveyor is installed has been found to comply with the European Directive 94/9/EC and the Standard prEN1710.

As the equipment supplied is only part of an overall system the operator is responsible for meeting the necessary safety requirements or installing the required safety systems for the devices/components not included in the scope of supply of this equipment and/or other devices/components required for operation. These shall be marked according to the legal provisions applicable at the time they are placed on the market.

These include: facilities preventing unauthorized starting pre-start warning systems water spraying systems at hazardous locations with ignition hazard such as – inlet guides at the drive frame – chain guides safe lock-out command systems emergency stop systems dust extraction systems noise protection warning statements etc..

All electrical equipment required to operate the conveyor shall be marked according to the legal provisions applicable at the time when it is placed on the market.

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The equipment/conveyor is only allowed to be operated when the safety requirements have been met.

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_________________________________________________ Your safety

Safety instructions General rules general Always work with full concentration.

Familiarize yourself with your working environment. noise emission Always wear your personal protective equipment. This also

includes ear protectors as the noise emitted by the conveyor may at times exceed 85 dB(A), (e.g. when the conveyor is being emptied).

Inform your colleagues of:  your exact location,

 the work you are performing,  the time which you will probably require. protective equipment Start the conveyor only when it is in a good and safe condition

and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

© BUCYRUS 2006

Keep the signaling and lighting systems in a proper functional condition.

Observe the acoustic and optical start-up warnings of the conveyor. symbol plates Observe the symbol plates on the conveyor.

EMERGENCY STOP Press the EMERGENCY STOP switch immediately in the event

of faults or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately. Also operate the emergency stop switch if protective devices such as for example firedamp protection devices fail. lock out  Lock-out the conveyor while performing:

 maintenance work  inspection work  repair work.

Never enter a conveyor that has not been locked out. cordon off working areas Cordon off your working area widely for monorail and mobile

handling systems. Never allow parts of your body to come between parts which could move, such as e.g.: conveyor chains flights chain sprockets tensionable drive frame.

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Your safety __________________________________________________ ignition hazard

Be sure to observe the intervals specified for maintenance and checks of the conveyor as hot surfaces might cause an ignition of explosive atmospheres (air) and dust.

Observe the separate operating manuals of the components used.

Storage and transport Maintain the prescribed storage periods and observe the instructions for storage.

Do not store materials or parts in the travelway or in your working area.

Inform the persons involved about the intended transport route and the anticipated duration of the transport. transport safety device Ensure that the transport safety devices are correctly fitted.

Fix all moving parts with transport locks.

means of attachment Connect the lifting equipment only to the points of attachment

provided for that purpose. Observe the different load limits of the attachment points. Also observe the instructions on the transport sheets.

Only use means of attachment which are in a good condition and have been designed for the loads to be handled.

For round components use transport straps, only. Never use chains or steel cables for this purpose.

Do not damage the treated or polished surfaces of shafts, sealing surfaces, etc.

Transport the pans only with conveyor pan grippers. mobile handling systems When using mobile handling systems for transport make sure

that the center of gravity is as low as possible.

Installation and start-up During installation, secure the electric motors fitted to prevent their unauthorized or unintentional starting. environmental acceptability When working with oils, greases and other chemical substances,

observe the safety regulations applicable to the product.

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Never stand under unsupported parts or suspended loads.

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_________________________________________________ Your safety environmental acceptability Dispose of cleaning rags, etc. which have been soiled with oil,

grease or other chemical substances in an environmentally safe manner.

Operation Operate the control system only if you have a profound knowledge of the control elements and their functions. It is necessary that you have been task trained on the respective control system.

Before switching it on, ensure that there are no persons in the conveyor.

Check that all protective devices are installed on the conveyor and function properly.

© BUCYRUS 2006

Clean the control panel at regular intervals. Ensure that the operating symbols are legible in order to avoid any operator errors and resulting accidents.

Maintenance and repair Be sure to observe the prescribed maintenance and inspection intervals.

Inform the supervisory personnel and the face crew of any maintenance and repair operations. Give them information on the intended operations and the anticipated duration. securing Secure your working area over a wide range, in order to avoid

endangering other persons.

Lock out the conveyor and secure it to prevent unauthorized and unintentional restarting. replacing components Stop and lock-out the conveyor and prevent from restarting

before replacing any defective components.

Immediately remove defective components from the face in order not to hinder the crew and to prevent these parts being reinstalled elsewhere.

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Your safety __________________________________________________ Pass them on for servicing without delay. original parts Use only spare parts which satisfy the specified technical

requirements. This is only ensured with original BUCYRUS spare parts. Please refer to the spare parts lists for the order numbers.

For raising the conveyor use only:  the lifting points provided,

 conveyor pan grippers designed for the pans on the conveyor,  hoists with adequate load-carrying capacity.

On no account should brackets of cylinders be used as they are not designed to withstand tensile loads. protective devices

Refit any protective devices removed immediately after completion of the work and check that they function properly.

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections. protective equipment hydraulic When removing protective equipment which includes hydraulic

components keep in mind that these components may be pressurized. You could be severely injured by hydraulic fluid jetting out in an uncontrolled manner. Therefore it is imperative that you depressurize the hydraulic components before removing the protective equipment.

Never use hydraulic fluids for rinsing or cleaning. Hydraulic fluids represent a very serious danger to health. maintenance, repair

Only persons who have and can demonstrate a special knowledge of hydraulics are allowed to work on the hydraulic system. pressure relief valves

Make sure that pressure relief valves are always provided with protection caps. Replace defective caps without delay.

 Carry out a visual inspection of all the hydraulic components at regular intervals. In particular check that:  the hoses are not pinched or trapped.

 the hoses have no bubbles or blisters.  the hoses or the outer sheathes of the hoses are not abnormally rigid or hard.

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handling of hydraulic fluids Hydraulics

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_________________________________________________ Your safety

 the outer sheath of the hose is not damaged.  the connectors are securely inserted into the sockets.  the connections are leak-tight.

Ensure that no dirt enters the hydraulic system during repair work. Dirt in the hydraulic system can cause serious damage in the whole system! Flush out the hydraulic lines thoroughly before connecting.

If hydraulic hose couplers are difficult to disconnect or cannot be disconnected, the hydraulic line may still be pressurized. Be sure to depressurize the line before disconnecting couplers.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely.

Never use nails, wire or similar materials for securing.

After finishing repair work, check all connectors and connections for leaks before pressuring the system again.

© BUCYRUS 2006

permissible hoses Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn O-rings.

Replace hydraulic hoses only with hoses of the same or a higher quality.

Observe the date of manufacture stamped on the hydraulic hoses. Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

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Your safety __________________________________________________ Never try to hold a pulsing hydraulic hose. Depressurize the line in question immediately.

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage. laying hydraulic hoses Lay the hydraulic hoses properly behind the brackets and clamps

provided for them.

Always lay hydraulic hoses so that they: always have a little slack, Laying hydraulic hoses slack

Laying hydraulic hoses twisted

are not bent directly behind the connections (distance minimum 1.5 x normal diameter) Laying hydraulic hoses bending

cannot chafe

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are not twisted

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_________________________________________________ Your safety Laying hydraulic hoses crossing

are not kinked do not have to withstand tensile strains are protected against thermal radiation

© BUCYRUS 2006

are accessible at all times.

Push hydraulic hoses into the sockets only by hand. Never try to drive the hydraulic hoses in with a tool as this will damage the connections.

When installing the hydraulic hoses, ensure that they cannot be: torn out, kinked, crushed, driven over or twisted by the movement of the equipment.

Laying hydraulic hoses, connections on moving parts

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Your safety __________________________________________________ Overview of the safety instructions This is a summary of all the safety instructions which have to be observed in the following chapters. This summary is intended only to give you an overview of all the instructions. In some cases, there is no logical relationship between the individual instructions.

Chapter 3: Storage and transport

DANGER

YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. OBSERVE THE SAFE WORKING LOAD OF THE LIFTING EYES AND KEEP A SAFE DISTANCE AWAY FROM SUSPENDED LOADS.

Never use only one pan gripper. The pan(s) could slip out of the gripper if only one gripper is used, seriously injuring or even killing you. Always use two pan grippers!

IMPORTANT

TAKE CARE TO ENSURE THAT NEW SUPPLIES ARE STORED SEPARATELY FROM EXISTING STOCK AND THAT REMOVAL TAKES PLACE ON THE ”FIRST IN, FIRST OUT” PRINCIPLE. Chapter 4: Installation

DANGER

NEVER USE THE DRIVES FOR TENSIONING OR COUPLING THE ENDS OF THE CHAIN. The drives generate chain forces which can destroy the chain locking device. As a result, you or others can be seriously injured or even killed.

With the chain locking device installed operate the chain assembly only by means of a hydraulic chain tensioning device.

Working on chains which are under tension requires particular care. Cordon off your working area and make sure that no unauthorized persons are present in this area. During the tensioning procedure, ensure that all persons are kept out of the danger area, i.e. along the conveyor chain and in the immediate vicinity of the drives.

Always work from alongside of the conveyor chain.

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USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR THE WARNING TRANSPORT OF LOADS. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.

