Cat Bucyrus Ashton Services Equipment – Crawler Units (Size 9) Operation & Maintenance Manual

BI618953

© Bucyrus All Rights Reserved

BUCYRUS R

Technical Manual

BI618953

Ashton Services Equipment – Crawler Units (Size 9)

BI618953

Bucyrus Australia Ashton Services Equipment Crawler

BUCYRUS recommends that all Safe Working procedures should be approved and checked by Mine Officials.

BUCYRUS Australia declines all liability for direct or indirect consequences of printing errors.

This document is copyright. All intellectual property rights and copyright in the document (or any part of this document remains the property of BUCYRUS Australia PTY LTD. Except as provided for in the Copyright Act 1968 (Ctn) no part of this document may in any form or by any means (including without limitation electronic, mechanical, micro copying, photocopying, recording or otherwise) be reproduced, stored in a retrieval system or transmitted without the prior written permission of BUCYRUS Australia Pty. Ltd.

Revision

Date

Change

Modified by

1

Oct 2010

Bucyrus format

R Spencer

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GENERAL SAFETY ..................................................................................................................................................5 ISOLATION PROCEDURES ....................................................................................................................................7 SHIELDS ....................................................................................................................................................................7 Hydraulic Bleed Points ........................................................................................................................................8 Operation – Screw Type.......................................................................................................................................8 Operation – Manometer Gauge Port Type ..........................................................................................................8 AFC AND BSL...........................................................................................................................................................9 BOOTEND ................................................................................................................................................................10 SAFETY .....................................................................................................................................................................11 PERSONNEL .............................................................................................................................................................11 Operation...........................................................................................................................................................11 Installation and repair .......................................................................................................................................11 OPERATING CONDITIONS .........................................................................................................................................12 Intended use .......................................................................................................................................................12 Unauthorised use ...............................................................................................................................................12 SAFETY INSTRUCTIONS ............................................................................................................................................12 General rules: ....................................................................................................................................................12 Noise emissions..................................................................................................................................................12 Condition ...........................................................................................................................................................12 Safety equipment ................................................................................................................................................12 Information signs ...............................................................................................................................................12 EMERGENCY-STOP .........................................................................................................................................13 Block working area ............................................................................................................................................13 Moving parts ......................................................................................................................................................13 STORAGE AND TRANSPORT .....................................................................................................................................13 Transport safety device ......................................................................................................................................13 Lifting Equipment ..............................................................................................................................................13 Floor conveying device ......................................................................................................................................13 ERECTION AND COMMISSIONING .............................................................................................................................13 Environmental acceptability ..............................................................................................................................13 OPERATION .............................................................................................................................................................14 MAINTENANCE AND REPAIR ....................................................................................................................................14 Original parts ....................................................................................................................................................14 Safety equipment ................................................................................................................................................14 HYDRAULICS ...........................................................................................................................................................14 Handling of Hydraulic Fluids ............................................................................................................................14 Maintenance and Repair....................................................................................................................................14 Permissible Hoses..............................................................................................................................................15 Installation of Hydraulic Hoses .........................................................................................................................16 HOSING COLOURS ...................................................................................................................................................18 STORAGE AND TRANSPORT ..............................................................................................................................20 STORAGE .................................................................................................................................................................20 Corrosion protection..........................................................................................................................................20 STORAGE OF THE EQUIPMENT .................................................................................................................................20 No direct exposure to sunlight ...........................................................................................................................20 Dirt and moisture...............................................................................................................................................20 Short-term storage .............................................................................................................................................20 Long-term storage..............................................................................................................................................20 Plastic deformation............................................................................................................................................20 Random sample inspection ................................................................................................................................21 Natural ageing ...................................................................................................................................................21 HFA fluids..........................................................................................................................................................21 TRANSPORT .............................................................................................................................................................21 Load units; dimensions and weights ..................................................................................................................21

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BEFORE TRANSPORT ................................................................................................................................................21 Temperatures below freezing .............................................................................................................................21 Electrical and electronic components................................................................................................................22 TRANSPORT OF THE COMPONENTS ...........................................................................................................................22 Machine parts ....................................................................................................................................................22 PUMP AND TRANSFORMER STATION CRAWLER UNITS..........................................................................23 DESCRIPTION ...........................................................................................................................................................23 TOWING CRAWLER UNITS.................................................................................................................................27 CONNECT TOWING UNIT TO DRAW BAR .................................................................................................................27 DISENGAGE TRACKS ...............................................................................................................................................29 HOOKING UP AND DRIVING TRACK UNITS ..................................................................................................35 TRANSFORMER STATION CONNECTION AND OPERATION ..........................................................................................35 PUMP STATION CONNECTION AND OPERATION .........................................................................................................37 LOWERING PUMP PLATFORMS........................................................................................................................41 RAISING THE TANK ..............................................................................................................................................43 DISCONNECTING THE CRAWLER UNIT.........................................................................................................45 TRACK MAINTENANCE .......................................................................................................................................47 TENSIONING TRACKS ..............................................................................................................................................47 General ..............................................................................................................................................................47 Procedure ..........................................................................................................................................................47 REPLACEMENT OF TRACK TENSIONING CYLINDER..................................................................................................50 General ..............................................................................................................................................................50 Procedure ..........................................................................................................................................................50 REPLACEMENT OF TRACK FROM TRACK FRAME .....................................................................................................53 General ..............................................................................................................................................................53 Procedure ..........................................................................................................................................................53 TRACK ASSEMBLY REMOVAL COMPLETE ...............................................................................................................55 General ..............................................................................................................................................................55 Procedure - Removal .........................................................................................................................................55 Procedure - Refitting..........................................................................................................................................58 OIL FILLING OF PLANETARY HUBS................................................................................................................61

