CAT Continuous Haulage System Operation & Maintenance Manual BI016242 - PDF DOWNLOAD

BI016242 A6474X251 Jan 2014

Operation and Maintenance Manual Continuous Haulage System

SAFETY.CAT.COM

BI016242

___________________________________________________________ This manual is intended to provide GENERAL product information. The illustrations, descriptions and procedures contained in this publication apply only to THIS machine. Caterpillar reserves the right to revise models and designs without prior notice.

This machine was manufactured under the guidelines, procedures and requirements of the appropriate government regulatory agencies.

At the completion of the manufacturing process, this unit was issued the appropriate approval numbers and nameplates indicating it met the technical requirements of these regulatory agencies. Any change to the design or structure of this unit, without the consent of Caterpillar and these regulatory agencies, or any repair or replacement of parts contrary to the instructions, may invalidate these approvals and render this unit unsafe to operate.

Strict compliance with all laws, regulations and practices regarding the safe operation and maintenance of underground mining equipment and strict adherence to the instructions in this manual is necessary for the personal safety of those working on or around this unit.

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

© CATERPILLAR 2014 ALL RIGHTS RESERVED

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_________________________________________________ Table of contents

Table of contents 1. About this manual About this manual ................................................................... 1.3 Before starting to work ......................................................... 1.3 Who is this operating manual intended for? ......................... 1.3 What is the purpose of this operating manual? .................... 1.4 Characters and symbols ....................................................... 1.5

2. Your safety Your safety ............................................................................... 2.3 Personnel ............................................................................. 2.4 Operation ......................................................................... 2.4 Installation and repair ...................................................... 2.4 Operating conditions ............................................................ 2.5 Intended use .................................................................... 2.5 Unauthorized use ............................................................ 2.5 Safety instructions ................................................................ 2.7 General rules: .................................................................. 2.7 Storage and transport ...................................................... 2.8 Pre-start inspection.......................................................... 2.9 Installation and start-up ................................................... 2.9 Operation ......................................................................... 2.9 Maintenance and repair ................................................. 2.10 Overview of the safety instructions .................................... 2.15 Chapter 3: Storage and transport .................................. 2.15 Chapter 4: Installation ................................................... 2.15 Chapter 5: Operation ..................................................... 2.16 Chapter 6: Technical data ............................................. 2.23

3. Storage and transport Storage and transport ............................................................. 3.3 Storage ................................................................................. 3.3 Storage of the equipment ................................................ 3.3 Transport .............................................................................. 3.4 Dimensions and weights ................................................. 3.4 Before transport ............................................................... 3.5

4. Installation Installation ............................................................................... 4.3 Points to observe prior to installation ................................... 4.3 Who is allowed to carry out installation ........................... 4.3 Which tools are required for installation .......................... 4.3 Notes on installation ........................................................ 4.4 Pre-installation check list ................................................. 4.5 Safety features ................................................................ 4.6 Overview of the continuous haulage system ........................ 4.8

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Table of contents ________________________________________________ 5. Operation Operation ................................................................................. 5.3 How to operate the continuous haulage system .................. 5.3 Controls and indicators ........................................................ 5.4 CST and radio remote....................................................... 5.4 IR remote .......................................................................... 5.9 Displays ...........................................................................5.11 Operating procedure ...........................................................5.20 Checklist ..........................................................................5.20 Operating procedures ......................................................5.22 Designating MBC identifications ...............................5.22 Radio remote unique identification ............................5.23 Starting the pump motor ............................................5.24 Starting the conveyors (automatic mode) .................5.25 Starting the conveyors (individual mode) ..................5.26 Jogging the conveyors ..............................................5.27 Tramming ..................................................................5.28 Stopping the pump ....................................................5.29 Pump motor reset ......................................................5.30 Power fill………………………………………………...5.30 Continuous haulage system maintenance instructions .......5.31 Important notes ..............................................................5.31 Before maintenance .......................................................5.31 Lubricants .......................................................................5.33 MBC lubrication instructions ...........................................5.34 Central lubrication system .........................................5.34 Specific lubrication procedures .................................5.37 Every 8 hours ............................................................5.37 Daily...........................................................................5.39 Every week ................................................................5.40 After first 50 hours of service.....................................5.42 Every 2 weeks ...........................................................5.43 Every month ..............................................................5.46 Every 3 months .........................................................5.49 Every 6 months .........................................................5.50 As required ................................................................5.51 PIG lubrication instructions ............................................5.52 Specific lubrication procedures (PIG) ........................5.53 Daily...........................................................................5.53 Every week ................................................................5.54 Every 30 hours ..........................................................5.55 Every 3 to 6 months ..................................................5.56 Every 6 months .........................................................5.57 RFM tail dolly lubrication instructions .............................5.58 Specific lubrication procedures (RFM tail dolly) ........5.59 Every 8 hours ............................................................5.59 Every 24 hours ..........................................................5.59