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_________________________________________________ Your safety When using an additional pulling device (i.e. lifting tackle with adequate load limit) for coupling the ends of the conveyor chain, the chain ends must not be fitted and pulled with so called Clinks (chain link cut open). The C-links could fracture under the load. You could be seriously injured or even killed by the recoiling chain.

Use only the chain connectors specified for fastening and pulling the chain ends.

You could be seriously injured or even killed by a jumping hydraulic hose.

Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides.

Never use nails, wire or similar materials for securing.

© BUCYRUS 2006

Make sure that nobody is present in the danger area of the conveyor system during the test run! In this phase, a safe distance should be kept with respect to the conveyor as e.g. due to installation errors hazards may occur which would not occur during normal operation.

These hazards could cause severe injuries or even death! Make sure that nobody is present in the danger area of the conveyor system during the test operation! In this phase, a safe distance should be kept with respect to the conveyor as e.g. due to installation errors hazards may occur which would not occur during normal operation.

These hazards could cause severe injuries or even death!

WARNING

TAKE CARE TO ENSURE THAT THE CHAIN CURTAIN IS IN PLACE AND IS NOT DAMAGED. IMMEDIATELY REPLACE ANY DEFECTIVE OR MISSING PARTS. MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM WHEN YOU START OPERATING THE CONVEYOR. PARTICULARLY DURING THE FIRST STARTUP A SAFE DISTANCE SHOULD BE KEPT WITH RESPECT TO THE CONVEYOR AS E.G. DUE TO INSTALLATION ERRORS HAZARDS MAY OCCUR WHICH WOULD NOT OCCUR DURING NORMAL OPERATION!

C

SERIOUS DAMAGE CAN BE CAUSED TO THE CONVEYOR AND THE DRIVES AS A RESULT OF INCORRECT INSTALLATION. THE CONVEYOR AND ITS DRIVES CAUTION SHOULD THEREFORE ONLY BE INSTALLED UNDER THE INSTRUCTION OF SPECIALISTS FROM BUCYRUS.

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Your safety __________________________________________________ Use only the lifting points provided during transport and installation! Always use all four lifting eyes!

Never attach lifting equipment to the drive frame side panels!

Lubricate the whole drive frame before start-up! The lubrication points are marked in red.

Please take care to observe the respective separate operating manuals (e.g. for gearboxes, motors, etc.).

Serious damage can be caused to the conveyor and the drives as a result of incorrect installation. The conveyor and its drives should therefore only be installed under the instruction of specialists from BUCYRUS.

Blows on the motor shaft and/or gearbox shaft will damage the roller bearings! Therefore always use a mounting and pulling-off device for installation and removal of the coupling parts! Never operate the conveyor without cooling system. Check all components of the cooling system at least once every shift to make sure they function properly.

NOTICE

DIRT CAN ENTER THE GEAR BOXES AND COUPLINGS IF THE O-RINGS OF THE FLANGE PLATE ARE NOT CORRECTLY INSTALLED. THIS CAN RESULT IN SERIOUS DAMAGE TO THE GEAR BOXES AND COUPLINGS! ENSURE THAT THE O-RINGS ARE IN THE CORRECT POSITION WHEN INSTALLING THE FLANGE PLATE. Please be sure to also observe the operating manuals of the electric motors used.

Make sure that all connection elements are in place and fastened properly (e.g. tightening torque of bolted connections).

Starting the blocked conveyor can result in serious damage to the drives.

Remove the chain locking device before starting the conveyor.

In addition, observe the instructions in the separate operating manuals for the conveyor components, e.g. electric motors, gear boxes, drive connections, etc.

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© BUCYRUS 2006

Please be sure to observe the separate operating manuals for the gear box used. If the flange position ”W” at the electric motor is larger than at the drive connection, the motor shaft and gear box drive shaft bearings will be strained. This can result in damage to the gearbox and the electric motor!

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_________________________________________________ Your safety Use only biologically degradable vegetable oils of water hazard class 0 for lubricating the sprockets as the sprocket lubrication system is a total loss system. Be sure to observe the relevant environmental protection regulations.

DURING INSTALLATION, A DRAW ROPE MUST BE LAID IN THE BOTTOM RACE OF THE CONVEYOR WITH WHICH THE CONVEYOR CHAIN CAN LATER BE DRAWN INTO THE IMPORTANT BOTTOM RACE! The head part of the tensionable drive frame is mechanically locked in the sliding frame by means of pins during operation (see section ”Tensionable drive frame SPR 3”).

Remove the locking elements before extending or retracting the cylinders.

© BUCYRUS 2006

Be sure to tighten the bolts to the specified torque (see ”Tightening torques”). Be sure to tighten the bolts to the specified torque (see ”Tightening torques”).

Be sure to tighten the bolts to the specified torque (see ”Tightening torques”).

Take care during installation of the pans that the pans are laid in as straight a line as possible. Assemble the pans in such a way that the overlapping part of the deckplate is facing in conveying direction. The necessary bores and fittings are provided for the attachment of accessories.

Be sure to tighten the bolts to the specified torque (see ”Tightening torques”).

Grease the bevels with lubricating grease B3 before fitting nut M 72 to the screw bolt (see chapter 6, section “Lubricating greases and pastes”).

Be sure to tighten the bolts to the specified torque! The required torque with mtotal = 0.14 is 3670 Nm. Take care to ensure that the spraying system is always operating while the conveyor is running. Keep the spraying system always in a proper condition.

Check which type of chain connector is installed. The position and method of installation differs for the individual connector types. Observe the installation instructions of the respective manufacturer.

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Your safety __________________________________________________ Applying the required pretension to the chain assembly via lifting tackles or throttled drives is very inaccurate and therefore not recommended. A chain assembly without optimum pretension increases wear and reduces the life of the installation.

The use of a chain tensioner permits to apply the optimum pretension to the chain. Be sure to observe the separate operating manual for the chain tensioner used.

Chapter 5: Operation

DANGER

INCORRECT OPERATION ENDANGERS YOURSELF AND OTHERS! INCORRECT OPERATION OF THE MACHINE IS OFTEN THE CAUSE OF VERY SERIOUS ACCIDENTS! OPERATE THE CONVEYOR ONLY WHEN YOU HAVE BEEN SUFFICIENTLY TRAINED ON THE INSTALLED CONTROL UNIT AND HAVE READ AND UNDERSTOOD ALL THE OPERATING MANUALS ON THE CONVEYOR SYSTEM. SHOULD ANYTHING BE UNCLEAR, PLEASE CONTACT YOUR SUPERIOR.

REPORT DAMAGE, DEFECTIVE COMPONENTS OR OTHER FAULTS TO THE RESPONSIBLE SUPERIOR IMMEDIATELY! CHECK ON WEAR OF THE CHAIN SPROCKETS AT LEAST CAUTION EVERY FOUR WEEKS! TURN THE CHAIN SPROCKET AS SOON AS THE SIZE OF THE MARKS INDICATING THE RATE OF WEAR HAS BEEN REDUCED BY HALF (APPROX. 4 MM).

PLEASE NOTE THAT THE LIFE OF THE TURNED CHAIN SPROCKET MAY BE MUCH SHORTER THAN THE ”INITIAL PERIOD OF USE” OF THE CHAIN SPROCKET. THIS IS DUE TO TOLERANCES IN THE HARDNESS PENETRATION DEPT. THEREFORE CHECK ON THE WEAR OF THE TURNED SPROCKET AT LEAST EVERY 2 WEEKS. Should the stripper work loose during operation, the chain sprocket or the drive frame could be damaged. Be sure to tighten the M24-8.8 fastening bolts to the specified torque during installation! The required torque is 655 Nm.

NOTICE

DURING OPERATION, THE RE-LUBRICATION INTERVALS MUST NOT EXCEED 100 HOURS. LUBRICATION MUST BE CARRIED OUT WITH THE CONVEYOR RUNNING, AS ONLY THEN WILL THE GREASE BE DISTRIBUTED UNIFORMLY!

DURING OPERATION, THE HEAD PART OF THE TENSIONABLE DRIVE FRAME IS LOCKED MECHANICALLY WITH THE SLIDING FRAME BY MEANS OF PINS (SEE SECTION ”MECHANICAL LOCKOUT OF THE TENSIONABLE IMPORTANT DRIVE FRAME”). REMOVE THE LOCKING ELEMENTS BEFORE EXTENDING OR RETRACTING THE CYLINDERS.

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© BUCYRUS 2006

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_________________________________________________ Your safety Inspect and maintain all the components of the hydraulic system such as pump station, filter systems, etc. in accordance with the corresponding operating manual.

Further information is contained in DIN 24320.

Chapter 6: Technical data

NOTICE

USE ONLY HYDRAULIC FLUIDS FOR WHICH A VALID CERTIFICATE ISSUED BY BUCYRUS GMBH HAS BEEN MADE AVAILABLE TO YOU. OTHERWISE, THERE IS THE DANGER OF SERIOUS DAMAGE TO THE HYDRAULIC EQUIPMENT AND THE LOSS OF WARRANTY CLAIMS.

THE TIGHTENING TORQUES STATED IN THE SPARE PARTS LISTS HAVE TO BE OBSERVED, AS WELL, FOR IMPORTANT INSTALLATION AND MAINTENANCE.

