CAT Armored Face Conveyor ARMORED FACE CONVEYOR Operation & Maintenance Manual

EM012261-0 (EN-US)

September, 2012

Operation and Maintenance Manual ARMORED FACE CONVEYOR

SAFETY.CAT.COM

EM012261-0 (EN-US)

________________________________________Before starting to work preface

This manual is intended to provide basic operating information on CATERPILLAR AFC systems. Additional information can be obtained by referring to the Parts Book supplied with your equipment, or by contacting your local CATERPILLAR 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. CATERPILLAR 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 CATERPILLAR and these agencies, may void these approvals and render the equipment illegal or dangerous for use.

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 CATERPILLAR 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 _________________________________________________

TABLE OF CONTENTS (Continued) overview of the safety instructions............................................................... 2.14 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 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 the impact roll crusher drive unit............................................... 4.5 main components and weights .................................................................... 4.6 assembling tensionable drive frame and drive............................................. 4.7 flushing system............................................................................................ 4.8 hydraulic control system on the SPR3 ......................................................... 4.9 hydraulic control unit (image)....................................................................... 4.9 line and circuit diagram on the SPR3 (images)............................................ 4.10 cover for the SPR3 (image) ......................................................................... 4.11 discharge box (image) ................................................................................. 4.12 flange plate (image)..................................................................................... 4.13 instructions for installation of the gear box................................................... 4.14 drive connection assembly (image) ............................................................. 4.15 flange position “W”....................................................................................... 4.16 how to install the conveyor pans (image)..................................................... 4.17 pan line—return head/crusher (image) ........................................................ 4.18 pan line—crusher/tensionable drive frame SPR3 (image) ........................... 4.19 conveyor pans in the overlapping area (image)........................................... 4.20 stageloader pan (image).............................................................................. 4.21 convex pan (image) ..................................................................................... 4.22 stageloader pan (image).............................................................................. 4.23 adaptor pan connecting to the SPR3 (image).............................................. 4.24 pan connection (image) ............................................................................... 4.25

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TABLE OF CONTENTS (Continued) anchor dog bone connection on the return assembly (image) ..................... 4.26 clamping bolt connection M72 in the overlapping area (image)................... 4.27 connecting pans by clamping bolts.............................................................. 4.27 tensioning the screw bolt (image) ................................................................ 4.28 space between wedges (image) .................................................................. 4.28 clamping bolt—fitted (image) ....................................................................... 4.29 tightening the screw connections of the clamp wedges (image).................. 4.29 screw bolt connection on the SPR3 (image)................................................ 4.30 accessories (generic)................................................................................... 4.31 cable bracket (generic) ................................................................................ 4.31 entry spraying system.................................................................................. 4.34 skizze—basic arrangement of spray system (sketch).................................. 4.34 cooling system (image)................................................................................ 4.35 how to assembly the chain (image) ............................................................. 4.37 adjusting chains........................................................................................... 4.38 installing the chain connector ...................................................................... 4.38 opening the block type connector ................................................................ 4.39 closing the block type connector.................................................................. 4.39 dimensions of different flat type connectors................................................. 4.40 how to tension the chain assembly.............................................................. 4.40 necessary tensioning force .......................................................................... 4.40 correct pre-tension....................................................................................... 4.40 too much slack............................................................................................. 4.41 excessive chain pre-tension ........................................................................ 4.41 changes in chain pre-tension during operation ............................................ 4.41 monitoring the chain assembly .................................................................... 4.41 how to tension the conveyor chain .............................................................. 4.41 fitting the chain locking device (image)........................................................ 4.42 securing the center section with pins (image).............................................. 4.43 sequencing control of the conveyor ............................................................. 4.44 starting......................................................................................................... 4.45 stopping ....................................................................................................... 4.45 how to start-up conveyor system ................................................................. 4.45 test run the conveyor ................................................................................... 4.46 after the test run .......................................................................................... 4.47 test operation of the loaded conveyor.......................................................... 4.48 after the test operation................................................................................. 4.48 releasing the conveyor................................................................................. 4.48 how to dismantle and withdraw the conveyor system.................................. 4.49 draw up dismantling plan ............................................................................. 4.49 handling delicate components ..................................................................... 4.49

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_________________________________________________Table of contents OPERATION .......................................................................................................... 5.0 operation...................................................................................................... 5.3 who is allowed to operate the conveyor....................................................... 5.3 when may conveyor be started.................................................................... 5.3 how to operate the drive frame SPR3.......................................................... 5.3 hydraulic control unit on the SPR3 .............................................................. 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 (image) ............................................................... 5.6 lubricating points (image)............................................................................. 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 (image) ................................................................................ 5.10 chain stripper (image).................................................................................. 5.11 guides in concave pan (image).................................................................... 5.12 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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About this manual

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_______________________________________________________________

________________________________________________________________

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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

new operating manual

CATERPILLAR-ARMORED FACE CONVEYOR—DRIVES SERIAL NUMBER: 334545

The operating manual is to be used only for this ARMORED FACE CONVEYOR (AFC).

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.

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 POINTS IN THE TEXT MARKED WITH THIS SYMBOL DRAW YOUR ATTENTION TO IMMEDIATELY IMPENDING DANGER. POSSIBLE CONSEQUENCES ARE: VERY SERIOUS INJURY OR EVEN DEATH.

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 a pointing finger at the start of the line.



Points in the text marked in this way describe areas of interest under sublists.

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

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Your safety

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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 PF6 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 PF6. All modifications and changes must be approved by CATERPILLAR. 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, 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.