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Section

1

General Safety

Isolation and tagging procedures must be followed when working on equipment.

Isolate and tag any other related equipment where its operation will cause danger to personnel or damage to equipment.

Before operating equipment make sure that nobody is inside or in the immediate area of the equipment.

Maintenance and repair should be undertaken by trained personnel.

Always wear safety glasses when working on hydraulics systems.

Ensure that any relevant circuits are depressurised. Release of high pressure fluids can be fatal. As a final check twist the hose to ensure it is loose before removing staples.

Always be aware of E Stop locations, in case of emergency.

Before attempting to free-wheel the machine, ensure the hydraulic power to the crawler circuit is switched off, the machine is positioned on a level ground and not moving, and the towing vehicle has the capacity to brake this additional load in up and down grades.

Do not disengage the hubs until the Towing vehicle is attached to this machine

Once both hubs are disengaged, this machine will not have any sort of brake capability and there is a danger of running away on grades if the towing vehicle does not have the braking capacity

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Section

2

Isolation Procedures ocedures The electrical supply is isolated at the transformer station, and as such isolation procedures are detailed in the Ampcontrol Transformer Station manual. Shearer isolation procedures are found in the oem’s manual.

Hydraulic isolation to the longwall system is performed at the filter station, or by powering down the services equipment pump station. The SES procedures are found in the SES Pump Station and Filter station manuals respectively.

Shields When working on an individual shield, confirm with the section official that it is safe to carry out this job.

Mine safety tag procedures must be followed.

Electrical Isolation - Push in the lockout button on the support control unit (SCU).

Push red E-Stop button Push black lockout button

Hydraulic Isolation - Isolate the support from the incoming hydraulic pressure supply using the main isolation valve on the supply manifold.

Shield pressure gauge

PTO Isolation Valve

Main pressure Isolation Valve

Pilot pressure gauge

Relieve Hydraulic Pressure - Dissipate pressure by operating the manual hydraulic control buttons, or bleed valves. The button must be pressed repeatedly to relieve the accumulated pressure. Ensure pressure is dissipated by checking system pressure and pilot pressure gauges. As a final check, twist hoses to ensure they are not pressurised.

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Manual hydraulic control buttons

Hydraulic Bleed Points Bleed points are fitted to the system to allow residual pressure to be bled from a hydraulic circuit, and to bleed air out of the system. The Ashton system is fitted with two types of bleed point, the bleed screw type and the manometer gauge port type.

Bleed screw type

Manometer gauge port type

Operation – Screw Type The bleed screw operates by engaging a normally shut valve inside the fitting. To open the valve, turn the screw clockwise. To shut the valve, turn the screw anti-clockwise until the screw is loose and the valve is shut.

Bleed screw open

Operation – Manometer Gauge Port Type The manometer gauge port type requires a separate fitting to open it. The fitting should be connected to a hose which in turn is led to an appropriate area for the hydraulic fluid to be bled.

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Booster connection hose

Hose connected and Manometer Gauge port open

Remove the plastic cap and screw the fitting clockwise into the manometer gauge port. Hydraulic fluid will be bled through the valve and hose. When the valve is to be shut, unscrew the valve fitting. Refit the plastic cap to prevent the Manometer Gauge port being contaminated.

AFC and BSL Confirm Safe to Start - Confirm with the section official that it is safe to carry out this job. Mine safety tag procedures must be followed.

Run the armoured face conveyor and stage loader / crusher until it is clear.

Stop the AFC by using the lockout on stage loader / crusher, lock out on AFC, or stop button at DCB. DAC lock-out button

Full isolation is achieved by removing the supply cables at the DCB, capping and locking/tagging to ensure complete electrical isolation.

Check the Scanda screens for indication of equipment status.

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Bootend Confirm Safe to Start - Confirm with the section official that it is safe to carry out this job. Mine safety tag procedures must be followed.

Hydraulic Isolation - The bootend is isolated hydraulically by operating the Pilot Operated Control Valve by using the Panic Bar, and also the isolation valve at the control panel filter.