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_________________________________________________ Table of contents RFM pulley support section lubrication instructions ...... 5.60 Specific lubrication procedures ............................. 5.61 Every 8 hours ........................................................ 5.61 Every 6 months ..................................................... 5.61 Intermediate RFM section lubrication instructions ........ 5.62 Specific lubrication procedures ............................. 5.63 Every 6 months ..................................................... 5.63 MBC inspection ............................................................. 5.64 MBC wear part inspections ........................................... 5.65 MBC Fire suppression inspection .................................. 5.65 MBC Fire suppression recharge.................................... 5.67 PIG inspection ............................................................... 5.70 PIG wear part inspections ............................................. 5.70 RFM inspection.............................................................. 5.71 Adjustment procedures ...................................................... 5.73 Mobile bridge carrier ...................................................... 5.73 Conveyor chain ..................................................... 5.73 Crawler track ......................................................... 5.75 Piggyback bridge conveyor - conveyor chain ................ 5.77 Replacement of parts .........................................................

Mobile bridge carrier (MBC) .......................................... 5.79 Conveyor drive ...................................................... 5.79 Drive shaft ............................................................. 5.80 Removal .......................................................... 5.81 Installation ....................................................... 5.84 Drive shaft sprocket............................................... 5.88 Removal .......................................................... 5.89 Installation ....................................................... 5.89 Field replacement ........................................... 5.90 Conveyor drive module ......................................... 5.92 Removal .......................................................... 5.93 Installation ....................................................... 5.94 Disassembly.................................................... 5.95 Assembly ........................................................ 5.96 Tail shaft ................................................................ 5.98 Removal .......................................................... 5.99 Installation ....................................................... 5.99 Disassembly................................................... 5.101 Assembly ....................................................... 5.102 Conveyor chain .................................................... 5.103 Conveyor chain section assembly ................. 5.104 Removal ......................................................... 5.105 Installation ...................................................... 5.106 Crawler track ........................................................ 5.108 Removal ......................................................... 5.109 Assembly ....................................................... 5.109 Installation ...................................................... 5.110 Crawler drive module ........................................... 5.111 Disassembly .................................................. 5.112 Assembly ...................................................... 5.113 Crawler take-up and idler ..................................... 5.114 Removal ......................................................... 5.115 Installation ...................................................... 5.116

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Table of contents ________________________________________________ Piggyback bridge conveyor (PIG) ................................ 5.117 Conveyor drive..................................................... 5.117 Drive shaft............................................................ 5.118 Removal ........................................................ 5.119 Installation ..................................................... 5.121 Drive shaft sprockets ........................................... 5.124 Removal ........................................................ 5.125 Installation ..................................................... 5.125 Field replacement.......................................... 5.126 Conveyor drive module ........................................ 5.127 Removal ........................................................ 5.128 Installation ..................................................... 5.129 Disassembly .................................................. 5.131 Assembly....................................................... 5.131 Tail shaft .............................................................. 5.133 Removal ........................................................ 5.134 Installation ..................................................... 5.134 Disassembly .................................................. 5.135 Assembly....................................................... 5.136 Conveyor chain .................................................... 5.138 Assembly....................................................... 5.139 Removal ........................................................ 5.140 Installation ..................................................... 5.141 Mobile bridge carrier (MBC)......................................... 5.143 Hydraulic components (MBC).............................. 5.143 Tram hydrostatic pump ........................................ 5.145 Disassembly .................................................. 5.146 Assembly....................................................... 5.147 Tram motor .......................................................... 5.148 Removal......................................................... 5.148 Installation...................................................... 5.148 Conveyor lift cylinders (inby and outby) .............. 5.149 Removal ........................................................ 5.149 Installation .................................................... 5.150 Canopy cylinder ................................................... 5.151 Removal......................................................... 5.151 Installation...................................................... 5.151 Troubleshooting procedures ........................................ 5.153 Hydraulic system (general) .................................. 5.154 Hydraulic cylinders .............................................. 5.156 Hydraulic pump .................................................... 5.157 Valves .................................................................. 5.160 Error codes .......................................................... 5.161 Communication faults .................................... 5.162 Fault log codes .............................................. 5.162 Real time codes ............................................ 5.165