As a fundamental rule, installation and repair work may only be carried installation and repair out by personnel who have been adequately trained for these particular requirements.

Installation and repair work on: safety components (pressure relief valves, extinguishers, etc.) the electronics (controllers, etc.) the hydraulics may only be carried out by service engineers from CATERPILLAR or by specially qualified personnel of the mine.

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Your safety __________________________________________________ operating conditions

Intended use The conveyor has been designed and manufactured purely for use as a conveyor unit in face areas.

Employ the conveyor only for its intended use!

Intended uses include: The haulage of coal and debris between the face conveyor and belt conveyor system.

unauthorized use

Applications not expressly listed as intended uses are unauthorized uses are not allowed to be performed with the conveyor.

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

CATERPILLAR 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 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.

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__________________________________________________Your safety The equipment has to be stopped at once and secured to prevent a restart if firedamp protection facilities are found to be damaged. pre-requisites for operation 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.

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

These include, among other things: Facilities preventing unauthorized starting Pre-start warning systems Water spraying systems at hazardous locations with ignition hazards 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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Your safety __________________________________________________ Safety instructions General rules Always work with full concentration.

Familiarize yourself with your working environment. general 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 noise emission 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.

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

2.6

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.

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__________________________________________________Your safety lockout 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. pushing devices

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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.

Never stand under unsupported parts or suspended loads.

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

2.8

When working with oils, greases and other chemical substances, observe the safety regulations applicable to the product.

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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.

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. Stop work on the conveyor before the mining machine reaches your area. securing

Secure your working area over a wide range, in order to avoid endangering other persons.

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 CATERPILLAR 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.

Hydraulics

handling of hydraulic fluids 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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__________________________________________________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. 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

 are not twisted 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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__________________________________________________Your safety Laying hydraulic hoses crossing

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

WARNING

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

TAKE CARE TO ENSURE THAT NEW SUPPLIES ARE STORED SEPARATELY FROM EXISTING STOCK AND THAT REMOVAL TAKES PLACE ON THE ”FIRST IN, FIRST OUT” IMPORTANT PRINCIPLE. Chapter 4: Installation NEVER USE THE DRIVES FOR TENSIONING OR COUPLING THE ENDS OF THE CHAIN. DANGER

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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__________________________________________________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.

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 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!

C

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 CAUTION INSTALLED UNDER THE INSTRUCTION OF SPECIALISTS

FROM CATERPILLAR.

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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 CATERPILLAR. 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 gearbox drive shaft bearings will be strained. This can result in damage to the gearbox and the electric motor!

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 GEARBOXES AND COUPLINGS IF THE O-RINGS OF THE FLANGE PLATE ARE NOT CORRECTLY INSTALLED. THIS CAN RESULT IN SERIOUS DAMAGE TO THE GEARBOXES 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, gearboxes, drive connections, etc.

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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.

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

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2.17

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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 EVERY CAUTION 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.

C

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 IMPORTANT SECTION ”MECHANICAL LOCKOUT OF THE TENSIONABLE DRIVE FRAME”). REMOVE THE LOCKING ELEMENTS BEFORE EXTENDING OR RETRACTING THE CYLINDERS.

2.18

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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

IMPORTANT

USE ONLY HYDRAULIC FLUIDS FOR WHICH A VALID CERTIFICATE ISSUED BY CATERPILLAR 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 INSTALLATION AND MAINTENANCE.

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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2.19

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Your safety __________________________________________________

2.20

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3

Storage and transport

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______________________________________________________________

______________________________________________________________

EM012261-0 (EN-US)

________________________________________ 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 day-to -day work.

Storage of the equipment corrosion protection

no direct exposure to sunlight

Components coated with temporary corrosion inhibitor are protected for around six months.

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.

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 CATERPILLAR. 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 IMPORTANT STORED SEPARATELY FROM EXISTING STOCK AND THAT 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.

WARNING

temperatures below freezing

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

Before transport Transport of equipment at temperatures between -21 C and -40 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.

electrical and electronic components

machine parts

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 components must be removed for 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 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

3.4

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________________________________________ Storage and transport

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3.5

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Storage and transport _________________________________________ Transport of the components Drive frame, gear boxes, 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.

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.

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

3.6

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4

Installation

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______________________________________________________________

______________________________________________________________

EM012261-0 (EN-US)

__________________________________________________ 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 CATERPILLAR service engineers or by specially trained personnel.

Which tools are required for installation? tool box

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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

4.3

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

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! laying of the conveyor pans

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 tightening torques for screws and bolts the components please refer to the list in chapter 6. Also observe the tightening torques specified in the spare parts lists provided. instruction for treatment connections

4.4

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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__________________________________________________ Installation intended use

The AFC transfers the coal to the gate conveyor belt, via the BSL and crusher. The capacity of the AFC is rated at 4,000 tons per hour, however this is dependent on the crusher setting which can vary from 3,000 tons per hour.

IT IS IMPORTANT TO SET THE CRUSHER HEIGHT TO MATCH THE AFC CAPACITY OR STALLING MAY OCCUR ON THE AFC IMPORTANT DUE TO EXCESSIVE LOAD. The BSL has 1542mm pans and runs at a higher speed to ensure the product is removed from the face faster than the face production rate, to reduce the likelihood of blockages. The AFC runs at 465 FPM, approximately 30% faster than the AFC. The BSL as a unit, is advanced by the hydraulic rams in the shields on the face, advancing over the BSL on an overlap system. The overlap allows approximately four (4) pushes of the AFC before the BSL must be advanced.