Panic bar

Check valve

Pressure filter

Pilot control units

12 stack control unit

Pilot operated check valve

The emergency shut-off valve arrangement is operated when the emergency shut off panic bar (dead man control) is pushed down. The upward position of the panic bar operates the control valve which allows pilot pressure to open the check valve and let fluid flow to the control valve banks so that they may be operated. The downward position stops the pilot flow and closes the check valve preventing the flow of fluid to the valve banks ceasing operation.

DANGER: Use caution while operating or maintaining the diversion valve since the system is under extreme pressure.

DANGER: Do not perform work on or attempt to disconnect any of the hydraulic hoses while pressurised.

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Safety This chapter contains important information for your safety.

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

The crawler assemblies have been manufactured to the state-of-the-art and in accordance with recognised 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 crawler. All modifications and changes must be approved by BUCYRUS. Use only original spare parts from BUCYRUS. Note that the use of parts from other manufacturers will void the guarantee.

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 Inspectorate and

of the mining supervisory authorities

Please read also the operating manuals of the components required for operation, e.g. of gearboxes, electric motors, etc., carefully and thoroughly. Clarify any questions before starting work.

Personnel Operation The crawler may only be operated by qualified, trained personnel.

The crawler may only be operated by personnel who can provide proof of having been trained on the installed controller.

The reading of the operating manual, and in particular of the "Safety" chapter, must form part of this training.

You must have, and be able to prove, an adequate knowledge of the following systems:

Mechanics,

Hydraulics and

Control engineering

Installation and repair As a fundamental rule, installation and repair work may only be carried 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 electrics (controllers, signalling devices, etc.)

the hydraulics

may only be carried out by service engineers from BUCYRUS or by specially qualified personnel of the mine.

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Operating conditions Intended use The crawler has been designed and manufactured purely for use as a transport device for the pump station and transformer station.

Use the crawler only for its intended use!

Unauthorised use Applications not expressly listed as intended uses are unauthorised uses and must not be carried out with the conveyor.

Such unauthorised uses include but are not limited to:

Transport of persons

Transport of objects of any kind such as e.g. individual props, boards, spare parts, etc.

DANGER: Large material can tip over or fly around, causing serious injury or even death.

BUCYRUS accepts no liability for injury or damage resulting from any such unauthorised use.

Safety instructions General rules: Always work with full concentration.

Familiarise yourself with your working environment.

Noise emissions Always wear your personal protective equipment.

Inform your colleagues:

Where exactly you are working.

What work you are carrying out.

How long you expect the work to take.

Condition Operate the crawler 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.

Safety equipment Keep the signal and lighting systems in a proper functional condition.

Information signs Observe the signs on the crawler.

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EMERGENCY-STOP Press the EMERGENCY STOP switch immediately in the event of faults or irregularities in operation.

Report any peculiarity to your superior so that necessary measures can be taken immediately.

Block working area Ensure the working area is clear of personnel during:

Operation of the crawler unit

Maintenance operations

Inspection operations

Repair operations

Moving parts Never allow parts of your body to come between parts which could move, such as e.g.:

tracks

draw bar

pump equipment

Chain sprockets

Tensionable drive frame

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

Do not store materials or parts in the travel route 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 hub brakes are enabled, especially prior to detaching the crawler unit from a tow vehicle.

Never stand under unsupported parts or suspended loads.

Lifting Equipment Attach lifting equipment only to the lifting points provided. Pay attention to the different load limits of the lifting points. Observe the instructions on the transport sheets.

Use only lifting equipment that is in good condition and designed for the loads to be handled.

Use only transport belts for lifting round parts. Never use chains or steel ropes.

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

Floor conveying device When transporting using floor conveyors, ensure that the centre of gravity is as low as possible.

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

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Dispose of cleaning rags, etc. which have been soiled with oil, grease or other chemical substances in an environmentally safe manner.

Operation Operate the controller only when you have full knowledge of the operating elements and its method of operation. You must have been trained on the controller concerned.

Ensure that there are no persons on or near the crawler before switching on.

Check that all protective devices are installed on the conveyor and in proper functioning order.

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 working crew of any maintenance and repair operations.

Give them information on the intended operations and the anticipated duration.

Cordon off your working area with sufficient space so that other persons are not endangered.

Secure the crawler to prevent any unauthorised or accidental switching on.

Remove defective parts from the face area immediately in order not to hinder the face crew. This also avoids the risk of these parts being inadvertently installed again elsewhere.

Send these parts for repair immediately.

In faces with inclines, secure spare parts e.g. with chains or hoists.

Original parts Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original BUCYRUS spare parts.

Please refer to the spare parts lists for the order numbers.

Safety equipment Install the removed protective devices again immediately on finishing the work and check that they are functioning correctly.

Hydraulics Handling of Hydraulic Fluids Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infections.

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

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

Carry out a visual inspection of all the hydraulic components at regular intervals. In particular, pay attention that:

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the hoses are not pinched or trapped.

the hoses have no bubbles or blisters.

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the hoses or the outer sheathes of the hoses are not abnormally rigid or hard.

the outer sheath of the hoses 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 pressurised. Be sure to depressurise the line before disconnecting couplers.