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_________________________________________________ Table of contents 6. Technical data Technical data ......................................................................... 6.3 Components of the continuous haulage system .................. 6.3 Mobile Bridge Carrier (MBC) ........................................... 6.3 Piggyback Bridge Conveyor (PBC) ................................. 6.4 Piggyback Bridge Conveyor (PBC—liquid cooled) ......... 6.5 MBC dolly ........................................................................ 6.5 RFM pulley section .......................................................... 6.5 RFM intermediate section ............................................... 6.5 Tail dolly .......................................................................... 6.5 Tightening torques ................................................................ 6.7 Permissible media .............................................................. 6.13 Lubrication fluids and greases ....................................... 6.13

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1

About this manual

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___________________________________________ Before starting to work

About this manual This chapter provides important information making it easier for you to use this manual. You will also be given information on the structure of the manual and the symbols and characters used.

Before starting to work applicable operating manual machine type

Take care to ensure that the operating manual available to you is applicable for the type of equipment or machine used.

This operating manual is intended for: Continuous Haulage System Serial No.: N/A and is only permitted to be used for equipment of this type.

new operation manual

The operating manual must be accessible at all times to all persons working on or with the machine.

It should, if possible, always be available at the place of operation.

Send for a new operation 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 those persons who work with or on the machine.

Every person working on the face or in the intersection between face and entry or in the entry must read this operating manual.

This includes persons who: ■ ■ ■ ■ ■ ■ ■

are in charge of transport perform assembly / disassembly work operate the machine eliminate faults perform daily routine work on the face or in the entry perform maintenance work perform repair work

supervisory personnel who: ■ ■

initiate and/or supervise the activities just indicated.

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Before starting to work____________________________________________ What is the purpose of this operating manual? cost-effectiveness

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 machine.

Read this operating manual completely and at ease. Pay special attention to the safety instructions. Try to memorize the appearance and the meaning of the safety and instruction symbols.

service

If any details are not clearly understood, please contact our service department. Our service address is given in the chapter titled “For your information”.

safety

Read the chapter “For your safety” with special attention. The chapter contains important information indicating possible hazards. Observe the information given and follow the procedural instructions .

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___________________________________________ Before starting to work Characters and symbols used The following characters and symbols are used for safety instructions and important information in the operating manual.

Try to memorize the symbols and their meanings.

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

WARNING! These points contain information on dangerous situations.

Possible consequences are: very serious injury or even death.

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

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

IMPORTANT! 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.

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Before starting to work____________________________________________

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Your safety

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_____________________________________________________ Your safety

Your safety This chapter provides vital information for your safety. Pay special attention to this chapter. The safety instructions and rules of procedure will help you to avoid hazardous situations and to perform the necessary work as safely as possible. state of the art

The machine has been manufactured in accordance with the state of the art and generally recognized safety standards and 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 machine. All modifications and changes must be approved.

Use only original spare parts. Note that the use of parts from other manufacturers will void the guarantee.

In addition to this operating manual be sure to also observe the respective legal provisions and regulations in your country.

Observe the safety and accident prevention regulations:

further operating manuals

■

of the mine

■

of the mine’s inspectors, 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.

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Personnel_______________________________________________________ Personnel Operation training

The machine may only be operated by qualified, trained personnel.

The machine is only allowed to be operated by qualified personnel who can provide proof of having been trained on this unit. Reading of the operation manual, especially the chapter on safety, shall constitute a part of this training.

You must have adequate knowledge of the ■

mechanics,

■

hydraulics, and

■

control engineering

and must be able to prove this knowledge.

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 (motors, controllers, etc.)

■

the hydraulics (controls, cylinders, etc.)

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

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_____________________________________________ Operating conditions Operating conditions Intended use The continuous haulage system has been designed and manufactured purely for transporting mined material from a continuous miner to the main conveying system for transporting outside.

Intended uses include: ■

the transport of mined material between continuous miner and main conveying system

Unauthorized use Applications not expressly listed as intended uses are unauthorized uses and are not allowed to be performed with the machine.

■

the transport of persons

■

the transport of objects of any kind such as e.g. single props, boards, spare parts, etc.

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

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Operating conditions _____________________________________________

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_______________________________________________ Safety instructions Safety instructions General Rules general

Always work with full concentration.

Familiarize yourself with your working environment.

noise emissions

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).