The BSL is fully enclosed from outbye the crusher to the delivery end, with dust suppression sprays installed along the BSL, in the crusher and at the delivery to minimize dust exposure.

The side plates are supporting units and are used to attach brackets for cable and hose installation.

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4.5

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Installation___________________________________________________ Overview of Main Drive

4.6

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__________________________________________________ Installation Overview of Tail Drive

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4.7

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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 CAUTION

1 2 4 5 6 7

4.8

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!

CROSS FRAME ASSEMBLY DRIVE UNIT CHAIN DEFLECTOR ASSEMBLY CENTRAL LUBRICATION UNIT GREASE WEAR LINER

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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 ( s ee chapter 5, section “ Replacement of wear parts ” ) . tensionable drive frame The fine materials located on the guide ways ( drive frame – MRHS 35 base frame ) can be rinsed via the three rinser connections ( A ) . Using inspection plugs, close the connections again after rinsing.

Tensionable drive frame 5322 213 050 00 02

1 2 3 4

TENSIONABLE DRIVE FRAME DRIVE UNIT STRIPPER BRACKET CENTRAL LUBRICATION

C

LUBRICATE THE WHOLE DRIVE FRAME BEFORE COMMISSIONING (SEE SECTION 5, CHAPTER “LUBRICATION POINTS”).

CAUTION

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Installation___________________________________________________ Spacer box The spacer 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 \ tightening torque

properly fitted and fastened.

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 ” .

1 2 3 4 5

4.10

SPACER BOX CONNECTOR PLATE HORIZONTAL SUPPORT ASSEMBLY BAR TUBE

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__________________________________________________ Installation Flange plate The flange plate is the connecting link between the tensionable drive frame and the gearbox on the head-end drive and the tail loose parts tightening torque

end drive.

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

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 ” .

Flange plate 5322 189 700 00 00

1 2 3 4

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spacer box shaft bolt bolt

5 6 7 8

bolt nut bolt bolt

4.11

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Installation___________________________________________________ Return head to the stageloader The return head serves to return the stageloader chain in a free-running operating mode. It is connected with the main drive frame of the face conveyor via anchor dog bones (see section “Anchor dog bone connection”).

storage

lubrication

The swivel-joint roller bearings of the chain wheel bearing are equipped with a constant supply of lifetime oil. The bearings are sealed against dirt and water by means of axial face seals which must be regularly supplied with grease (see chapter 5, section “Lubrication”).

The axial face seals are lubricated on both sides by means of the lubricating nipples in the crowns. The crowns are each equipped with a grease inlet (lubricating nipple) and a grease outlet (check valve).

Return head

1 2 3 4 5 6

RETURN HEAD BOTTOM CLAMP PIECE L.H. CLAMP PIECE R.H. RETURN SPROCKET BEARING STRIPPER PLATE BOLT

4.12

7 NUT 8 BACK PLATE 9 LOWER BACK COVER 10 UPPER BACK COVER 11 SIDE COVER L.H. 12 SIDE COVER R.H.

13 COVER PLATE 14 BOLT

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__________________________________________________ Installation Coal Deflector The Coal Deflector 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.

The Coal Deflector is positioned onto the drive frame and screwed down onto it in accordance with the hole pattern.

Head Drive Coal Deflector #882059

1 2 3 4 5 6 7

COAL DEFLECTOR BOLT NUT COVER PLATE COTTER HAIR-PIN HARDLINER EXTENSION BOLT

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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.

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 gear box is not tilted when installing it!

The screw dimensions must be accurately chosen in accordance with the respective gear box.

Observe the tightening torque for the connection screws.

4.14

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__________________________________________________ Installation Drive connection assembly 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.

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.

Drive Connection #1958 515 140 00 00 (See spare parts list)

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Installation___________________________________________________ Cooling system The cooling system prevents the conveyor gearboxes and motors overheating.

C

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

4.16

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__________________________________________________ Installation Cooling system—view on Y

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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 48x144/160.

The distance between flights is 912 mm.

Chain Strand Arrangement #615136 (See spare parts list)

MAKE SURE THAT ALL CONNECTION ELEMENTS ARE IN PLACE AND FASTENED PROPERLY (E.G. TIGHTENING TORQUE OF BOLTED CONNECTIONS).

NOTICE

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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 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.

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

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.

4.20

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__________________________________________________ Installation The following information pertains to the proper use of the Chain Locking Device. opening the block type  Drive out the roll pin(s) connector  Push the block connector halves in the direction of the arrows The block connector is open.

closing the block type connector  Push the block connector halves together opposite the direction of the arrow

 Drive in the roll pin(s)

The block connector is closed. open block type connector

how to tension the chain assembly

DANGER

1 roll pin 2 directional arrows

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!

auxiliary facilities for holding the For safe holding during connecting of the conveyor chain, the following auxiliary facilities have to be used: chain assembly  Chain Locking Device

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Installation___________________________________________________ chain locking device To connect the conveyor chain ends or to tension the conveyor chain, the upper chain is blocked in the adaptor pan area by one (1) Chain Locking Device (see graphic below).

One (1) Chain Locking Device.

The Chain Locking Device is designed for retaining the chain assembly when shortening, repairing or replacing chain

DANGER

DANGER

4.22

PRIOR TO INSTALLING THE CHAIN LOCKING DEVICE, VERIFY THAT THE POWER TO THE CONVEYOR AND SHEARER HAVE BEEN VISUALLY DISCONNECTED AND LOCKED OUT. FAILURE TO DO SO COULD CUASE SERIOUS INJURY OR EVEN DEATH. WHEN INSTALLING OR REPLACING CHAIN ON THE CONVEYOR ALWAYS WORK FROM THE SIDES OF THE CONVEYOR. ENSURE THAT ALL PERSONS ARE KEPT OUT OF THE DANGER AREA AND THAT THE DANGER AREA IS CORDONED OFF WIDELY! FAILURE TO DO SO COULD CAUSE SERIOUS INJURY OR EVEN DEATH.