© BUCYRUS 2006

The lubricant, which is to be used, is specified in the respective chapter, e.g. assembly, maintenance ... .

The greases listed in the same table can be mixed. Other products may only be used if the supplier can guarantee that they are equivalent. Differently composed lubricating greases must not be mixed as this may change the consistency, i.e. the mixture can become thinner so that the lubrication effect is not sufficient. It may also be dangerous to use lubricating greases having the same saponification base but different origins.

In case of doubt, the manufacturer of the lubricating grease to be used should be contacted as to the compatibility of the grease in question.

The instructions for the use of the lubricating greases given under ”important” also apply to the lubricating pastes.

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© BUCYRUS 2006

Your safety __________________________________________________

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3

Storage and transport

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_________________________________________ Storage and transport This chapter contains important information on the correct storage and transport of the AFC. Observance of the instructions and tips will increase the service life and availability of the AFC. You will also be able to carry out the transport work quicker and more safely. Careful attention to the points in this chapter will help you to simplify your dayto-day work.

Storage of the equipment corrosion protection Components coated with temporary corrosion inhibitor are

protected for around six months. no direct exposure to sunlight Protect the equipment against direct exposure to sunlight. Store

the electrical equipment, electronic components, spare parts of rubber or plastic - such as seals and hoses - and hydraulic fluids only in closed rooms at temperatures of 15 C to 25 C. moisture and dirt Protect all parts of the equipment stored outdoors against

moisture and dirt, e.g. using tarpaulins.

© BUCYRUS 2006

The mounting surfaces of hydraulic components must be protected against corrosion and sealed with blind plates. Protect the hydraulic plug connectors and the connectors of the electrical cables with the caps and plugs supplied. short-term storage During short-term storage (approx. 4 weeks) of equipment

outdoors, but at temperatures above freezing, electrical components need not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

long-term storage During long-term storage (more than 4 weeks), the equipment

must not be stored outdoors. It must be stored in a dry, well ventilated room.

After a storage period of approx. two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage have prevented damage. On request, the inspection can be carried out by BUCYRUS. natural aging

Even with proper storage, seals and hoses are subject to natural ageing. A storage period of approx. two years is therefore quoted as an indicative value for these parts.

TAKE CARE TO ENSURE THAT NEW SUPPLIES ARE STORED SEPARATELY FROM EXISTING STOCK AND THAT IMPORTANT REMOVAL TAKES PLACE ON THE ”FIRST IN, FIRST OUT” PRINCIPLE.

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Storage and transport __________________________________________

Transport Load units; dimensions and weights Observe the transport sheets for the various transport units.

They contain information on: Dimensions Weight Lifting points Centre of gravity, etc.

Where technically possible, the load units have suitable lifting points for transport and assembly.

USE ONLY LOAD HANDLING DEVICES COMPLYING WITH THE TECHNICAL AND LEGAL REGULATIONS FOR THE TRANSPORT OF LOADS. YOU COULD BE SERIOUSLY WARNING INJURED OR EVEN KILLED BY FALLING LOADS. USE ONLY SUITABLE LOAD HANDLING DEVICES.

Before transport C is only permissible when certain measures were taken to meet these conditions at the design and manufacturing stages.

Nevertheless, the individual parts and devices of this equipment must not be subjected to sudden impact loads at such low temperatures and are only loaded statically or quasi-statically.

During transport of this equipment with floor-mounted vehicles at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads. At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to max. 25 kph for truck transport. electrical and electronic Electrical and electronic components must be removed for components overseas transport or prolonged storage outdoors unless these

components or the complete equipment is protected against harmful environmental influences by a suitable packaging. The electrical cables remain in the equipment. They must be carefully protected against transport damage and soiling of the connections.

Transport of the components machine parts Drive frame, gearboxes, motors, etc. are equipped with lifting

eyes or lifting points for transport.

In some cases you have to screw the lifting eyes into the bores provided before transport and to remove them again immediately after transport.

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© BUCYRUS 2006

temperatures below freezing Transport of equipment at temperatures between -21 C and -40

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_________________________________________ Storage and transport

DANGER

YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY FALLING LOADS. OBSERVE THE SAFE WORKING LOAD OF THE LIFTING EYES AND KEEP A SAFE DISTANCE AWAY FROM SUSPENDED LOADS.

pans Conveyor pans are generally equipped with lifting points (lifting

shackles). The lifting points can be on the sides or at the ends of the pans. The lifting shackles at the end of the pans have to be removed again after transport.

© BUCYRUS 2006

For the transport of pans not provided with lifting eyes pan grippers must be used.

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© BUCYRUS 2006

Storage and transport __________________________________________

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4

Installation

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___________________________________________________Installation

Installation Points to observe prior to installation Who is allowed to carry out installation?

Installation work is only allowed to be carried out by personnel having received adequate training to perform these tasks Work on:  the safety components (pressure relief valves, fire extinguishing equipment etc.),  the electrical equipment (control units, signalling devices, etc.) and  the hydraulic equipment (cylinders, directional control valves, hoses etc.) should only be carried out by BUCYRUS service engineers or by specially trained personnel.

Which tools are required for installation?

© BUCYRUS 2006

tool box You need a number of tools in order to be able to install the

conveyor properly. We recommend that you deposit a tool box at the drive. The box should contain the following tools: 1 fitter‘s hammer 1500 gr. 1 fitter‘s hammer 1000 gr. 5 cross chisels 200 x 20 x 12 mm 5 flat chisels 200 x 23 x 13 mm 3 hex. screwdrivers 1 x 5.5 x 100 mm 3 hex. screwdrivers 1.6 x 10 x 175 mm 5 water pump pliers 1 set of split-pin drifts 5, 6, 8, 10, 3 and 16 mm 1 metal-cutting saw bow with wooden handle 3 saw blades, HSS FLEX 24 teeth 1 pliers for retaining rings I VPJ-6 1 pliers for retaining rings A VPA-6 1 hex. socket offset screwdriver, 1000 CV N/SB 1 set of hex. socket offset screwdrivers 12 mm - 27 mm 1 torque wrench 100 - 500 Nm 1 torque wrench 20 - 100 Nm 1 torque multiplier 3500 Nm 1 set of hex. sockets 22 mm - 60 mm 1 power holder for repl. hex. 26809, 1 drive x 22 hex. 1 set of hex. pins for power holder 14 mm - 27 mm x 22 hex. 1 extension for power holder, 250 mm 1 socket spanner set 1481 06 MM C 1 socket spanner set 1672 09 MM C 1 converter for sockets 1539 C 1 set of sledge type ring spanners SG 41, 46, 55, 65 & 75 mm

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Installation ___________________________________________________ shutdown procedure In addition, various items of ancillary equipment and machines

are required at the point of installation. These include: lifting equipment with adequate load-bearing capacity means of attachment with an adequate lifting capacity impact wrenches incl. accessories drill incl. Accessories

Notes on installation SERIOUS DAMAGE CAN BE CAUSED TO THE CONVEYOR AND THE DRIVES AS A RESULT OF INCORRECT INSTALLATION. THE CONVEYOR AND ITS DRIVES SHOULD THEREFORE ONLY BE INSTALLED UNDER THE INSTRUCTION OF SPECIALISTS FROM BUCYRUS.

The sequence of operations during installation must be adapted to the individual conditions prevailing at the site. Before starting the work a detailed list of all steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

DURING INSTALLATION, A DRAW ROPE MUST BE LAID IN THE BOTTOM RACE OF THE CONVEYOR WITH WHICH THE CONVEYOR CHAIN CAN LATER BE DRAWN INTO THE IMPORTANT BOTTOM RACE! Take care during installation of the pans that the pans are laid in as straight a line as possible.

For tightening torques not stated in the installation instructions for the components please refer to the list in chapter 6. Please also observe the tightening torques specified in the spare parts lists provided.

Pins, holes, screws, bolts, and locking elements should be greased with grease A 1 (see Chapter 6, Section ”Lubricating greases and lubricating pastes”) prior to installation.

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© BUCYRUS 2006

PLEASE TAKE CARE TO OBSERVE THE RESPECTIVE SEPARATE OPERATING MANUALS (E.G. FOR GEARBOXES, MOTORS, ETC.).

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___________________________________________________Installation

© BUCYRUS 2006

Overview of head end drive—1921 055 000 00 00

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___________________________________________________Installation Assembly drive frame and drive Cross frame The cross frame MRKR 35 1300 is fitted at the head-end. The material to be conveyed is guided to entry conveyor via a screwed-on directing bracket.

C

USE ONLY THE LIFTING POINTS PROVIDED DURING TRANSPORT AND INSTALLATION! ALWAYS USE ALL CAUTION FOUR LIFTING EYES! NEVER ATTACH LIFTING EQUIPMENT TO THE DRIVE FRAME SIDE PANELS!

© BUCYRUS 2006

Cross Frame—5322 177 020 00 00

1—Cross Frame MKRK35 2—Side Wall Protection 3—Deck Plate 4—Transport Locking

5—Bolt {hh} din931-m24x12-8.8 6—Nut [hh] din934-M24-8 7—Transverse Assembly—Left Hand 8—Transverse Assembly—Right Hand

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___________________________________________________Installation Tensionable drive frame The tensionable drive frame MRHS 35 on the tail-end drive can be pushed hydraulically in the base frame for tensioning the conveyor chain in operation (see chapter 5, section “How to operate the tensionable drive frame”).