Inform your colleagues of:

safety equipment

■

your exact location

■

the work you are performing

■

the time that you will probably require

Start the machine only when it is in a good and safe operating condition and all protective devices, e.g. EMERGENCY STOP devices, cover plates, etc. are correctly installed.

Observe the acoustic and optical start-up warnings of the haulage system.

symbol plates EMERGENCY STOP

lock-out

cordon off working area

Observe the symbol plates on the machine.

Press the EMERGENCY STOP switch immediately in the event of fault or irregularities in operation. Report any peculiarity to your superior so that necessary measures can be taken immediately.

Lock-out and disconnect the power system while performing: ■

maintenance work

■

inspection work

■

repair work

Cordon off your working area widely for continuous haulage systems.

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Safety instructions _______________________________________________ moving parts

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

conveyor chains

■

flights

■

pivot points

■

boom assemblies

■

crawler assemblies

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

Do not store materials or parts in the travel way 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 sheet.

Only use means of attachment which are in 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 pans only with conveyor pan grippers.

mobile handling equipment

When using mobile handling systems for transport make sure that the center of gravity is as low as possible.

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_______________________________________________ Safety instructions Pre-start inspection operation

Read this entire guide before attempting to operate this machine.

inspection

Inspect the machine and have any malfunctioning, broken, or missing parts corrected or replaced before use.

maintenance instruction and safety tags operator’s compartment cab/canopy

Verify that all maintenance has been performed.

Verify that all instruction and safety tags are in place and readable.

These are as important as any other equipment on the machine.

Clean any foreign material from the operator’s compartment.

This machine was shipped from the factory equipped with a protective cab/canopy. The cab/canopy MUST be securely in place before operating the unit unless all appropriate approvals are received.

Installation and start-up inclined face

On inclined faces secure all component parts by chains, e.g. to the support.

The Piggyback Bridge Conveyor (PIG) must be secured with anchorages to prevent it from shifting sideways.

environmental acceptability

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

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

controls

starting procedures

When starting up the machine, do not operate any controls located inside the operator’s compartment from outside the compartment.

Follow the starting procedure in chapter 5 of this manual.

Operation training

before start-up protective devices

Operate the haulage 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 haulage system.

Before start-up, ensure that there are no persons or obstructions in your line of travel or around the machine.

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

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Safety instructions _______________________________________________ operator’s compartment

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

Never climb onto, or climb out of the machine while it is in motion.

Do not operate the machine with any part of your body outside of the operator’s compartment in order to prevent body parts from being crushed between the machine and outside objects.

Do not leave the operator’s compartment with the unit running. Always properly shut down the unit before leaving the operator’s compartment.

passengers

Never carry passengers to prevent the passengers from being thrown off or crushed between the machine and outside objects.

safety rules

Always follow all safety rules of each particular mine when operating the machine

problems and malfunctions

If problems or malfunctions are encountered while operating the unit, it must be shutdown and the problem corrected immediately.

Maintenance and repair securing

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.

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

Lock-out and disconnect power from the machine to prevent unauthorized and unintentional restarting.

Protect your work area against falling rocks.

replacing components

Stop, lock-out, and disconnect power from machine to prevent restarting before replacing any defective components.

Pass defective components removed on for servicing without delay in order to prevent these parts being reinstalled elsewhere.

original parts

Use only spare parts which satisfy the specified technical requirements.

This is only ensured with original spare parts.

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

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_______________________________________________ Safety instructions lifting the PIG

handling of hydraulic fluids

For raising the piggyback bridge conveyor (PIG) use only: ■

crib blocks with adequate load-holding capacity

■

hoists or cranes with adequate load-carrying capacity

Avoid direct contact between the skin and hydraulic fluids.

Hydraulic fluid can penetrate the skin and cause serious infection.

Never use hydraulic fluid for rinsing or cleaning. Hydraulic fluid represents 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.

Avoid, whenever possible, servicing, cleaning, or examining the machine in congested areas.

Do not alter the electrical or hydraulic settings from that indicated in this manual or as set at the factory.

Always replace damaged or lost decals and metal instruction plates.

Lock-out and disconnect power when working with the electrical system, or when welding on the unit to prevent electrical shock.

Always follow all safety procedures of each particular mine when performing maintenance.

It is important that any procedure not specifically recommended in this guide be thoroughly evaluated from the standpoint of safety before it is implemented.

Some illustrations in this manual show guards or cover panels removed for purposes of clarity. Never operate unit without guards or cover panels in place.

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 hose or outer sheathes of the hose 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

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Safety instructions _______________________________________________ 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.