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__________________________________________________ Installation how to set the conveyor chain pre-tension

DANGER

WORKING ON CHAINS WHICH ARE UNDER TENSION REQUIRES PARTICULAR CARE. YOU OR OTHERS COULD BE SERIOUSLY INJURED OR EVEN KILLED BY THE RECOILING CHAIN! DURING THE TENSIONING PROCEDURE. ENSURE THAT ALL PERSONS ARE KEPT OUT OF THE DANGER AREA AND THAT THE DANGER AREA IS CORDONED OFF WIDELY!

always work from along side the Using the chain locking device, the chain assembly can be coupled and conveyor chain tensioned by means of the hydraulic or pneumatic chain tensioner.

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.

chain pre-tension diagrammatic view of tail end drive

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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.

4.23

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Installation___________________________________________________ chain locking device

Position the section of chain to be removed between the sprocket and the square holes in pan deck. This may include a connector as some customers prefer to remove only from the ends of chain sections.

Place the chain block in the square holes as shown below.

4.24

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__________________________________________________ Installation Insert the Chain Locking Device into the square holes in pan deck.

Engage the hook under the deck.

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4.25

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Installation___________________________________________________ Drop the spacer into the hole to prevent the hook from disengaging from the deck.

IF REQUIRED, REMOVE ANY FLIGHTS PRIOR TO THEM BECOMING TRAPPED UNDER THE PROFILE IN WORK AREA. THIS IS TO BE DONE PRIOR TO ANY CHAIN IMPORTANT TENSION BEING APPLIED. Using sprocket closest to the work area, operate the hydraulic chain tensioner until the flights contact the Chain Locking Device.

4.26

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__________________________________________________ Installation Tension the chain using the sprocket closest to the work area. Pull chain slack into work area.

Before working with the chain slack 1. Remove the inspection window at the center of the baffle plate and flip the chain (ratchet) pawl into engagement with the chain strand.

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Installation___________________________________________________

Chain Ratchet Pawls

Pawls are fitted to the Drive Frame cover plates to lock the sprockets

pawl and AFC and Plow chains in position while work is being carried out on the chains .

When in use the pawl locks onto the chain and sprocket to prevent the sprocket from rotating forward.

THERE IS NO ELECTRICAL INTERLOCK ON THE PAWL. WHEN IN USE ENSURE THAT ELECTRICAL POWER TO THE AFC HAS BEEN VISUALLY DISCONNECTED AND LOCKED OUT.

4.28

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__________________________________________________ Installation

After removing the slack chain and reconnecting the strands: 1. Disengage the chain (ratchet) pawl 2. Hydraulically release the chain tension by operating the tensioning unit.

3. Bump the chain strand forward to reposition the flight bar away from the chain locking device.

4. Lift the spacer and unhook the locking device.

5. Remove the device and all foreign materials from the deck’s surface.

6. Replace the inspection window into the baffle plate.

Secure the pawl with the clamp pin and hair-pin prior to operation

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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 changes in chain pretension during operation

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.

As the face advances, the conveyor chain pretension can change 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.

monitoring the chain assembly

In order to ensure trouble-free operation with favorable drive powers and long service lives of chains and sprockets, the 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 chain The following auxiliary facilities are required for tensioning the chain assembly: assembly  

Chain locking device Hydraulic or pneumatic 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 ALLOWS YOU TO APPLY THE OPTIMUM PRETENSION TO THE CHAIN. fitting the chain locking device

4.30

Place the Chain Locking Device onto the face-end gradient / special pans by inserting the pins of the Chain Locking Device into the slots of the pan deck plate.

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__________________________________________________ Installation tensioning the conveyor chain

DANGER

DANGER

TAKE SPECIAL CARE WHEN WORKING ON CHAINS WHICH ARE UNDER TENSION. 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. WHEN USING AN ADDITIONAL PULLING DEVICE FOR COUPLING THE ENDS OF THE CONVEYOR CHAIN, DO NOT USE SO-CALLED C-LINKS (CHAIN LINK CUT OPEN). THE CLINKS 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. Please proceed as follows:

 Apply pressure to the tensioning motor of the tensioning device until the required chain pretension has been reached.

IMPORTANT

BE SURE TO OBSERVE THE SEPARATE OPERATING MANUAL FOR THE CHAIN TENSIONER USED!  As soon as the optional Chain Locking Device has locked into a horizontal chain link, you must depressurize the tensioning motor.  Shorten or lengthen the chain.  Couple the chain.

The chain assembly is now pre-tensioned.

disengaging the chain locking After the chain assembly has been tensioned the Chain Locking Device must be disengaged and secured. device  Re-tension the chain briefly.  Disengage the Chain Locking Device.

NOTICE

IF THE CHAIN LOCKING DEVICE IS DIFFICULT TO BE LIFTED IT IS STILL FIRMLY ENGAGED WITH THE CHAIN. NEVER TRY TO FREE THE CHAIN LOCKING DEVICE FROM THE CHAIN BY USING A HAMMER OR THE LIKE. BY RETENSIONING THE CHAIN AGAIN SLIGHTLY, THE CHAIN LOCKING DEVICE WILL BE LIFTED FROM THE CHAIN LINK. THE CHAIN LOCKING DEVICE CAN THEN BE REMOVED.  Close the cover of the coal deflector.