The tensionable drive frame is equipped with a bolted-on inlet guide (hold-down bracket (B)). The inlet guide can be replaced when worn (see chapter 5, section “Replacement of wear parts”).

The fine materials located on the guide ways (drive frame – base frame) can be rinsed via the three rinser connections (A). Using inspection plugs, close the connections again after rinsing.

© BUCYRUS 2006

Tensionable drive frame MRHS 65

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CAUTION! Lubricate the whole drive frame before commissioning (see section 5, chapter “Lubrication Points”).

CAUTION

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Installation ___________________________________________________ Flange box The flange box is the connecting link between the cross frame on the head-end drive and the KP gearbox.

Loose parts Make sure that the parallel keys required for torque support are \ properly fitted and fastened.

Tightening torque The fastening bolts must be tightened to the specified torque.

Tightening torques not listed here are given in the list in chapter 6 “Technical data”.

© BUCYRUS 2006

Flange box for MRKR 65—5322 166 610 00 00

(See spare parts list)

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___________________________________________________Installation Flange plate The flange plate is the connecting link between the tensionable drive frame and the P gearbox on the head-end drive and the tail end drive.

Loose parts Make sure that the parallel keys required for torque support are properly fitted and fastened.

Tightening torque The fastening bolts must be tightened to the specified torque.

Tightening torques not listed here are given in the list in chapter 6 “Technical data”.

© BUCYRUS 2006

Flange plate—5322 166 610 00 00

(See spare parts list)

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Installation ___________________________________________________ Directing bracket The directing bracket is only used on the head-end drive of a face conveyor system. It serves to redirect the conveying flow at right angles onto the subsequent conveyor unit. stripper bracket The directing bracket is positioned onto the drive frame and screwed down onto it in accordance with the hole pattern.

The screwed down strips for the stripper blade (2) can be changed when necessary (see chapter 5, section “Replacement of wear parts”).

© BUCYRUS 2006

Stripper bracket—5322 177 520 00 00

Deflector Bracket 2—Bolt {HH} din931-M36X150-10.9 3—Nut {Lock} din980-M36-10

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___________________________________________________Installation Instructions for installations of the gear box Notice!

Please be sure to also observe the separate operating manuals for the drives used.

© BUCYRUS 2006

All flange surfaces, centering bores, parallel keys and grooves must be clean and free from burr. Before flanging on, carefully grease the gearing – use B3 lubricating paste in accordance with chapter 6, section “Recommendations for lubricating greases and lubricating pastes”. The gearbox must be aligned in such a way that it can slide into position on centering bores and parallel keys or shear pins without tilting. Align the gearing such that tooth and tooth gap are exactly opposite one another to ensure that they mesh smoothly. Avoid damage to the gearing and make sure the gearbox is not tilted when installing it! The screw dimensions must be accurately chosen in accordance with the respective gearbox. Observe the tightening torque for the connection screws.

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Installation ___________________________________________________ Drive connection assembly—1958 515 140 00 00 The drive connection assembly comprises all components arranged between the electric motor and the gearbox. It mainly consists of a protective hood and a coupling.

© BUCYRUS 2006

The drive connection assembly is equipped with a crown gear. A chain tensioner can be flanged to the protective hood for coupling the conveyor chain. The pinion of the chain tensioner engages with the crown gear of the drive connection assembly.

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___________________________________________________Installation Pan line – return head/crusher The pans between the return unit and the crusher are interconnected by means of dog bones (see section “Pan connection”).

Return head 1500 The return head is designed for the non-driven deflection of the stageloader chain. It is connected with the adaptor pan by means of anchor dog bones (see section “Anchor dog bones”).

The self-aligning roller bearings of the chain sprocket assembly are provided with a constant lifetime oil supply. The bearings are sealed against the ingress of dirt and water by an axial face seal which has to be supplied with grease regularly (see chapter 5, section ”Lubrication”).

The face seals are lubricated at both ends via the lubricating nipples in the bearing covers. The covers are provided with a grease inlet (lubricating nipple) and a grease outlet (check valve) each.

© BUCYRUS 2006

Return head

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Installation ___________________________________________________ Cooling system The cooling system prevents the conveyor gear boxes and motors from overheating.

NEVER OPERATE THE CONVEYOR WITHOUT COOLING SYSTEM. CHECK ALL COMPONENTS OF THE COOLING SYSTEM AT LEAST ONCE EVERY SHIFT TO MAKE SURE CAUTION THEY FUNCTION PROPERLY.

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© BUCYRUS 2006

Cooling system

See Spare Parts List for details.

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___________________________________________________Installation Cooling system—1946 007 170 00 00

© BUCYRUS 2006

See

Spare Parts List for details.

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Installation ___________________________________________________

How to assemble the chain Chain assembly The chain assembly consists of preassembled individual chain strands comprising the following components: flights with mounting elements chain length chain connector.

The flights are bolted to the horizontal links of the chain 34x126.

The distance between flights is 756 mm.

Chain—5951 716 060 00 00

1– Power Chain 2-Block Type Connector 3-Chain Bow 4-Flight bar 5-Bolt 6-Nut 8-Chain Block Device 9-Fuse Link

NOTICE

Make sure that all connection elements are in place and fastened properly (e.g. tightening torque of bolted connections).

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Twin center chain assembly with flights

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___________________________________________________Installation Adjusting chains Adjusting chains are provided for adapting the length of the chain to the length of the conveyor, e.g. for shortening the chain in the event of too much slack developing.

Installing the chain connector The individual chain strands are joined with connectors. The chain connectors described here are block-type and flat-type connectors.

CHECK WHICH TYPE OF CHAIN CONNECTOR IS INSTALLED. THE POSITION AND METHOD OF INSTALLATION DIFFERS FOR THE INDIVIDUAL IMPORTANT CONNECTOR TYPES. OBSERVE THE INSTALLATION INSTRUCTIONS OF THE RESPECTIVE MANUFACTURER. BLOCK-TYPE CONNECTOR

© BUCYRUS 2006

A block-type connector must always be installed such that is passes over the sprocket drum in vertical position. The

assembled connector halves are held together with roll pins.

Normal size of the chain

t

Permissible deviation

a maximum

b maximum

c maximum

l maximum

26 X 92

92

± 0.9

28

75

28

213

30 X 108

108

± 1.1

32

87

32

252

34 X 126

126

± 1.3

37

99

36

297

38 X 137

137

± 1.4

41

111

40

322

42 X 146

146

± 1.5

45

115

46

341

48 X 144 *)

144

± 1.5

51

124

54

334

*) SPECIAL TYPE

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Installation ___________________________________________________ Opening the block-type connector:  Drive out the roll pin(s).

 Push the block connector halves in the direction of the arrows.

The block connector is open.

Closing the block connector:  Push the block connector halves together opposite the direction of the arrow.  Drive in the roll pin(s).

The block connector is closed.

Please keep in mind that dimension b of the flat-type connectors is larger than dimension b of the respective round steel link chain according to DIN 22252. Therefore, make sure to check the passage dimension of vertically installed flat-type connectors, e.g. in the bottom race of the conveyor.

Also observe the position of the chain link in the flight. Flat-type connectors are not allowed to be installed vertically in conveyors with flat link chains according to DIN 22255.

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Flat-type connector The flat-type connector can be installed in horizontal and vertical position.

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___________________________________________________Installation Dimensions of different flat type connectors Normal size of the chain

t

Permissible deviation

a maximum

b maximum

c maximum

l maximum

26 X 92

92

± 0.9

28

97

26

146

30 X 108

108

± 1.1

32

109

30

170

34 X 126

126

± 1.3

36

121

34

196

38 X 137

137

± 1.4

40

134

38

215

42 X 146

146

± 1.5

44

150

42

238

How to tension the chain assembly

© BUCYRUS 2006

NEVER USE THE DRIVES FOR TENSIONING OR COUPLING THE ENDS OF THE CHAIN. THE DRIVES GENERATE CHAIN FORCES WHICH CAN DESTROY THE CHAIN LOCKING C DEVICE. AS A RESULT, YOU OR OTHERS CAN BE SERIOUSLY INJURED OR EVEN KILLED. WITH THE CHAIN LOCKING DEVICE INSTALLED OPERATE THE CHAIN CAUTION ASSEMBLY ONLY BY MEANS OF A HYDRAULIC CHAIN TENSIONING DEVICE. ADJUSTING THE CHAIN

PRETENSION Using the chain locking device the chain assembly can be coupled and tensioned by means of the hydraulic chain tensioner. necessary tensioning force The tensioning force required for pre-tensioning the chain

assembly to suit the individual operating conditions is given in the operating manual for the chain tensioner. Set the pressure relief valve to the pressure value determined. correct pre-tension For trouble-free operation, the conveyor chain in an empty

conveyor must have such a pretension that only a moderate amount of slack is created under load during operation.