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

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 and with both sides. Never use nails, wire or similar materials for securing. permissible hoses

Use only hydraulic hoses approved for the prevailing pressures.

Do not use any hydraulic hoses with damaged connectors or worn orings.

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

Observe the date of manufacture stamped on the hydraulic hoses (Fig. 1). Never use hydraulic hoses which are more than 2 years old, even if they have no visible signs of damage.

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

Never try to repair damaged hydraulic hoses.

Replace hydraulic hoses at the first suspicion of damage.

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_______________________________________________ Safety instructions laying hydraulic hoses

Lay the hydraulic hoses properly behind the brackets and clamps provided for them.

Always lay hydraulic hoses so they: ■

always have a little slack (Fig. 1).

Fig. 1: Laying hydraulic hoses, slack RIGHT

■

WRONG

are not twisted (Fig. 2).

Fig. 2: Laying hydraulic hoses, twisting RIGHT

■

WRONG

are not bent directly behind the connections (Fig. 3). (distance min. 1.5 x nominal diameter).

Fig. 3: Laying hydraulic hoses, bending RIGHT

WRONG

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Safety instructions _______________________________________________ ■

cannot chafe (Fig. 4).

Fig. 4: Laying hydraulic hoses, crossing RIGHT

■

are not kinked.

■

do not have to withstand tensile strains.

■

are protected against thermal radiation.

■

are accessible at all times.

WRONG

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 movement of the machine (Fig. 5).

Fig. 5: Laying hydraulic hoses, connections on moving parts RIGHT

WRONG

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3

Storage and transport

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____________________________________________ Storage and transport

Storage and transport This chapter contains important information on the correct storage and transport of the continuous haulage system. Observance of the instructions and tips will increase the service life and availability of the system. 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 approximately six months.

Before delivery, the hydraulically operated equipment is operated with a test medium which is drained as far as possible prior to shipment.

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

dirt and moisture

Store the equipment indoors or cover with a tarpaulin to protect against direct exposure to sunlight. Store the electrical equipment, electronic components, spare parts of rubber or plastic – such as seals, hoses and tires – and hydraulic fluids only in closed rooms at temperatures of 60° F (15° C) to 77° F (25°C).

Protect the equipment and all spare parts 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 (approximately 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

If the equipment is to be stored more than six months, the hydraulic components must be completely filled with a corrosion inhibiting/frostproofing fluid.

Fill the hollow areas of hydraulic components (e.g. the piston chambers) in horizontal position (ports facing upwards) until they start to overflow. Then seal the ports with plastic or steel plugs.

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

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Storage and transport ____________________________________________ plastic deformation

random sample inspection

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

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.

natural aging

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 chapter 6 in this operating manual.

IMPORTANT! Take care to insure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

Transport Dimensions and weights Observe the transport sheets for the machine and spare parts. They contain information on: ■

dimensions

■

weight

■

lifting points, etc.

Additional information on the dimensions and weights can be found in chapter 6 in this operating manual.

WARNING! 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.

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____________________________________________ Storage and transport 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 inhibitor/frostproofing fluid.

Transport of equipment at temperatures between -6° F (-21° C) and -40° F (-40° C) is only permissible when certain measures were taken to meet these conditions at the design and manufacture 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-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 a maximum of 15 mph (25 kph) for truck transport.

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.

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Storage and transport ____________________________________________

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4

Installation

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______________________________________________________ Installation

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

Installation is only allowed to be carried out by personnel having received adequate training to perform this task.

Work on: ■

the safety components (pressure relief valves, fire extinguishing equipment etc.)

■

the electrical equipment (control units, signaling devices, etc.), and

■

the hydraulic equipment (cylinders, directional control valves, hoses etc.)

should only be carried out by service engineers or by specially trained personnel.

Which tools are required for installation? tool box

No special tools are required to put the continuous haulage system into service.

In addition, various items of auxiliary equipment and machines are required at the point of installation.

These include: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

impact wrenches, including accessories

■

jacks with adequate lifting capacity

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Installation ______________________________________________________ Notes on installation CAUTION! Serious damage can be caused to the continuous haulage system as a result of incorrect installation. The system should therefore only be installed under the instruction of specialists. installation plan

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 steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established.

IMPORTANT! 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 steps to be taken with respect to transport and assembly should be prepared and a corresponding plan established

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______________________________________________________ Installation Pre-installation check list NOTICE! The machine was inspected prior to shipment from the factory to ensure proper functioning and installation of all components.