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Installation___________________________________________________ removing the chain The chain locking device is removed in the reverse order of installation.  Move the chain assembly forward briefly. locking device  Pull out the locking frame.

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

sequencing control of the Switching conditions between face & entry conveyors conveyors 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 start-up. 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.

On conveyors which are equipped with drive units at the head and at switching conditions the tail the individual drives have to be started and stopped one at a between head end & tail time to avoid an excessive formation of slack chain. end drives

starting 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 head-end drive. If this cannot be guaranteed the conveyor is not allowed to start at all.

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

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__________________________________________________ Installation start-up the conveyor system Start-up of the conveyor system must be carried out under the instruction of specialists from CATERPILLAR .

WARNING

NOTICE

MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM WHEN YOU START OPERATING THE CONVEYOR. PARTICULARLY DURING 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. A SAFE DISTANCE SHOULD BE KEPT WITH RESPECT TO 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.

before start-up The following work has to be performed before beginning with the actual start-up:  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.

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.      

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Check the oil level and the cooling of the gear boxes.

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

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Installation___________________________________________________ test run of the conveyor

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! MAKE SURE THAT YOU KEEP SUFFICIENT DISTANCE BETWEEN YOU AND THE CONVEYOR SYSTEM DURING THE TEST OPERATION.

test run of the empty When you have checked the conveyor and remedied any faults discovered, the proper interaction of the individual components of the conveyor complete system must be checked. For this purpose, carry out a test run with the empty conveyor for approx. ½ hour).



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.

  

4.34

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

Lubricate the whole system at the lubrication points.

Check and test the following points: Uniform and constant current consumption of the electric motor  Adequate cooling of the electric motors  Adequate cooling and proper oil filling of the gear boxes  Steady and quiet running of the gear boxes  Steady rolling behavior of the chain at the chain drums  Uniform entry of the chain to the drive frame  Uniform entry of the flights to the chain guides  Correct conveyor flight spacing  Correct number and direction of installation of the flights  Correct fitting and installation position of the chain connectors  Optimum chain pretension of the conveyor chain  Function of the sequencing control of the conveyor drives  Function of the safety devices such as e.g. the signaling devices, Emergency STOP circuit, etc.

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__________________________________________________ Installation after the test run

Lock-out the conveyor to prevent restarting and carry out the following operations: .Shorten the chain until an optimum chain pretension is 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 operations of the conveyor

DANGER

test operations of the loaded conveyor

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 YOU KEEP SUFFICIENT DISTANCE BETWEEN YOU AND THE CONVEYOR SYSTEM DURING THE TEST OPERATION. Carry out a test operation of the loaded conveyor for approx. 6 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 gear boxes 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:

  releasing the conveyor

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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.

When the inspection reveals no further faults and all the functions can be performed without problems, the conveyor can be released for operation.

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Installation___________________________________________________ tightening the screw Screws can become loose or even detached due to the placing of connections screw connections or components!

This is why you have to tighten the following conveyor screw connections listed after an initial operating time of approx. 60 hours. In doing so, observe the respective torque required or the required tension force!           

selecting tightening torques

4.36

Drive connection assembly (motor and gear box side) Gear box (attachment on the drive frame) Chain sprocket screws on chain drums (chain sprockets) Chain stripper on chain drums Directing bracket Coal deflector Attachments of the inspection doors in the bottom plate of the drive frame Replaceable chain guides Anti-wear strips on drive frame Guide strips on tensionable drive frame Attachments on the drive substructure

Refer to the appropriate replacement parts list for the tightening torque of the respective screw connection. If the replacement parts list should have no other details on this, then the tightening torque in chap. 6 “Technical data” will apply.

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__________________________________________________ Installation dismantling and withdrawing Before the conveyor system is to be dismantled, a dismantling plan should be drawn up. The plan helps you to coordinate dismantling and the conveyor system transport operations.

Dismantling should be carried out in the most favorable sequence, generally in the reverse order assembly. Dismantling depends on the conditions prevailing in the mine.

who is authorized to dismantle Dismantling and withdrawing operations may only be carried out by and withdraw the conveyor persons with adequate knowledge of the work to be performed and who have been adequately trained for these particular requirements. system important instructions for dismantling

  

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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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Installation___________________________________________________ How to tension the chain assembly 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. 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

correct pre-tension

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.

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

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

delay

If the entry conveyor stops as a result of a fault, the face conveyor must be automatically switched off without 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.

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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 CATERPILLAR.

WARNING

NOTICE

MAKE SURE THAT NOBODY IS PRESENT IN THE DANGER AREA OF THE CONVEYOR SYSTEM WHEN YOU START OPERATING THE CONVEYOR. PARTICULARLY DURING 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!

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.

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__________________________________________________ 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

DANGER

test run of the empty conveyor

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! 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

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

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

4.42

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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__________________________________________________ Installation test operation of the loaded Carry out a test operation of the loaded conveyor for approx. 6 hours paying attention to the following points: conveyor

 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. releasing the conveyor

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When the inspection reveals no further faults and all the functions can be performed without problems, the conveyor can be release for operation.

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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 by persons with adequate knowledge of the work to be performed and who have been adequately trained for these particular requirements.

handling of delicate components

4.44

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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5

Operation

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______________________________________________________________

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___________________________________________________ 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.

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.

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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.

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 CATERPILLAR 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.

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___________________________________________________ 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.

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!

Central lubrication system 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 points of the tensionable drive frame

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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

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.