Chain pre-tension

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Installation ___________________________________________________ too much slack If too much slack develops climbing and jumping of the chains on

the chain sprockets will increase. excessive chain pre-tension Excessive tensioning of chains results in power losses as the

chains pass around the sprockets. This could lead to excessive wear of chains and sprockets, as well as extreme noise. changes in chain pre- As the face advances, the conveyor chain pretension can change tension during operation as the conveyor takes on different angles in both horizontal and

vertical directions.

Changes can also be caused by compression or stretching of the pan line and by changes in the face angle. In addition, changes in load are possible due to fluctuations in the properties of the material conveyed, e.g. changes in moisture content or in the debris content.

Finally the conveyor chain assembly itself changes due to increasing permanent elongation.

chains must therefore be constantly monitored with respect to the criteria slack chain and noise level. This can give an early indication of when a chain assembly has to be lengthened or shortened.

How to tension the conveyor chain The following auxiliary facilities are required for tensioning the chain assembly: chain locking device, hydraulic chain tensioner.

APPLYING THE REQUIRED PRETENSION TO THE CHAIN ASSEMBLY VIA LIFTING TACKLES OR THROTTLED DRIVES IS VERY INACCURATE AND THEREFORE NOT IMPORTANT RECOMMENDED. A CHAIN ASSEMBLY WITHOUT OPTIMUM PRETENSION INCREASES WEAR AND REDUCES THE LIFE OF THE INSTALLATION. THE USE OF A CHAIN TENSIONER PERMITS TO APPLY THE OPTIMUM PRETENSION TO THE CHAIN.

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© BUCYRUS 2006

monitoring the chain In order to ensure trouble-free operation with favorable drive assembly powers and long service lives of chains and sprockets, the

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___________________________________________________Installation Fitting the chain locking device  Place the two outer parts (claws) on the adaptor pan and fasten them by inserting the pins into the respective bores provided in the upper profile of the pan. The closed end of the outer parts should face in pulling direction.  Secure the claws by turning the pins half a turn.

 Place the center part on a horizontal chain link between two chain flights and the open end of the claws.

© BUCYRUS 2006

Fitting the chain locking device

 Next, pull the center part slowly into the outer parts until it meets with resistance.  Connect the parts by inserting the respective pins and secure the pins in the same way as the outer part pins by turning them one half turn.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 4.21

EM022621-0 (EN-US)

Installation ___________________________________________________ Securing the center section with pins

DANGER

DANGER

WORKING ON CHAINS WHICH ARE UNDER TENSION REQUIRES PARTICULAR CARE. CORDON OFF YOUR WORKING AREA AND MAKE SURE THAT NO UNAUTHORIZED PERSONS ARE PRESENT IN THIS AREA. DURING THE TENSIONING PROCEDURE, ENSURE THAT ALL PERSONS ARE KEPT OUT OF THE DANGER AREA, I.E. ALONG THE CONVEYOR CHAIN AND IN THE IMMEDIATE VICINITY OF THE DRIVES. ALWAYS WORK FROM ALONGSIDE OF THE CONVEYOR CHAIN.

The chain tensioner is used to bring the ends of the chain together in the drive area until the chain has been tightened without applying too much force.

BE SURE TO OBSERVE THE SEPARATE OPERATING MANUAL FOR THE CHAIN TENSIONER USED. IMPORTANT

DANGER

WHEN USING AN ADDITIONAL PULLING DEVICE (LE.G. LIFTING TACKLE WITH ADEQUATE LOAD LIMIT) FOR COUPLING THE ENDS OF THE CONVEYOR CHAIN, THE CHAIN ENDS MUST NOT BE FITTED AND PULLED WITH SO CALLED C-LINKS (CHAIN LINK CUT OPEN). THE C-LINKS COULD FRACTURE UNDER THE LOAD. YOU COULD BE SERIOUSLY INJURED OR EVEN KILLED BY THE RECOILING CHAIN. USE ONLY THE CHAIN CONNECTORS SPECIFIED FOR FASTENING AND PULLING THE CHAIN ENDS.

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© BUCYRUS 2006

Tensioning the conveyor chain

EM022621-0 (EN-US)

___________________________________________________Installation Please proceed as follows: Apply pressure to the tensioning motor of the tensioning device until the required chain pretension has been reached.  Separate the chain.

 Shorten or lengthen the chain.  Couple the chain.

The chain assembly is now pre-tensioned.

Removing the chain locking device The chain locking device is removed in the reverse order of installation.  Move the chain assembly forward briefly.

© BUCYRUS 2006

 Pull out the pins connecting claw and center part.  Remove the center part.  Pull out the pins from the claws.  Remove the claws from the pans.

NOTICE

STARTING THE BLOCKED CONVEYOR CAN RESULT IN SERIOUS DAMAGE TO THE DRIVES. REMOVE THE CHAIN LOCKING DEVICE BEFORE STARTING THE CONVEYOR.

Sequencing control of the conveyors Switching conditions between face & entry conveyors starting The entry conveyor must always start before the face conveyor. stopping The face conveyor must always be stopped before the entry

conveyor. faults If the entry conveyor stops as a result of a fault, the face

conveyor must be automatically switched off without delay. delay

A delay time of around 10 seconds should be allowed for startup. Be sure to adapt the delay to the conditions in the mine. The time of 10 seconds stated here should be regarded as an approximate value, only.

Switching conditions between head-end & tail-end drives starting On conveyors which are equipped with drive units at the head

and at the tail the individual drives have to be started and stopped one at a time to avoid an excessive formation of slack chain.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 4.23

EM022621-0 (EN-US)

Installation ___________________________________________________ starting

stopping

First, the tail-end drive is started, and after a certain time delay the head-end drive follows. An interlock facility must be provided to ensure that the tail-end drive always starts before the headend drive. If this cannot be guaranteed the conveyor is not allowed to start at all.

First, the head-end drive is stopped, and after a certain time delay the tail-end drive follows.

How to start-up conveyor system Start-up of the conveyor system must be carried out under the instruction of specialists from BUCYRUS.

NOTICE

IN ADDITION, OBSERVE THE INSTRUCTIONS IN THE SEPARATE OPERATING MANUALS FOR THE CONVEYOR COMPONENTS, E.G. ELECTRIC MOTORS, GEARBOXES, DRIVE CONNECTIONS, ETC.

Before start-up The following work has to be performed before beginning with the actual start-up procedure:  Align the conveyor.

 Remove all tools, auxiliary equipment, etc. from the conveyor and your working area.  Check all bolted connections, in particular the connections of the drives.  Check that all the bolted connections are tightened to the specified torque.  Check the hydraulic connections and pipes/hoses for leaks or damage.  Check the proper laying of all the supply lines.

 Check the hydraulic plug connectors. In particular, check that the coupling clamps are completely pushed in.

_________________________________________________________________ 4.24 VSVL / 01_________________________ BUCYRUS – AFC ©

© BUCYRUS 2006

MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM WHEN YOU START OPERATING THE CONVEYOR. PARTICULARLY DURING WARNING THE FIRST START-UP A SAFE DISTANCE SHOULD BE KEPT WITH RESPECT TO THE CONVEYOR AS E.G. DUE TO INSTALLATION ERRORS HAZARDS MAY OCCUR WHICH WOULD NOT OCCUR DURING NORMAL OPERATION!

EM022621-0 (EN-US)

___________________________________________________Installation

DANGER

You could be seriously injured or even killed by a jumping hydraulic hose. Secure the connectors of the hydraulic elements only with the proper coupling clamps. Always fasten the clamps completely and with both sides. Never use nails, wire or similar materials for securing.

 Check the oil level and the cooling of the gearboxes.  Check the cooling of the electric motors.  Check the direction of rotation of the electric motors.  Check the electrical connections.  Test the sequencing control of the conveyor drives.  Test the function of the signaling devices and the intercom system.

Test run of the conveyor

© BUCYRUS 2006

DANGER

MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM DURING THE TEST RUN! IN THIS PHASE, A SAFE DISTANCE SHOULD BE KEPT WITH RESPECT TO THE CONVEYOR AS E.G. DUE TO INSTALLATION ERRORS HAZARDS MAY OCCUR WHICH WOULD NOT OCCUR DURING NORMAL OPERATION. THESE HAZARDS COULD CAUSE SEVERE INJURIES OR EVEN DEATH!

test run of the empty conveyor When you have checked the conveyor and remedied any faults

discovered, the proper interaction of the individual components of the complete system must be checked. For this purpose, carry out a test run with the empty conveyor for approx. ½ hour.

 As the conveyor runs empty, you have to lubricate the chain at the chain sprockets in order to avoid excessive wear of the sprockets.

NOTICE

USE ONLY BIOLOGICALLY DEGRADABLE VEGETABLE OILS OF WATER HAZARD CLASS 0 FOR LUBRICATING THE SPROCKETS AS THE SPROCKET LUBRICATION SYSTEM IS A TOTAL LOSS SYSTEM. BE SURE TO OBSERVE THE RELEVANT ENVIRONMENTAL PROTECTION REGULATIONS.