However, to ensure that no transit damage has occurred, the following pre-startup checks should be performed: ■ ■ ■ ■ ■

Perform daily maintenance.

Visually inspect all hydraulic hoses and electrical cables for damage.

Clean any foreign material from the operator’s compartment.

Clean any foreign material from the conveyors.

Check conveyor chain for tension.

WARNING! Working on chains which are under tension requires particular care. You or others could be seriously injured or 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 alongside of the conveyor chain.

■ ■

Check safety provisions for operational condition on the fire suppression system.

Start up the machine and check for correct operation of the panic strip and emergency stop which are located inside the operator’s compartment.

WARNING! Make sure that nobody is present in the danger area of the conveyor 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.

■ ■ ■ ■

Check that all covers and guards are in place and secure.

Check that all tags and instruction labels are in place and secure.

Check that operator’s canopy is in place and secure.

Start the machine and allow the hydraulic system to warm up for 5 to 10 minutes.

WARNING! You could be injured or killed by a jumping hydraulic hose.

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.

■ ■

Check hydraulic system pressures (refer to the hydraulic schematic supplied for your particular machine for pressure settings).

Check all control switches to all machine functions are operation properly.

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Installation ______________________________________________________ Safety features NOTICE! The operator must become familiar with all the safety features and their location on the system prior to installation or operation.

Safety features include (Fig. 7): panic strip

The MBC is equipped with a panic strip located on the operator’s left while sitting in the in the operator’s compartment. The panic strip is actuated by striking it and can be actuated with only a small amount of force. The panic strips are used to break the control circuit, stopping all motors.

machine stop pushbutton

There is a machine stop pushbutton located inside the MBC operator’s compartment. If this button is pressed it will break the control circuit, stopping all motors. The machine stop button may be used to shut down the machine in emergency situations.

man-in-position switch

The MBC is equipped with a man-in-position switch (footswitch) in the operators compartment. If any operator takes his/her foot from the switch, it will break the control circuit, stopping all motors. The footswitch may be used to shutdown the machine in emergency situations

Canopy/cab

The MBC was shipped from the factory with a protective canopy/cab.

Ensure that the canopy/cab is in place and secure at all times to protect the operator from falling debris. The system must not be operated without the canopy unless all appropriate approvals are received.

fire suppression

The MBC is equipped with two fire suppression (remote) actuators.

The actuators are located as follows: ■ ■

To the operator’s left inside the MBC operator’s compartment Near the left crawler drive opposite the operator.

This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two actuators: ■ ■

Pull the safety pin Strike the plunger.

Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine. The fire suppression system must be completely recharged with dry chemicals and expellants after it has been actuated.

WARNING! If either of the fire suppression actuators is actuated, the system must be completely recharged with dry chemicals and expellants.

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______________________________________________________ Installation guards and covers

The system is equipped with guards and covers to reduce the possibility of personnel coming in contact with rotating or moving parts. All guards and covers must be installed and securely fastened during operation.

DANGER! Do not operate the system with any of the guards or covers removed. You or other personnel could be seriously injured from moving or rotating parts.

circuit breaker horn

The MBC is equipped with a circuit breaker located on the electrical box on the operator’s side of the machine.

The MBC is equipped with a horn located inside the operator’s compartment. The horn will sound automatically at times and can be sounded by hand. The horn should be used in accordance with the safety standards at the mine where the continuous haulage system is being used.

Fig. 6: Safety features on the continuous haulage system

Circuit breaker

Fire suppression actuator

Canopy/cab

Fire suppression actuator

Machine stop pushbutton

Horn

Man-in-position switch Panic strip

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Installation ______________________________________________________ Overview of the continuous haulage system Fig. 7: Overview of a typical 6 unit continuous haulage system

Piggyback bridge conveyor (PIG) Mobile bridge carrier (MBC) with hopper

Tail pulley support

Mobile bridge carrier (MBC)

RFM intermediate Piggyback bridge conveyor (PIG)

Mobile bridge carrier (MBC)

Piggyback bridge conveyor (PIG)

Tail dolly

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______________________________________________________ Installation Fig. 8: Overview of the mobile bridge carrier (MBC) MBC dolly

Receiving boom

Conveyor chain

Crawler drive (left)

Crawler drive (right)

Hydraulic oil tank

Adjustable canopy Discharge boom

Conveyor drive

Driveshaft

Operator’s compartment

Bolt-on yoke plate

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Installation ______________________________________________________ Fig. 19: Overview of the piggyback bridge conveyor (PBC) Pin-on yoke plate Tailshaft