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.

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.

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Example of 4SP hydraulic hose, designation

Never try to hold a jumping hydraulic hose. Depressurise the line in question immediately.

Never try to repair damaged hydraulic hoses. Immediately replace damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

Installation of Hydraulic Hoses Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so that they:

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always have a little slack.

are not twisted.

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are not bent directly behind the connections (distance min. 1.5 x nominal diameter).

cannot chafe.

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 machine.

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Hosing Colours Hosing manifolds are installed to assist in the changing of damaged / worn hoses. Hoses are colour coded to make identification easier.

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Section

3

Storage and transport This chapter contains important information on the correct storage and transport of the crawler.

Observance of the instructions and tips will increase the service life and availability of the crawler. 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 Corrosion protection Components coated with temporary corrosion inhibitor are protected for around six months.

The hydraulically operated equipment is operated before delivery with a test medium and then drained as far as possible before delivery.

The medium remaining in the equipment also protects all the internal parts against corrosion for at least six months.

Storage of the Equipment No direct exposure to sunlight Protect the equipment against direct exposure to sunlight. Store the electrical equipment, electronic components, and 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.

Dirt and moisture 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 Protect all parts of the equipment stored outdoors against moisture and dirt, e.g. using tarpaulins.

During short-term storage (approximately 4 weeks) of equipment outdoors, but at temperatures above freezing, electrical components must not be removed. Such components must be particularly protected against excessive temperatures, dirt and moisture.

Long-term storage If the equipment is to be stored for more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frost-proofing fluid such as e.g. CV 50.

Seal the ports with plastic or steel plugs.

The equipment must be stored in a well ventilated, dry room _ not outdoors.

Plastic deformation In order to prevent plastic deformation of the seal elements, cylinders must be stored in an upright position. Some cylinders, e.g. the tensioning cylinders, must be removed so that they can be stored upright.

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Random sample inspection After a storage period of approximately two years, a random sample inspection must be performed to determine whether the measures taken and the method of storage has prevented damage.

On request, the inspection can be carried out by BUCYRUS.

Natural ageing Even with proper storage, seals and hoses are subject to natural ageing. Do not use these parts if they have been stored for more than two years.

HFA fluids Instructions on the storage of concentrates for hydraulic fluids can be found, if required, in section "Barely flammable hydraulic fluids of Group HFA" in this operating manual.

Important: Ensure when storing that any new supplies are stored separately from existing stocks in such a way that on removal, old stocks are always taken first.

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

Warning: Use only load handling devices complying with the technical and legal regulations for transporting loads.

You could be seriously injured or even killed by falling loads.

Use only suitable load handling devices.

Before transport Temperatures below freezing Before transporting the equipment at temperatures below freezing, all hydraulic components operated with emulsion (HFAE or HFAS) must be completely drained and then filled with a corrosion inhibiting/ frost-proofing fluid (e.g. CV 50).

Transport of equipment at temperatures between -21°C and -40°C is only permissible when certain measures are 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 may only be loaded statically or quasi-statically.

During transport of this equipment with floor conveyors at such low temperatures, measures must also be taken to ensure that the parts and devices are not subjected to sudden impact loads.

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At very low temperatures and on poor roads, the transport vehicle speed must therefore be limited to a maximum of 25kph for truck transport.

Electrical and electronic components 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 Machine parts Drive frame, gearboxes, motors, etc. are equipped with lifting shackles or lifting points for transport.

In some cases you have to screw the lifting shackles 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 shackles and keep a safe distance away from suspended loads.

Warning: Use only approved lifting equipment!

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Section

4

Pump and Transformer Station Crawler Units Description The Size #9 crawler units fitted to the transformer and pump stations are hydraulically driven track units designed to carry loads of up to 55 tonnes GVM. The hydraulic supply (mineral oil) for driving the track units is from an external source, usually from the power take-off of an LHD or other mobile machine.

Control of the crawlers is remote via pendant controls that can be attached to either end of the pump and transformer stations.

The transformer and pump stations are essentially designed to be towed by an LHD when moving a significant distance and driven with the track units when manoeuvring the stations into or out of a cutthrough.

The specifications for the crawler units are as follows.

Drive Unit

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Torque Hub

Fairfield

Type

Planetary

Ratio

110:1

Maximum Output Torque

45 000 Nm

Drive Motor

Char-lynn

Motor Type

Geroler

Pressure at Maximum Hub Torque

140 bar

Minimum oil flow required for both tracks

150lpm

Brake Type

Multi Disc

Holding Torque

1600 Nm

Release Pressure, hydraulic

8 to 15bar minimum

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Tracks

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Sprocket Type

Cast – Komatsu

No. of Teeth

23

Pitch Diameter

650mm

Chain Type

Sealed & Lubricated

No. of Links

45

Pin Diameter

58.73mm

Shoe Type

Triple Grouser

Shoe Width

508 mm

Track Type

Komatsu Size 9 / 175.5mm Pitch

Track Joining Method

Bolted 4 per side

Idler Type

Komatsu, 1 per side

Tensioning System

Spring / Grease Cylinder

Bottom roller

Komatsu SF, 9 per side

Load Capacity

55 000 Kg GVM

Weight of crawler track drive assembly

3.7t

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Pump station and crawler unit

Transformer station and crawler unit

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Pump station front view

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Transformer station front view

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Section

5

Towing Crawler Units CAUTION: Before towing (or driving) pump station sleds, ensure that the tank is fully lowered.