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EM022621-0 (EN-US)

Installation ___________________________________________________

 Lubricate the whole system at the lubrication points.  Check and inspect the following points: Uniform and equal current consumption of the electric motors. Adequate cooling of the electric motors. Adequate cooling and proper oil filling of the gearboxes. Steady and smooth running of the gearboxes. Check that the chain passes over the sprockets properly. Uniform entry of the chain into the drive frames. Check that the flights enter the chain guides properly. Check conveyor flight spacing. Correct number and installation position of flights. Check that chain connectors are fitted correctly and in the right position. Optimum chain pretension. Function of the conveyor drive sequencing control. Function of safety devices such as e.g. the signaling devices, emergency circuit, etc.

following operations:

 Shorten the chain until an optimum chain pre-tension has been obtained in the conveyor chain.  Eliminate any faults discovered.

As soon as all faults have been eliminated or remedied, the test run with the conveyor loaded can commence.

Test operation of the conveyor

DANGER

MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM DURING THE TEST OPERATION! IN THIS PHASE, A SAFE DISTANCE SHOULD BE KEPT WITH RESPECT TO THE CONVEYOR AS E.G. DUE TO INSTALLATION ERRORS HAZARDS MAY OCCUR WHICH WOULD NOT OCCUR DURING NORMAL OPERATION. THESE HAZARDS COULD CAUSE SEVERE INJURIES OR EVEN DEATH!

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© BUCYRUS 2006

after the test run Lock-out the conveyor to prevent restarting and carry out the

EM022621-0 (EN-US)

___________________________________________________Installation Carry out a test operation of the loaded conveyor for approx. 6

test operation of the loaded conveyor hours paying attention to the following points:

 Increase the load on the conveyor gradually.  Check that the chain passes over the sprockets properly.  Monitor the conveyor continuously for slack chain.  Monitor the current consumption of the electric motors.  Check gearboxes for overheating.  Check all hydraulic connections and pipes/hoses for leaks and damage. after the test operation After the test operation, empty the conveyor completely. Observe

the following points before releasing the conveyor:

 Inspect the conveyor once again thoroughly for installation errors, damage or other faults.  Check the functions of the conveyor and the safety devices once again.

© BUCYRUS 2006

releasing the conveyor When the inspection reveals no further faults and all the

functions can be performed without problems, the conveyor can be release for operation.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 4.27

EM022621-0 (EN-US)

Installation ___________________________________________________

How to dismantle and withdraw the conveyor system draw up dismantling plan Before the conveyor system is to be dismantled, a dismantling

plan should be drawn up. This plan helps you to coordinate dismantling and transport operations. Dismantling should be carried out in the most favorable sequence, generally in the reverse order of assembly. Dismantling depends on the conditions prevailing in the mine.

Who is authorized to dismantle and withdraw the conveyor system?

Dismantling and withdrawing operations may only be carried out

handling of delicate components by persons with adequate knowledge of the work to be

Important instructions for dismantling  Protect all exposed shafts, hubs, labyrinth chambers and flanges against corrosion, contamination and damage.  Close off all open lines and separation points with protective caps or plugs.  Pack loose parts, bolts, etc. in suitable containers in order to protect them against soiling, damage and/or loss.

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© BUCYRUS 2006

performed and who have been adequately trained for these particular requirements.

EM022621-0 (EN-US)

________________________________________________________________

5

Operation

_________________________________________________________________

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_______________________________________________________________

______________________________________________________________

EM022621-0 (EN-US)

____________________________________________________Operation

Operation This chapter contains important information on the operation and maintenance of the conveyor. It also includes instructions on the replacement of wear parts. Read this chapter carefully and thoroughly. In particular, observe the safety instructions in chapter 2 ”Your safety”.

Who is allowed to operate the conveyor?

DANGER

INCORRECT OPERATION ENDANGERS YOURSELF AND OTHERS! INCORRECT OPERATION OF THE MACHINE IS OFTEN THE CAUSE OF VERY SERIOUS ACCIDENTS! OPERATE THE CONVEYOR ONLY WHEN YOU HAVE BEEN SUFFICIENTLY TRAINED ON THE INSTALLED CONTROL UNIT AND HAVE READ AND UNDERSTOOD ALL THE OPERATING MANUALS ON THE CONVEYOR SYSTEM. SHOULD ANYTHING BE UNCLEAR, PLEASE CONTACT YOUR SUPERIOR.

© BUCYRUS 2006

Who is allowed to operate the conveyor?

The conveyor is only allowed to be operated by persons with an adequate knowledge of the whole conveyor system.

This also entails knowing: what safety devices are installed on the system, where these safety devices are located, how these safety devices are to be operated.

When may conveying be started?

Conveying must not be started until the safe condition and proper function of the whole conveyor system has been checked and the daily maintenance operations have been carried out.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 5.3

EM022621-0 (EN-US)

Operation ____________________________________________________ DURING OPERATION, THE HEAD PART OF THE TENSIONABLE DRIVE FRAME IS LOCKED MECHANICALLY WITH THE SLIDING FRAME BY MEANS OF PINS (SEE SECTION ”MECHANICAL LOCKOUT OF THE TENSIONABLE DRIVE FRAME”). REMOVE THE LOCKING ELEMENTS BEFORE EXTENDING OR RETRACTING THE CYLINDERS.

Mechanical lockout of the tensionable drive frame To relieve the hydraulic cylinders during operation the head part of the tensionable drive frame must be interlocked with the slide frame by means of pins. The pins can be inserted into the holes provided at a spacing of 12mm in the brackets at the side of the tensionable drive frame.

The pins must be removed before applying pressure to the hydraulic cylinders.

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© BUCYRUS 2006

Hydraulic control unit—8154 011 000 00 00

EM022621-0 (EN-US)

____________________________________________________Operation

Instructions on the maintenance of the conveyor Maintenance at regular intervals increases the operational safety and prolongs the service life of the conveyor. In particular, observe the safety instructions in chapter 2 ”Your safety”. shearer mechanical stop Be sure to observe the intervals specified for maintenance and

checks of the conveyor since hot surfaces might cause an ignition of explosive atmospheres (air) and dust

Temperature and structure-borne noise monitoring Drive frames, gearboxes, and similar components of the conveyor can be equipped with a temperature and structureborne noise monitoring system.

The operator can use a continuous structure-borne noise monitoring system switching off the drives if: impermissible temperatures are reached. impermissible structure-borne noise characteristics are indicated.

© BUCYRUS 2006

Important notes Please observe the following notices: In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the conveyor system as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operating manual and the manuals of the other components. Inadequate maintenance can result in machine damage which leads to considerable costs.

Be sure to observe the specified maintenance intervals. Use only suitable and approved tools for maintenance work! Use only original BUCYRUS spare parts when replacing components.

Instructions on the maintenance of the steel structure Maintenance of the steel structure includes: Lubrication of the system in accordance with the lubrication schedule. Inspection of the system for faults and proper function. Inspection of wear parts.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 5.5

EM022621-0 (EN-US)

Operation ____________________________________________________ Lubrication schedule Lubrication according to run time Component

Medium 1.

Running time in hours 2.

3.

—

— Drive frame bearing —running tracks Return head — bearing

Grease

8

100

100

—-

Pump grease into the lubrication points with the conveyor running until fresh grease emerges.

Central lubrication system—5350 001 360 00 02 Central lubrication system – tensionable drive frame The central lubrication system allows the drive frame to be lubricated from a central point via a connection block (1). The bearings and the guide beams on the tensionable drive frame are provided with grease from the central lubrication system.

The grease lubricant manifold can be fitted either at the right or at the left of the tensionable drive frame.

Lubricating system of the tensionable drive frame

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© BUCYRUS 2006

NOTICE

DURING OPERATION, THE RE-LUBRICATION INTERVALS MUST NOT EXCEED 100 HOURS. LUBRICATION MUST BE CARRIED OUT WITH THE CONVEYOR RUNNING, AS ONLY THEN WILL THE GREASE BE DISTRIBUTED UNIFORMLY!

EM022621-0 (EN-US)

____________________________________________________Operation Lubricating points – return unit The return unit bearing covers are provided with a grease inlet (lubricating nipple) and a grease outlet (check valve) each.

 Press grease into the nipple at the respective side until fresh grease emerges at the respective check valve.

Lubricating points—return end—1921 055 900 00 00

© BUCYRUS 2006

1—Flextral 2—Flextral 3—Socket 4—Fitting

Inspection of the system J Inspect all the components of the system at least once per shift for visible signs of damage or faults. Damaged flights (deformation, cracks) could, for example, cause serious damage to the chain sprockets. For this reason, defective or missing parts must be replaced immediately. Inspect all the functions of the system at regular intervals. Pay particular attention to the tightness of all connecting elements.

Inspection of wear parts weekly In order to be able to determine in good time when a repair shift has to be scheduled and to avoid damage to other components, it is essential to inspect all the following wear parts once per week as to their degree of wear. Inspect: the conveyor chain, the flights (scrapers), the conveyor chain guides. monthly With some wear parts it is sufficient to inspect them once per

month. These include: the chain sprockets and the chain strippers.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 5.7

EM022621-0 (EN-US)

Operation ____________________________________________________ Instruction on the maintenance of the hydraulic system An exact knowledge of the various functions is essential for maintenance of the hydraulic system. For this reason, you have to familiarize yourself with the circuit diagrams of the controls and with the line plans. (The line plans can be found in the spare parts documentation). In particular, observe the safety instructions in chapter 2 ”Your safety”.