Conveyor chain

Conveyor drive

Drive shaft

Bolt-on yoke plate

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______________________________________________________ Installation Fig. 10: Overview of the RFM intermediate section

4” Diameter roll

Frame

Pin

Fig. 11: Overview of the tail pulley support section 12” Diameter pulley

Belt wiper

4” Diameter roll

Frame

Pin

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Installation ______________________________________________________ Fig. 12: Overview of tail dolly Wheel

Belt trainer

Breaker mounting plate

Bolt-on yoke plate

Wheel (4)

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5

Operation

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_______________________________________________________ Operation

Operation This chapter contains important information on the operation and maintenance of the continuous haulage system. 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”.

How to operate the continuous haulage system DANGER! Incorrect operation endangers yourself and others!

Incorrect operation of the system is often the cause of very serious accidents!

Operate the unit only when you have been sufficiently trained on the installed haulage system and have read and understood this operating manual.

Should anything be unclear, please contact your immediate supervisor.

Who is allowed to operate the continuous haulage system?

The continuous haulage system is only allowed to be operated by persons with adequate knowledge of the complete system.

This also includes: ■

what safety devices are installed on the system.

■

where these safety devices are located.

■

How these safety devices are to be operated.

When can conveying be started?

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

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Operation _______________________________________________________ Controls and Indicators Control Station (CST) or radio remote

The primary controls for the system are the CST, located in the MBC operator’s compartment (Fig. 13) or the radio remote. The CST and the radio remote operate identically with the exception that the radio remote has a power on (“TX PWR”) button and a “MODE” LED. The CST and radio remote each have the control switches, pushbuttons, and handles that are necessary to control the operation of one MBC and one outby side PIG (except for an attached system, where the most inby MBC’s CST will control one MBC and two PIGs, one inby side and one outby side).

WARNING! Each radio remote (transmitter) and machine controller (RF card) must be configured to the same unique mode for safe operation of the MBC. See the Operating Procedure section of this chapter for mode configuration.

Fig. 13: CST location in MBC operator’s compartment

CST

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_______________________________________________________ Operation Fig. 14: CST /radio remote controls 1

2

3

4

7

6

5

9

8

20 24

21 22 23

19

18

17

1. Motor start enable 2. System stop/reset 3. Conveyor jog 4. PIG #1 start/stop 5. PIG #2 start/stop 6. Conveyor mode control 7. Conveyor direction 8. MBC conveyor stop/start 9. MBC pump motor start/stop 10. Canopy up/down 11. Cab up/down 12. Lights on/off

16

15

14

13

12

11

10

13. Inby boom up/down 14. Outby boom up/down 15. Tram enable 16. Machine stop 17. Horn 18. Right tram control 19. Left tram control 20. Switch active LED 21. Mode LED (TX only) 22. Tram enable LED 23. End station power LED 24. Transmitter power (TX only)

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Operation _______________________________________________________ CST/radio remote control buttons and switches (reference Fig. 14)/ “MOTOR START ENABLE”

The green “MOTOR START ENABLE” button must be held when starting a motor or jogging the conveyor (two handed operations). Both the enable button and the function start switch must be held until the horn sounds, indicating that the MCU has received the start message.

“SYSTEM STOP/RESET”

The “SYSTEM STOP/RESET” toggle switch is a three position switch.

Moving the switch to the “STOP” position will stop all motors in the system. A system stop message will be displayed indicating which MBC activate the system stop. The switch will stay in the stop position until it is manually moved to another position.

WARNING! If an MBC is placed in “MANUAL/MAINTENANCE” mode using the IR remote and it is connected to other MBCs, it is a stand alone MBC and will not interact with other MBCs, therefore the “SYSTEM STOP” button on any other MBC will not shut down the system.

Any time the system is shut down by any method (“SYSTEM STOP”, “MACHINE STOP”, open foot switch, or by a fault), the “SYSTEM STOP/RESET” switch on each MBC must be moved to the “RESET” position before any motor can be restarted. The reset position is momentary, the switch will automatically return to the centered position when released.

If the tape switch is activated, the “IN POSITION” (located above the tape switch) must be pushed before “RESET” is engaged.

“JOG”

The conveyor “JOG” start/stop switch allows temporary conveyor use without running other conveyors in the system. The conveyor can be jogged in either the forward (towards the belt) or reverse (towards the face) direction. The jog function must be used in conjunction with the “MOTOR START ENABLE” button as well as the start button for the conveyor to be jogged.