Connect Towing Unit to Draw Bar The towing hitch has a cylinder mounted to raise and lower the draw bar.

Pump Station draw bar cylinder

Pump Station draw bar cylinder

Pump Station draw bar

Pump Station hand pump

Pump Station draw bar hand pump assembly

Hand pump locking valve

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Transformer Station drawbar

Transformer Station draw bar cylinder

Transformer Station draw bar

Transformer Station hand pump

Transformer Station Draw Bar Handpump

Hand pump Locking Valve

To connect the towing machine to the draw bar on the crawler unit, use the hand pump to raise the draw bar to the correct height, in order to couple to the towing machine.

When connected to the towing machine, unscrew the locking valve to release pressure from the cylinder.

Leave the locking valve unscrewed while towing. If the locking valve is left screwed in, pressure is locked into the draw bar cylinder making the draw bar rigid.

Note: There is a pressure relief valve incorporated into the pump unit. This is to relieve intensification in the event the locking valve is left closed.

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Disengage Tracks Prior to towing the crawler units, the hub brakes must be disengaged. Failure to disengage the brakes will cause damage to the equipment.

DANGER: Before attempting to free-wheel the machine, ensure the following: 1. Hydraulic power to the crawler circuit is switched off 2. Machine is positioned on a level ground and not moving 3. Towing vehicle has the capacity to brake this additional load in up and down grades 4. Towing vehicle is attached to this machine Once both hubs are disengaged, this machine will not have any sort of brake capability and there is a danger of running away on grades if the towing vehicle doesn’t have the braking capacity.

Torque Hub Disengage Cap in normal position; hub engaged

The picture above shows the normal tram condition of the Torque Hub Disengage Cap. The cap is secured by two ¼”UNC hex head bolts.

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Removing the cap bolts

1.

Remove the two UNC bolts using suitable socket spanner.

Cap removed

2.

Remove the Disengage cap as shown above. Do not remove any other component from the Hub.

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Reversing the disengage cap

3.

Reverse the Disengage cap as shown above.

Using the reversed cap to push in the pin.

4.

Push the pin in with the reversed cap and position as shown above.

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Secure the cap with the two bolts.

5.

Tighten the two bolts with the appropriate spanner.

Cap secured and the hubs disengaged.

6.

The hub is now disengaged and the brakes not operating.

Repeat the same procedure with the other Torque Hub. The Brake is now disengaged and ready for towing.

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Once the vehicle has been towed to the required location, the disengage cap on both hubs must be reversed to tram condition, as shown below, so that the brakes are activated before detaching the towing vehicle.

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Section.

6

Hooking Up and Driving Track Units Each crawler unit has the facility to drive the tracks using the mineral oil hydraulic supply from an LHD or similar machine.

The LHD PTO has the following connections:

¾” return quick coupler,

½” pressure quick coupler, and a

½” drain quick coupler.

Both the pump station and transformer station crawler units have the following PTO connections:

1” return female quick coupler

1” pressure male quick coupler

½” drain male quick coupler

Transformer station connection and operation Track unit PTO – Transformer station

1. Connect the 10m hose pack (consisting of three hoses) to the LHD PTO. 2. Connect the other end of the 10m hose pack to the crawler unit PTO. Connect to the inbye or outbye end of the crawler depending on the crawler position.

3. Connect the pendant control unit to the crawler unit using the 6m hose pack. The 6m hose pack consists of 6 hoses and uses quick couplers.

The hoses are connected in parallel connections; H1 of the pendant connects to H1 on the crawler, H2 on the pendant connects to H2 on the crawler and so on, for the six hoses.

The fittings are designed so that only the correct fittings can be connected into the pendant and the crawler PTO ports.

The pendant control unit is supplied with a shoulder harness. The unit weighs approximately 11kg, and has a single 8 position joystick, and a safety valve knob lever.

4.

When using the pendant control unit, ensure the safety valve knob lever is on the left of the joystick.

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Important: Ensure the LHD unit is running, the pendant is connected to the crawler unit, and the 10m hose pack is connected between the crawler unit and the LHD unit prior to operating.

5.

Pull the safety valve knob lever up to enable the joystick control. The safety valve knob lever is spring loaded to close and must be held up. There is no safety detent.

DANGER: Do not mechanically lock the safety valve knob lever in the up position. If this is done, any accidental or otherwise unwanted movement of the joystick will operate the crawler unit.

In the event of this occurring, there is high risk of equipment damage or injury or death to personnel.

6.