Maintenance of the hydraulic system daily The hydraulic system has to be maintained at regular intervals.

Carry out the following operations:

INSPECT AND MAINTAIN ALL THE COMPONENTS OF THE HYDRAULIC SYSTEM SUCH AS PUMP STATION, FILTER SYSTEMS, ETC. IN ACCORDANCE WITH THE CORRESPONDING OPERATING MANUAL.

C

REPORT DAMAGE, DEFECTIVE COMPONENTS OR OTHER FAULTS TO THE RESPONSIBLE SUPERIOR IMMEDIATELY!

CAUTION

Special measures After termination of the first 100 operating hours the filter cartridges of the control block, if any, must be replaced. The functions of all pressure-relief valves have to be checked at least once a year, in any case, however, after every face move. For reasons of safety and in order to keep the system functional all high-pressure hydraulic hose lines must be replaced every two (2) years irrespective of any visible damage.

Checking of the emulsion values weekly Check at least once per week:

the pH value the concentration —test method: by agreement with the concentrate manufacturer the microbial load —test method: dip slides FURTHER INFORMATION IS CONTAINED IN DIN 24320.

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© BUCYRUS 2006

Inspect all components for good condition. Ensure that the connecting and securing elements are in good working order. Check the proper laying of all lines and hoses. Check to make sure that all connections are tight. Check the proper function of all operating levers, linkages, cylinders, locking devices, springs, etc.

EM022621-0 (EN-US)

____________________________________________________Operation Instructions on the replacement of wear parts It is essential that wear parts are replaced before they reach the lowest wear limit, as otherwise damage can be caused to other parts of the machine. Inspect the wear parts at regular intervals.

(See also section ”Instructions on the maintenance of the steel structure” in this chapter.)

Sprocket drum The split sprocket drum transmits the drive torque from the gearbox via the keys to the chain assembly.

Wear marks are cut into the chain pockets permitting to determine the rate of wear of the chain sprocket

© BUCYRUS 2006

Wear marks

CHECK ON WEAR OF THE CHAIN SPROCKETS AT LEAST EVERY FOUR WEEKS! TURN THE CHAIN SPROCKET AS SOON AS THE SIZE OF THE MARKS INDICATING THE RATE OF WEAR HAS BEEN REDUCED BY HALF (APPROX. 4 MM).

PLEASE NOTE THAT THE LIFE OF THE TURNED CHAIN SPROCKET MAY BE MUCH SHORTER THAN THE ”INITIAL PERIOD OF USE” OF THE CHAIN SPROCKET. THIS IS DUE TO TOLERANCES IN THE HARDNESS PENETRATION DEPT. THEREFORE CHECK ON THE WEAR OF THE TURNED SPROCKET AT LEAST EVERY 2 WEEKS. assembly The threaded holes M 24 in the chain sprocket halves are

designed for screwing in ring bolts as assembly aid. After completion of assembly they have to be closed by screw plugs (10 - Fig. 70).

Before installing the chain sprocket, remove the rust preventive and apply a solid lubricant B3 (see chapter 6) to the points marked (30 – fig. 70). tappet To ensure a trouble free functioning of the face seal, the tappet

of the chain sprocket must extend into the respective groove of the face seal cover. Take care during assembly that the tappet of the face seal cover is flush with the groove of the parallel key.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 5.9

EM022621-0 (EN-US)

Operation ____________________________________________________ chain sprocket bolt The following guidelines must be observed when mounting the

chain sprocket bolts: only use original chain sprocket bolts, threads and contact surfaces of bolts and nuts must be greased – grease B3 (see chapter 6), tighten bolts with torque (e.g. torque multiplier and torque wrench).

Never use an impact wrench! tightening torque The torque required for tightening the chain sprocket bolts M30 x

2 x 110 used is 1600 Nm ( =0.14).

© BUCYRUS 2006

Chain sprocket

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EM022621-0 (EN-US)

____________________________________________________Operation Chain stripper The drive frames are provided with chain strippers which assist in releasing the circulating chain from the chain pockets of the sprocket. replacement When replacing a worn sprocket always replace the strippers, as

well.

The stripper plate (2) is bolted to the drive frame. The chain strippers (1) are secured in position by means of one section bar each welded to the recesses and the stripper plate (2). disassembly With the chain sprocket in place, remove the stripper plate and

pull the stripper out to the top.

Should the stripper work loose during operation, the chain sprocket or the drive frame could be damaged. Be sure to tighten the M 24-8.8 fastening bolts to the specified torque CAUTION during installation! The required torque is 655 Nm.

C

© BUCYRUS 2006

Chain stripper

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EM022621-0 (EN-US)

© BUCYRUS 2006

Operation ____________________________________________________

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6

Technical data

_________________________________________________________________

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_______________________________________________________________

______________________________________________________________

EM022621-0 (EN-US)

________________________________________________ Technical data technical data

main dimensions and connection Length ..................................................1268 (center to center) dimensions Drive Motors.........................................3 x 1650 HP {Mohler)

Capacity ...............................................3,500 TPH @353 Ft./Min Chain ...................................................2 x 48 x 152mm—6-links M/G Drive .............................................MRKR65 1100 / 1500 T/G Drive .............................................MRHS65 1100 Gear boxes...........................................KP-65 W/CST P-65 W/CST Sprocket ..............................................

Chain Centers ......................................2 x 48 x 152mm CD—6-links Line Pan ...............................................PF6-1142 x 2050

© BUCYRUS 2006

Connectors...........................................490 Ton Dog Bone Style Haulage ................................................Jumbrotrack 2000 Rack Bar Specials................................................

Flight Bar Distance ..............................250mm Deck Plate thickness ...........................30mm Bottom Deck thickness .......................40mm Pan weight ...........................................4,442 Lbs.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 6.3

EM022621-0 (EN-US)

Technical data ________________________________________________ Twin outboard chainDKB ......34 x 126 Pan connectors.....................Anchor dog bone Dog bone PF 6 Clamp bolt M 72x320 Screw bolt M 42x587-10.9 Screw bolt M 42x317-10.9 Chain connectors ..................Block-type connector, 34 x126 Tensioning device .................Hydraulic chain tensioner, Messrs. BUCYRUS 3) Crusher Sk1118, Messrs. BUCYRUS Mineral Processing 3) Dust protection......................Water spraying system Tools.....................................Mounting and pulling-off device Tool box with tools Miscellaneous .......................Cable holder to support the supply lines Permissible power rating SPR3-1700

Speed of rotation

Transmission ratio Drive arrangement

1470 min

1780 min

-1

-1

1500 16

21

28

Sum of transferable power in KW

1 Drive

1 X 800 = 800

1 X 800 = 800

1 X 690 = 690

2 Drives

2 X 650 = 1300

2 X 495 = 990

2 X 370 = 740

1 Drive

1 X 930 = 930

1 X 930 = 930

1 X 835 = 835

2 Drives

2 X 785 = 1570

2 X 600 = 1200

2 X 450 = 900

(rpm)

(rpm)

The power ratings given in the table above are continuous ratings.

They apply to electric motors with a rated speed of 1470 rpm resp.

1780 rpm. When starting the electric motors a pull-out torque of 2.5 must be exceeded.

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© BUCYRUS 2006

Nominal width

EM022621-0 (EN-US)

________________________________________________ Technical data Marking of the tensionable drive frame Manufacturer: BUCYRUS GmbH Type ..........................Drive unit SPR3-1700 Year of construction ..MM/YY (e.g: 08.05—Aug. 2005) Ident. No 5322 124 010 00 03 Weight 7,155 kg

© BUCYRUS 2006

Typical type plate on SPR3-1700

The design of the cross frame meets the requirements of the European Directive 94/9/EC and of pr-EN1710. It is suitable for use in potentially explosive atmospheres.

______________________________________________________________ BUCYRUS – AFC © VSVL / 01 6.5

EM022621-0 (EN-US)

Technical data ________________________________________________ Tightening torques—screws with ISO metric thread Recommended tightening torques at mges = 0,14

Thread 1)

Pitch

(mm)

(mm)

d

P

8.8

10.9

12.9

8.8

10.9

12.9

M8

1,25

16,5

23,2

28

23

32,5

39

M10

1,5

26,5

37

44,5

46

65

78

M12

1,75

38,5

54

65

80

113

135

(M14)

2

53

74

89

127

178

215

M16

2

73

102

123

195

275

330

(M18)

2,5

88

124

149

270

380

455

M20

2,5

113

160

192

380

535

640

(M22)

2,5

142

199

239

510

720

865

M24

3

164

230

275

655

920

1100

(M27)

3

215

300

365

965

1360

1630

M30

3,5

260

370

440

1310

1845

2215

(M33)

3,5

325

460

550

1780

2500

3000

M36

4

380

540

645

2290

3220

3860

(M39)

4

460

645

775

2970

4170

5000

M42

4,5

525

740

885

3670

5160

6190

(M45)

4,5

615

865

1040

4590

6450

7740

M48

Pre-tensioning force Fv

Tightening torque MA(Nm)

5

690

975

1170

5540

7790

9350

2)

3

134

-

-

535

-

-

DM272)

3

129

-

-

580

-

-

2

-

300

-

-

1450

-

DM24

M32x2

3)

1)

Dimensions in brackets in exceptional cases only

2)

According to works standard (EWN6110), February 1985 edition

3)

Only for necked down bolts having a shaft diameter (reduced shaft diameter) of 24,2mm

4)

The pre-tensioning forces and tightening torques comply with EWN 6003 works standard

Note:

The tightening torques stated in the spare part lists have to be observed, as well, for installation and maintenance.