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___________________________________________________ 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 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.

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. weekly Checking of the emulsion values

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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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 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

5.8

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.

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___________________________________________________ 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

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The torque required for tightening the chain sprocket bolts M30 x 2 x 110 used is 1600 Nm ( =0.14).

5.9

EM012261-0 (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 CAUTION M 24-8.8 FASTENING BOLTS TO THE SPECIFIED TORQUE DURING INSTALLATION! THE REQUIRED TORQUE IS 655 NM.

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___________________________________________________ Operation How to operate the tensionable drive frame The chain pretension can be adapted to the operating conditions by retracting or extending the hydraulic cylinder of the drive frame at the tail end.

The cylinder is impinged by means of the electro-hydraulic control unit (2).

The pilot-operated check valve is used to hydraulically close the piston chambers of the cylinders pressure-tight.

A pressure relief valve fitted to the check valve is designed for overload protection and is set to operate at 480 bar. The pressure gauge (35) is provided for checking on the specified chain pretension.

Extending the cylinders tensions the chain, retracting the cylinders releases the tension. The max. cylinder stroke is 500 mm.

The conveyor is equipped with an automatic chain tensioning system (FACTS 1)).

Control and lines – tensionable drive frame

1)

2 electrohydraulic control unit, double 6 HP block-ball valve 7 check valve 9 plug type filter socket 10 socket 11 socket DN 10 12 F-F plug-in elbow 13 double nipple 14 reducing socket 15 restrictor 16 female tee 17 reducing bushing

18 reducer socket 19 staple 20 staple 21 staple 22 staple 35 glycerine pressure gauge 40 O-ring 43 SHL line 44 SHL line 45 SHL line X pressure relief valve contained in cylinder

FACTS = Full automatic chain tensioning system

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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.

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 CATERPILLAR 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.

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___________________________________________________ Operation Technical description of FACTS System General information The automatic chain tensioner system was developed to enable the pretension of the conveyor chain to be adapted as well as possible to the current operating condition of the conveyor.

The automatic chain tensioner system ensures optimum adaptation of

Advantages with the the chain pretension to the prevailing load conditions at the conveyor. automatic system This results in the following advantages:  Longer service life of the chain  Less maintenance of

• the chain • the chain sprocket • the drive components  Less friction on all circulating and friction surfaces  Optimum current consumption of the motors. 

System description The basic electric system consists of two main components:

Configuration of the basic  A pressure sensor electric system  A displacement sensor.

The two components are connected to the electro-hydraulic control unit.

The control unit is located on the tail-end drive in the vicinity of the hydraulic system of the chain tensioner and regulates the chain pretension by means of one or more hydraulic tensioner cylinders, depending on the design of the tensionable drive frame.

Configuration of the The control unit consists of the individual controller PMCR widely used in face automation. The PMCR controls a double solenoid valve via a control unit

valve control block. The double solenoid valve controls the movements of the tensioner cylinders in the tensionable drive frame.

The PMCR also has various communication ports, either analog or digital, for connection of an underground host computer (conveyor signal interface).

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Operation____________________________________________________ Input parameters for the control of the chain pretension are: The pressure at the non-return valve of the tensioner cylinders.

The control of the chain tension takes place between two key values.

These are characterized by the minimum and maximum chain slack.

The chain slack is maximum when the conveyor is operating with a full load.

The chain slack is reduced to a minimum when the conveyor is operating under no load. The automatic chain tension control takes place between these two extreme slack chain values. Starting from the preset parameters for pressure and current consumption for these two key points, we obtain a nominal value curve.

Fig. 56 shows the nominal value curve corresponding to the basic setting on delivery.

Using the PMCR, the pressure at the tensioner cylinders is controlled according to the nominal value curve.

The default setting of the nominal value curve must be adapted to the prevailing conditions during commissioning of the conveyor.

The following values are preset on delivery: No load: Pressure 65 bar Full load: Pressure 100 bar.

Nominal value curve pressure at the tensioner cylinder

Adaption of the nominal value curve to the prevailing operating conditions is described below. Further information can be found in the operating manual for the PM4.

Adaption of the nominal value curve The parameters preset in the PMCR for the nominal value curve may have to be altered according to the actual conditions prevailing at the place of operation of the conveyor. For this, the parameters for the pressure have to be determined at no load and at full load and input into the PMCR. This adapts the nominal value curve to the prevailing conditions. While determining the parameters, the conveyor has to be running and the chain running off at the tensionable drive frame has to be observed.

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___________________________________________________ Operation No load The parameters for the operating condition no load are determined as follows: ⇒ Empty the conveyor. ⇒ Extend the tensioner cylinder manually with the conveyor running until no more slack chain is to be observed on the outgoing chain in the top race of the tensionable drive frame. The chain is “taut“, see Below.

“Taut chain”

1 tail end drive Important!

If no slack chain forms even when the tensioner cylinder is almost completely retracted, the conveyor chain has to be extended.

Ensure that the cylinder always has a certain amount of residual IMPORTANT travel when determining the parameters for the no load condition, otherwise you will obtain distorted values. .Then retract the tensioner cylinders in approx. 25 mm steps until a little slack chain is just to be observed (see below).

Optimum chain tension with the conveyor running at no load Slight slack chain formation in the top race

1 tail-end drive

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Operation____________________________________________________

IMPORTANT

Important!

The transition from “taut chain” to “slack chain” can be very well observed at the top race inlet of the tensionable drive frame.