Operate the joystick lever in the required direction to initiate crawler movement. The joystick is spring loaded to neutral, so will return to the neutral position when released.

7.

Once the crawler unit is in the required position, release the safety valve knob lever. Accidental movement of the joystick will not operate the crawler once the safety valve knob lever is released.

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Pump station connection and operation Track unit hydraulic connections – Pump station Outbye / Inbye PTO

Pendant connection fittings

Drain Line

Return Line

Pressure Connection

Levelling control levers

PTO Selector valve. Used to change inbye or outbye operation of pendant

1. Connect the 10m hose pack (consisting of three hoses) to the LHD PTO. 2. Connect the other end of the 10m hose pack to the crawler unit PTO. Connect to the inbye or outbye end of the crawler depending on the crawler position.

3. Connect the pendant control unit to the crawler unit using the 6m hose pack. The 6m hose pack consists of 6 hoses and uses quick couplers.

4. The hoses are connected in parallel connections; H1 of the pendant connects to H1 on the crawler, H2 on the pendant connects to H2 on the crawler and so on, for the six hoses.

The fittings are designed so that only the correct fittings can be connected into the pendant and the crawler PTO ports.

5. Operate the PTO selector valve to enable the required PTO location.

6. The pendant control unit is supplied with a shoulder harness. The unit weighs approximately 11kg, and has a single 8 position joystick, and a safety valve knob lever.

7. When using the pendant control unit, ensure the safety valve knob lever is on the left of the joystick.

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Important: Ensure the LHD unit is running, the pendant is connected to the crawler unit, and the 10m hose pack is connected between the crawler unit and the LHD unit prior to operating.

Note: Ensure the 10m hose pack is connected between the LHD unit and the crawler skid, and that the hydraulic supply is available before operating the jack cylinders.

8. The levelling cylinders must be retracted prior to moving the crawler unit. Failure to do so will cause equipment damage. The pendant control does not have lift (jack) cylinder controls; this can only be done with the levelling levers on the crawler unit.

CAUTION: There is no lockout to prevent the crawler operation while the tank lifts are extended. The operator MUST lower the tank before driving the tracks, otherwise the unit will be damaged.

Tank Levelling section. This function can only be done at these controls on the crawler unit.

Track control levers. This function can only be done from the pendant

9. Operate the levers to retract the pump lifting cylinders 10. Pull the safety valve knob lever up to enable the joystick control. The safety valve knob lever is spring loaded to close and must be held up. There is no safety detent.

DANGER: Do not mechanically lock the safety valve knob lever in the up position. If this is done, any accidental or otherwise unwanted movement of the joystick will operate the crawler unit.

In the event of this occurring, there is high risk of equipment damage or injury or death to personnel.

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11. Operate the joystick lever in the required direction to initiate crawler movement. The joystick is spring loaded to neutral, so will return to the neutral position when released.

12. Once the crawler unit is in the required position, release the safety valve knob lever. Accidental movement of the joystick will not operate the crawler once the safety valve knob lever is released.

Note: Forwards direction moves the machine away from the end that the pendant controls are plugged into.

Pendant Control Unit

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Section

7

Lowering Pump Platforms forms When level the pumps should be lowered to improve fluid supply to the suction side of the pumps. The pumps should be set at the minimum height or as low as possible before raising tank.

Tank Levelling section. This function can only be done from the pendant Track control levers

1. Operate the levers to lift (or raise) the pump lifting cylinders to take the weight of the pumps off the pins.

2. Remove the pins.

Pins and pin holders

Pin hole

3. Lower the pumps to its minimum height.

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Section.

8

Raising the Tank When level the tank should be raised to improve fluid supply to the suction side of the pumps. The tank should be set at the maximum height or as high as is possible.

1.

Operate the level controls on the crawler to lift (or raise) the tank lifting cylinders to take the weight of the tank off the pins.

2.

Remove the pins.

Retaining Pins

Rack & pin tank support arrangement

3.

Raise the tank to its maximum height and replace the pins. The cylinders only lift and lower the tank. During service the tank is supported by the rack and pin supports.

4.

When the sled is level and the tank is raised, the hydraulic supply from the mobile machine can be disconnected, and the pump or transformer unit can be connected to hydraulic supply lines, or connected to cables, and put into service.

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Section.

9

Disconnecting the crawler unit Once the crawler unit is in position and the LHD unit is required to be disconnected, the following must be observed: 1. The LHD unit is to be powered down as per relevant procedure.

2. The 6m hose pack can then be disconnected from the pendant and stowed.

3. The 10m hose pack can then be disconnected and stowed.

The crawler units do not retain pressure in the hydraulic system once the LHD unit is shut down, with the exception of the pump station jacking cylinders. The jacking cylinders will retain fluid pressure until the levelling lever on the crawler unit is operated.

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Section

10.

Track Maintenance Tensioning Tracks General Tensioning the tracks is achieved by a grease filled cylinder, which extends the idler bogie in each of the tracks. Access to the cylinder and grease valve is by two plates on each of the track assemblies.