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(kN)

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Permissible media Hydraulic fluids Permissible hydraulic fluids

NOTICE

USE ONLY HYDRAULIC FLUIDS FOR WHICH A VALID CERTIFICATE ISSUED BY BUCYRUS GMBH HAS BEEN MADE AVAILABLE TO YOU. OTHERWISE, THERE IS THE DANGER OF SERIOUS DAMAGE TO THE HYDRAULIC EQUIPMENT AND THE LOSS OF WARRANTY CLAIMS. For the operation of hydraulic components of BUCYRUS GmbH generally only such hydraulic fluids are allowed to be used for which a valid certificate in accordance with EWM 8350 or an exemption permit of BUCYRUS GmbH is available to the respective operator. BUCYRUS GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

© BUCYRUS 2006

In addition, national - and sometimes also regional - regulations on health and safety at work and any environmental regulations must be observed for operation.

If a mine only uses individual hydraulic components without applying BUCYRUS shield supports or if obtaining a valid certificate would require too much effort, the same hydraulic fluid as is used for the existing shield support shall be allowed to be used for these individual components, subject to approval by BUCYRUS. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by BUCYRUS GmbH upon request.

Suitability test Before the certificate of BUCYRUS GmbH is issued for a hydraulic fluid the respective fluid has to be subjected to a suitability test. However, this suitability test only refers to the technological properties of the hydraulic fluid and does not allow any conclusions to be drawn with respect to its properties regarding health and safety and environmental protection.

Original samples of the concentrate and the water which will be used later when preparing the hydraulic fluid at the mine are required to perform the suitability test.

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Technical data ________________________________________________ The suitability test will be carried out by an independent testing institute authorized by BUCYRUS GmbH. For the tests, the criteria as specified in EWN 8350 will be applied. The suitability test mainly serves to clarify the properties of the hydraulic fluid with respect to stability sealing materials corrosion In addition, a chemical ”fingerprint” of the concentrate will be prepared in order to exclude or prove any possible changes in the composition of the concentrate, if required.

© BUCYRUS 2006

If the suitability test shows that the hydraulic fluid meets the requirements, the operator will receive the respective certificate

by BUCYRUS GmbH.

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Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of hydraulic systems of BUCYRUS GmbH for each product tested. The respective certificate shall be valid for a period of one year and, after a simplified test, can be extended for an additional year each. The certificate shall become invalid if one or several of the prerequisites for obtaining the certificate are no longer fulfilled.

This is the case, for example, if the quality of the water has changed substantially and/or the composition of the concentrate has been changed, a different concentrate is used or the concentrate and water mixture ratio does not correspond to the data given on the certificate. For further information, please refer to EWN 8350, part 1.

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Technical data ________________________________________________ Hydraulic fluid maintenance A consistent good quality of the hydraulic fluid is essential for the operational reliability of hydraulic systems. Therefore, maintenance of the hydraulic fluid must not be neglected but should be performed with special care. The most important properties of the hydraulic fluid should ideally be monitored automatically and recorded in order to be able to directly counter any harmful effects. These properties include: temperature, foaming, pH-value, concentrate ratio, and microbial load.

The operator of the equipment has to prepare a hydraulic fluid maintenance concept for any individual application. The maintenance concept should be prepared in close cooperation with the manufacturer of the concentrate and has to be applied consistently.

pH-value – Target value: 7.5 to 9.5 Concentrate ratio – Target value: see certificate Microbial load – Target value: < 105 Kol/m In addition, the electrical conductivity, foaming and the operating temperature of the hydraulic fluid should be monitored regularly.

The permissible max. temperature of the hydraulic fluid is 55 °C. During normal operation, however, an operating temperature of 45 °C should not be exceeded. A higher operating temperature will reduce the stability of the emulsion and shorten the life of the sealing material.

Quality of the process water The quality of the water used for the preparation of the hydraulic fluid has an enormous influence on the properties of the hydraulic fluid. Accordingly, the requirements for monitoring the water quality are very high.

The following table lists limit values for the essential properties and components of the water.

If the limit values shown are maintained it can be assumed that the water is basically suitable.

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If it is not possible to monitor the hydraulic fluid continuously the properties listed in the following should be checked at least once every week:

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________________________________________________ Technical data If one or several of the limit values mentioned are not met this should be taken into consideration when selecting a concentrate.

Additional water treatment may also be required.

The customer shall in any case, however, provide a sample of the original water to permit performing the tests required for the issue of the certificate.

© BUCYRUS 2006

Changes in the composition of the water will also lead to the loss of the certificate even if they are within the limit values mentioned.

Test criteria

Limit value

Appearance, color, smell

No particularities permissible, e.g. turbidity, bad smell etc.

Electrical conductivity

< 1800 S/cm

Ph-value

6.5 —- 8.5

Na+ - content

Not specified

Mg+ - content

Not specified

Water hardness

< 750 mg/CaCO3—equivalent

CI—content

≤ 201 mg/I

SO4 2-- content

≤ 145 mg/I

NO 3-- content

≤ 20 mg/I

Fe—content

≤

Bacteriological requirements

≤ 10 5 Kol/ml

1 mg/I

Ratio of solid foreign matter to 1.2 ≤ 10 mg/I m—filtering in conformity with DIN EN 12662 Concentration class according to ISO 4406: 1999

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Technical data ________________________________________________ Lubricating greases and pastes THE LUBRICANT, WHICH IS TO BE USED, IS SPECIFIED IN THE RESPECTIVE CHAPTER, E.G. ASSEMBLY, MAINTENANCE ... .

IMPORTANT Lubricating greases base:.....................................lithium soap NLGI class: ...........................2 worked penetration: ..............265 to 295 (0.1 mm) behavior in the presence of water:................................ practically non-soluble in water temperature of application:....-20 to +120 °C flash point: ............................≧ 200 °C Lubricating greases for general application e.g. for roller bearings subject to normal load, for labyrinths and for assembly according to EWN *) 7068 Lubricating grease for general application

Lubricating greases containing additives for application under Type

Flash point in °C

ARAL

Aralub HL 2

300

ESSO

BEACON 2

200

high pressure e.g. for roller bearings and bearing locations subject to extreme load.

Lubricating grease for general application

THE GREASES LISTED IN THE SAME TABLE CAN BE Supplier

Type

Flash point in °C

ARAL

Aralub HLP 2

300

ESSO

BEACON EP 2

200

MIXED. OTHER PRODUCTS MAY ONLY BE USED IF THE SUPPLIER CAN GUARANTEE THAT THEY ARE EQUIVALENT. DIFFERENTLY COMPOSED LUBRICATING IMPORTANT GREASES MUST NOT BE MIXED AS THIS MAY CHANGE THE CONSISTENCY, I.E. THE MIXTURE CAN BECOME THINNER SO THAT THE LUBRICATION EFFECT IS NOT SUFFICIENT. IT MAY ALSO BE DANGEROUS TO USE LUBRICATING GREASES HAVING THE SAME SAPONIFICATION BASE BUT DIFFERENT ORIGINS.

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Supplier

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________________________________________________ Technical data Lubricating pastes Lubricating pastes free from molybdenum disulfide, containing solid lubricants for lubricating centering and connections of splined shafts of sprocket drums and chain sprockets during assembly.

Lubricating pastes free from molybdenum disulfide Supplier

Type

Base

gleitmolybdan

Gleitimo 805 Li

NLGI class

Flash point

2

220

When the equipment is lubricated in our works for the first time, the lubricant type used as lubricating paste B 3 according to the BUCYRUS works standard EWN 7068 is: gleitmolybdän ”gleitmo 805”

© BUCYRUS 2006

THE INSTRUCTIONS FOR THE USE OF THE LUBRICATING GREASES GIVEN UNDER ”IMPORTANT” ALSO APPLY TO IMPORTANT THE LUBRICATING PASTES.

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Technical data ________________________________________________

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7

For your information

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__________________________________________________ Our service for your information If you need to order spare parts, or if technical problems occur, please contact our after-sales service personnel or contact us directly. our service Service address BUCYRUS (Manufacturing & Design Facility) 2045 West Pike Street Houston, PA 15342-1010 Telephone (724) 743-1200 FAX (724) 743-1201 BUCYRUS (Rebuild and Service Facility) Berry Road Washington, PA 15301 Telephone (724) 743-1200 FAX (724) 743-1201

© BUCYRUS 2006

BUCYRUS (Rebuild and Service Facility) 3206 West DeYoung Street Marion, Illinois 62959 Telephone (618) 997-4335 FAX (618) 993-5618 BUCYRUS (Service Center) 2301 West Pike Street Houston, PA 15342 Telephone (724) 743-1200 FAX (724) 743-1521 Internet: http://www.bucyrus.com

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Our service ___________________________________________________

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