1 tail-end drive

 Read off the values for the pressure and current consumption at the PMCR when the transition to slack chain is reached. Record these values and enter them as parameters for the no load condition into the PMCR.

example

No load: Pressure 30 bar

Full load The following preconditions must be satisfied in order to obtain realistic values for the full load operating condition: 1. Expedient parameters are preset in the PMCR: The previously determined parameters for no load, and, for example, the values preset at the factory for full load.

2. The conveyor must be under maximum load.

The parameter for the operating condition full load is determined as follows:

 Observe the chain run-off at the tail-end drive. If the chain tension is set correctly, slack chain formation should be clearly visible as shown in Fig. below.

Fig. 59: Slack chain formation

1 tail-end drive

 If no slack chain is formed, gradually reduce the parameter forpressure for the operating condition full load at the PMCR in stepsof approx. 10 bar. Repeat this procedure until a large amount ofslack chain is formed. Ensure that the tensioner cylinder still hassufficient residual stroke.

 If you observe that the conveyor chain creates too much slackchain even with the preset value for the parameter pressure, thefull load pressure must be gradually increased in steps of approx.10 bar as long as the tensioner cylinder still has sufficient residualstroke.

 Read off the values for the pressure and current consumption at thePMCR when sufficient slack chain is produced. Record thesevalues and enter them as parameters for the full load condition into

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___________________________________________________ Operation Full load: Pressure 80 bar

Adapted nominal value curve, example The adapted nominal value curve then looks like the example shown in Fig. 60 when the following parameters, for example, were determine dusing the method described above: No load: Pressure 30 bar Full load: Pressure 80 bar Nominal value curve pressure at the tensioner cylinder

In this range, the controller PMCR regulates the optimum chain pretension necessary for these operating conditions.

Caution!

Examine the slack chain formation criteria for the outgoing chain at the tensionable drive frame on a daily basis. Adjust the nominal CAUTION value setting at the PMCR if necessitated by the observed slack chain formation. Only regular monitoring of the slack chain formation and adjustment of the nominal value curve to changing conditions in good time permit optimum control of the chain pretension.

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Operation____________________________________________________ Flow Charts

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___________________________________________________ Operation Flow chart—full load (pressure setting with conveyor loaded)

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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, also observe the safety instructions in chapter 2 “Your safety”.

Ignition hazard 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, gearbox and similar components of the conveyor can be equipped with temperature and/or impact sound monitoring.

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.

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

 You can, for example, draw up a checklist using this operating manual and the manuals of the other components. Be sure to observe the specified maintenance intervals Use only suitable and approved tools for maintenance work!

 Use only original CATERPILLAR spare parts when replacing components.

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___________________________________________________ Operation 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.

Lubrication of the system in accordance with the lubrication Schedule Tab. 5: Lubrication after running time

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

NOTICE

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!

1. The listing is general and does not relate to one certain type of conveyor system.

2. A2 lubricating grease, see chapter 6, section “Lubricating greases and pastes” 3. See details in the separate, respective operating manuals.

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Operation____________________________________________________ Lubricating points The bearings at the head and at the tail are supplied with grease by a central lubrication system. Lubricate the bearings until fresh grease emerges at the grease outlet.

Central lubrication for MRKR 35-1100—head drive

1 holding plate 2 cover 3 hex. head screw 4 locknut 5 hose line 6 hose line 7 hose line 8 staple lock 9 screw plug 10 hydraulic-type lubricating nipple

5.22

11 check valve 12 sealing ring 13 socket 14 sealing ring 15 screw-in socket 16 muff joint 17 plug-in elbow 18 hose line 19 hose line

20 plug-in elbow 21 adaptor 22 screw-in socket 23 shield for return unit 24 shield for drive frame 25 grooved drive stud a grease inlet b grease outlet

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___________________________________________________ Operation Central lubrication for MRHS 35—dual sided

1 holding plate 2 cover 3 hex. head screw 4 locknut 5 hose line 6 hose line 7 hose line

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8 hose line 9 staple lock 10 socket 11 screw plug 12 hydraulic-type lubricating nipple 13 check valve 14 sealing ring

15 screw-in socket 16 plug-in elbow a lubricating direction b bleeding direction

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Operation____________________________________________________ Inspection of the system 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.

Weekly Inspection of wear parts 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 and hold-down brackets.

Monthly With some wear parts it is sufficient to inspect them once per month.

These include:

 The chain sprockets (chain drums)  The chain strippers.

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6

Technical data

EM012261-0 (EN-US)

______________________________________________________________

______________________________________________________________

EM012261-0 (EN-US)

_______________________________________________ Technical data technical data

main dimensions and connection Length .................................................... 1500 FEET dimensions

Drive Motors .......................................... 3 X 1900HP Chain ..................................................... 2 X 48 X 144 / 160 M/G Drive .............................................. MRKR65 / 1100 MRHS65 / 1100 T/G Drive ............................................... MRKR65 / 1100

Gear boxes............................................. 2 X KP65 W/CST 1 X P65 W/CST Sprocket ................................................ 2 X 48 X 7Z Chain Centers........................................ 250MM Line Pan ................................................. L/A Flight Bar Length .................................. 976MM Deckplate thickness ............................. N/A Bottom deck thickness......................... N/A

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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

(kN)

MA(Nm)

5

690

975

1170

5540

7790

9350

2)

3

134

-

-

535

-

-

DM272)

3

129

-

-

580

-

-

2

-

300

-

-

1450

-

DM24

M32x2

6.4

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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_______________________________________________ Technical data

Permissible media Hydraulic fluids Permissible hydraulic fluids

NOTICE

USE ONLY HYDRAULIC FLUIDS FOR WHICH A VALID CERTIFICATE ISSUED BY CATERPILLAR 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 CATERPILLAR 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 CATERPILLAR GmbH is available to the respective operator. CATERPILLAR GmbH will not accept any claims under warranty for components which have been or are operated with a different hydraulic fluid.