Idler hub assembly

Track tensioner shock absorber spring

Tensioning cylinder

Track master link

Procedure Carry out any specific safety work or isolation procedures to ensure the equipment is safe to be worked on.

To check the track tension you must raise the track frame clear of the ground by driving the crawler unit onto suitable chocks. Ensure the chocks are far enough under the track to prevent them moving out, but not so far that they cause a false sag indication.

Measure the distance between the underside of the track frame and the inside of the track pad, as shown below.

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DANGER: Under no circumstances are personnel to place any part of their body beneath the crawler unit while it is on the chocks.

Ensure the chocks are far enough under the track to prevent them moving out due to the weight of the crawler unit.

Chocks

Sag from bottom of roller to inside track pad

The tension should be such that the distance when checked between the base of the guide roller flange and the track is approximately 55mm.

Any less than this and the track is too tight and requires slackening, and any more than this and the track is too loose and requires tensioning.

Important: Drive the crawler off the chocks before performing any track adjustment.

Remove the covers to gain access to the tensioning cylinder.

Cylinder and grease valve access plates

Clean around the tensioning cylinder and associated parts to allow access.

Tension the track using a grease gun connected to the track tensioning cylinder. Pump out the cylinder until the desired amount of tension is left in the track.

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Grease valve

To loosen the tracks, open the grease valve a few turns to relieve pressure in the tensioning cylinder, and drive the crawler unit back and forwards to force the tensioning hub in.

When the desired amount of tension is left in the track, the valve is to be closed.

Run the tracks again to ensure all is correct.

Once correct operation has been confirmed, the covers can be replaced and any isolation and safety procedures for the task removed.

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Replacement of Track Tensioning Cylinder General Tensioning the tracks is achieved by a grease filled cylinder, which extends the idler bogie in each of the tracks. Access to the cylinder and grease valve is by two plates on each of the track assemblies.

Procedure Carry out any specific safety work or isolation procedures to ensure the equipment is safe to be worked on.

Remove the covers to gain access to the tensioning cylinder.

Cylinder and Valve access plates

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Cylinder side

Grease valve side

Clean around the tensioning cylinder and associated parts to allow access.

Open the needle valve to allow grease to come out of the tensioning cylinder to enable it to be retracted.

Remove the crawler tracks as per procedure.

Remove the tensioning hub retaining plates.

Remove the two tensioning cylinder bolts from inside the grease valve port.

Retaining plate

Disconnect any grease supply lines from the tensioning cylinder.

Using a prise bar or other similar equipment, roll the tensioning hub assembly back along the track.

When the cylinder is free it can be removed from the track frame. Ensure the heavy cylinder is securely held when being lifted.

The bolt holes on the end of the cylinder are shown over page.

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Tensioning cylinder

To refit a tensioning cylinder, place the cylinder in the cylinder base securing block then roll the tensioning hub back into place.

Fit the two tensioning cylinder bolts from inside the grease valve hub.

The grease system should be reconnected correctly as per design.

Refit the track as per procedure, and re-tension the track using a grease gun on the grease valve.

The tension applied to the track should be checked and set according to procedure.

Once correct operation has been confirmed, the covers can be replaced and any isolation and safety procedures for the task removed.

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Replacement of Track from Track Frame General Tensioning the tracks is achieved by a grease filled cylinder, which extends the idler bogie in each of the tracks. Access to the cylinder and grease valve is by two plates on each of the track assemblies.

Procedure Carry out any specific safety work or isolation procedures to ensure the equipment is safe to be worked on.

Remove the covers to gain access to the tensioning cylinder.

Clean around the tensioning cylinder and associated parts to allow access.

Drive the crawler unit so that the track master link is accessible.

Open the grease valve a few turns to allow grease to come out of the tensioning cylinder, in order for it to be retracted.

Remove the tension from the track by driving the crawler unit back and forwards, forcing the tensioning cylinder back.

An example of the tensioning hub assembly is shown below.

Reduce the track tension sufficiently to allow access to the track master link.

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Track master link

When access is available to the track master link, the area must be made safe.

This is done by packing up the track in that area so that it cannot fall when work is been undertaken, or when the track is parted.

To break the track, the master link bolts can be removed, allowing the track to come apart.

Once parted, the track can be removed by pulling the track out from the frame, or driving it out using the drive system of the track.

Ensure safety by being aware of the many articulation points and therefore nip points on the track, and the weight of the track.

To refit a track, the track can be driven around the frame using the drive system once the track has been laced onto the drive sprocket.

It can also be installed by manipulating by hand and lifting equipment.

Ensure the track tensioning system has been fully retracted when installing a new track, to allow for tensioning to occur later.

When the track has been installed into the frame, the track will require rejoining. This is done by connecting the two end track pads together to check the track length.

When the track is test joined and all is correct, the method to permanently join the track is to install the track master link bolts.

The packing should then be removed from under the track.

The grease system should be operated and the track tensioned as per the track tensioning procedure.

Test run the track to ensure all is correct.

Once correct operation has been confirmed, the covers can be replaced and any isolation and safety procedures for the task removed.

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Track Assembly Removal Complete General This procedure is for the removal of the track and drive hub assembly as a complete unit from the crawler frame.

There are two locating keys that are used to locate the track units to the crawler frame. These are bolted to the track frame, but can be unbolted and rotated 180° and refitted. This provides a 50mm height adjustment of the crawler unit.

DANGER: Under no circumstances are personnel to place any part of their body beneath the crawler unit while it is suspended.

All care must be taken to ensure the crawler track drive frame does not fall or topple over when the securing bolts are removed.

Procedure - Removal 1.

Carry out any specific safety work or isolation procedures to ensure the equipment is safe to be worked on.

2.

Ensure the crawler unit is disconnected from the LHD hydraulic supply, and the hubs are not set to freewheel.

DANGER: The crawler must not be lifted more than 55mm during the removal procedure, otherwise damage to the drive frame keys will occur, and danger to personnel if the track drive frame should fall.

3.

Lift the crawler unit so that the weight is just taken off the track drive assembly, and support the crawler frame in place. The track drive assembly must not be lifted more than 55mm, otherwise damage to the drive frame keys will occur, and danger to personnel if the track drive frame should fall.

4.

Label the position and purpose of all 4 hydraulic connections so that they can be refitted correctly. The hoses are:

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Torque Hub A

Torque Hub B

Hydraulic Motor Drain

Torque Hub Brake Release

CAUTION: If hydraulic connections are installed incorrectly, damage to the hydraulic system WILL occur. Ensure the hydraulic hoses are clearly labelled.

5.

Disconnect the four (4) hydraulic hoses from the drive hub, and fit dust caps to all open hydraulic connections to prevent dirt ingress.

Hydraulic connections – drive hub

Hydraulic connections

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6.

Remove 14 off the 16 securing bolts, located behind the track. Leave one bolt at each end of the track drive assembly in place to prevent the unit from dislodging.

Frame securing bolts

M30 frame securing bolts

Track drive assembly – inner view

Frame locating key

M30 frame securing bolts

7. Using a lifting arrangement, fit two slings to the track drive assembly (one at each end of the track drive assembly, as far in as possible). Take the weight of the track drive assembly, and remove the last two bolts.

8. Carefully separate the track drive assembly from the crawler frame. It is located on two keys, and care must be taken to prevent damage to them.

9. The track drive assembly can now be moved clear of the crawler unit.

10. Repeat the procedure for the second track drive assembly.

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Procedure - Refitting DANGER: Under no circumstances are personnel to place any part of their body beneath the crawler unit while it is suspended.

All care must be taken to ensure the crawler track drive frame does not fall or topple over while being positioned.

1.

Ensure the crawler frame is positioned securely and at an adequate height.

2.

Using appropriate lifting equipment, position the track drive assembly so that the keys line up with the keyways on the crawler frame, and fit the track drive assembly into place. Each track drive assembly weighs 3700kg.

CAUTION: Do not use the securing bolts to draw the track drive assembly into place on the keyways, as this may cause equipment damage.

3.

Fit all 16 securing bolts in place and hand tighten. Using an appropriate torque wrench and socket extension, tighten the 16 M30 Cap Screw bolts in two stages so the final torque is 1700Nm. Frame securing bolts

Frame locating key

M30 frame securing bolts

CAUTION: If hydraulic connections are installed incorrectly, damage to the hydraulic system WILL occur. Ensure the hydraulic hoses are correctly installed.

4.

Fit the 4 hydraulic hoses to the drive hub in their correct locations. The hoses are:

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Torque Hub A

Torque Hub B

Hydraulic Motor Drain

Torque Hub Brake Release

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Hydraulic connections – drive hub

Hydraulic connections

5. Repeat the procedure for the second track drive assembly.

6. The crawler unit can now be lowered onto the ground and tested.

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Section.

11

Oil Filling of Planetary Hubs Track hubs are only to be filled with the track unit on level ground. The fill plug is to be horizontal with the centre line of the hub. There are three fill/drain plugs, allowing for ease of draining and filling depending on the orientation of the hub.

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Oil Capacity

3.75L

Oil Type

Omala 320

Oil Grade

320

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Top plug – Oil fill

Middle plug – Oil level

Bottom plug – Oil drain

The hub is fitted with three plugs. The hub must be positioned so that at least one of the plugs is on the centreline horizontal to the hub centre. This allows for the oil level to be checked and the oil can be topped up in this position.

The ideal position is with the hub orientated so the middle plug is on the hub centreline, as shown in the diagram above. The oil change procedure is as follows: 1.

Remove the top and middle plugs.

2.

Remove the bottom plug and allow the oil to drain from the hub.

3.

Once the hub is drained, refit the bottom plug.

4.

Fill the hub via the top plug hole until oil is present at the middle plug hole.

5.

Refit the middle and top plugs.

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