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 CATERPILLAR 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 CATERPILLAR. The same applies e.g. to hydraulic chain tensioners, hydraulically tensionable drive units etc. The respective exemption permit will be issued by CATERPILLAR GmbH upon request.

Suitability test Before the certificate of CATERPILLAR 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 CATERPILLAR 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.

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

by CATERPILLAR GmbH.

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_______________________________________________ Technical data Certificate The customer will be given a certificate attesting the suitability of the hydraulic fluid for the operation of hydraulic systems of CATERPILLAR 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.

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:  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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_______________________________________________ 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.

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________________________________________________ Greases and lubricating pastes Only the recommended lubricants or products certified as equivalent may be used.

IMPORTANT

Important!

The lubricants to be used are specified in the respective chapters.

Greases

lubricating grease A1

Greases for general application, e.g. for roller bearings subject to normal load, for labyrinths, and for installation.

Greases A1 Supplier

Make

Base

NLGI class

Fuchs

Renolit MP

Lithium soap

2

Worked penetration: ...................265 to 295 (0.1 mm) Reaction in the presence of water:….practically insoluble in water Temperature of application: .......-40 to +120 °C lubricating grease A2

Greases containing additives for high pressure applications, e.g. for roller bearings and bearing locations subject to extreme load.

Lubricating grease A2 Supplier

Make

Base

Shell

Alvania E.P. grease 2

Lithium soap

NLGI class

Flashpoint in ºC

2

205

Worked penetration: ...................265 to 295 (0.1 mm) Reaction in the presence of water:….practically insoluble in water Temperature of application: .......-15 to +120 °C A8 grease

High-load grease for heavy loading and low speeds, e.g. for roller bearings in drive frames and crushers, for installation and anticorrosive purposes, suitable for central lubrication systems.

A8 grease Supplier

Make

Base

Castrol

Molub-Alloy 777-1ES

Lithium soap

NLGI class

Flashpoint in ºC

1

260

Worked penetration: ...................310 to 340 (0.1 mm) Reaction in the presence of water:….insoluble in water at 90ºC Temperature of application: .......-20 to +120 °C

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_______________________________________________ Technical data Lubricating pastes lubricating paste B3

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

Lubricating paste B3 Supplier

Make

Gleitmolybdän Gleitmo 805

Lubricant carrier

NLGI class

Lithium soap

2

Flashpoint in ºC 220

Worked penetration: ...................265 to 295 (0.1 mm) Reaction in the presence of water:….insoluble in water Service temperature range:........-20 to +120 °C

Lubricants Parting agents and lubricants with organic lubricating media on synthetic base material for greasing threaded areas and fitting points on lubricant B6 props and hydraulic props, on pin connections and similar connecting elements at the support.

Lubricant B6 Supplier

Make

Lubricant carrier

Chesterton

Parting agent/lubricant 785

Paraffin base

Flashpoint in ºC 132

Reaction in the presence of water:….insoluble in water Application temperature range: ..-34 to +120 °C

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7

For your information

EM012261-0 (EN-US)

______________________________________________________________

______________________________________________________________

EM012261-0 (EN-US)

_________________________________________________ Our service

For your information Our service If you need to order spare parts or if technical problems occur, please contact our after-sales service personnel or contact us direct.

Service address Beckley, WV 200 George Street, Suite 4 Beckley, WV 25801 Phone: (304) 256-5927 Fax: (304) 256-5928

Craig, CO 400 Mack Lane Craig, CO 81625 Phone: (970) 824-3249 Fax: (970) 824-8851

Duffield, VA P.O. Box 847 ters) 6808 Fraley Avenue Duffield, VA 24244 Phone: (276) 431-7000 Fax: (276) 431-2464

Houston, PA (Corporate Headquar-

Carrier Mills, IL 9580 State Route 13 West Carrier Mills, IL 62917 Phone: (618) 982-9000 Fax: (618) 982-9912

Oak Hill, WV P.O. Box 60 Oak Hill, WV 25901

Paonia, CO P.O. Box 566 Paonia, CO 81428

Huntington,UT P.O. Box 1190 Route 10, 1 Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

719 Second Street Paonia, CO 81428 Phone: (970) 527-3151 Fax: (970) 527-6846 Pulaski, VA 4041 Wurno Road Pulaski, VA 24301 Phone: (540) 980-4530 Fax: (540) 980-6211

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2045 West Pike Street Houston, PA 15342 Phone: (724) 743-1200 Fax: (724) 743-1201

843 Lochgelly Road Oak Hill, WV 25901 Phone: (304) 469-3302 Fax: (304) 465-0450

Washington, PA 255 Berry Road Washington, PA 15301 Phone: (724) 743-1200 Fax: (724) 228-2177

7.3

EM012261-0 (EN-US)

Our service __________________________________________________ Rebuild facility address Huntington, UT P.O. Box 1190 Route 10, 1Mile North Huntington, UT 84528 Phone: (435) 687-9831 Fax: (435) 687-2522

Norris City, IL 635 Illinois Highway 1 Norris City, IL 62869 Phone: (618) 378-3441 Fax: (618) 378-3106

Pearisburg, VA P.O. Box 463 222 Industrial Park Drive Pearisburg, VA 24134 Phone: (540) 921-2111 Fax: (540) 921-2711

7.4

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