“PIG #1”

The “PIG #1” start/stop switch starts the outby side PIG attached to that MBC when operated in individual mode. This switch must be used in conjunction with the “MOTOR START ENABLE” switch and is momentary (will return to center when released).

“PIG #2”

The “PIG #2” start/stop switch starts the most inby side PIG on the most inby side MBC on an attached haulage system when operated in individual mode. This switch must be used in conjunction with the “MOTOR START ENABLE” switch and is momentary (will return to center when released).

“CONV CNTRL”

The conveyor control, “CONV CNTRL”, toggle switch allows the system to be placed in individual or automatic mode. Automatic mode is used for normal operation and the switch should be kept in this position. Individual mode allows each conveyor in the system to be started individually and is used for maintenance and troubleshooting.

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_______________________________________________________ Operation “CONV DIR”

The conveyor direction switch, “CONV DIR”, is used to choose the direction of operation of the conveyor. Forward (toward the belt) is the normal mode of operation and the switch should be kept in this position.

Reverse (towards the face) is only used during maintenance and troubleshooting and is a jog only function.

“MBC”

The MBC conveyor start/stop toggle switch, “MBC”, is used in conjunction with the “MOTOR START ENABLE” switch. When in automatic mode, the “MBC” start switch will turn on both the MBC conveyor and the PIG’s conveyor. This switch is momentary and will return to center when released.

“MOTOR”

The “MOTOR” start/stop toggle switch is used to turn the pump motor on and off. This switch must be used in conjunction with the “MOTOR START ENABLE” switch and is momentary (will return to center when released).

“CANOPY”

The “CANOPY” up/down toggle switch is used to adjust the vertical position the operator’s compartment protective canopy. This switch is momentary (will return to center when released).

“CAB”

The “CAB” up/down toggle switch is used to adjust the vertical position of the operator’s compartment. This switch is momentary (will return to center when released).

“LIGHT”

The “LIGHT” toggle switch is used to turn the MBC lights (if equipped) on and off.

“INBY”

The “INBY” switch is used to vertically position the inby side boom. The switch is momentary (will return to center when released).

“OUTBY”

The “OUTBY” switch is used to vertically position the inby side boom.

The switch is momentary (will return to center when released).

“TRAM ENABLE”

The “TRAM ENABLE” button must be pressed before tramming functions are active. All pump motors on all MBCs must be running and both tram handles must be in the centered position before tramming can be enabled. After pressing tram enable, the operator has eight seconds to activate a tram function. If the eight seconds elapses before a tram function is engaged, or if there are eight seconds between tramming function engagements, tramming will be disabled. The tram enable button will have to be pressed again.

“MACHINE STOP”

The “MACHINE STOP” button functions as a secondary “SYSTEM STOP”. Pressing the “MACHINE STOP” button will break the control circuit, shutting down all motors in the system. A system stop message will be displayed indicating which MBC was stopped. This button will stay in the stopped position until the “SYSTEM RESET” switch is activated.

WARNING! If an MBC is placed in “MANUAL/MAINTENANCE” mode using the IR remote and it is connected to other MBCs, it is stand alone and will not interact with other MBCs, therefore the “SYSTEM STOP” button on any other MBC will not shut down the system.

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Operation _______________________________________________________ “HORN”

Depressing the “HORN” button will sound the MBC’s warning horn. All applicable laws and regulations regarding horn use must be followed.

tram levers

The left and right tram handles are used to control the left and right tram tracks. The right and left tram handles are independent of each other to allow turning. The farther the tram handles are pushed away from center, the faster the machine will tram. The tram handles will automatically return to center (neutral) when released.

“SW ACTIVE” LED

The switch active LED, “SW ACTIVE”, will illuminate red whenever a switch on the CST or radio remote is active.

“MODE” LED

The “MODE” LED (radio remote) only, is used when setting the unique radio remote identification mode. See the Operating Procedure section of this chapter for mode configuration.

“TRAM ENABLE” LED

The “TRAM ENABLE” LED will illuminate red when tramming is enabled.

“EST POWER” LED

The end station power LED, “EST POWER”, is a diagnostic LED. It indicates how many messages per second the CST or radio remote is sending the MCU (machine controller).

“TX PWR”

The transmitter power button, “TX PWR, is only functional on the radio remote. This button is used to turn on the radio remote. The “MACHINE STOP” button is used to turn off the radio remote. If the radio remote does not receive switch input for approximately thirty minutes, it will turn itself off.

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_______________________________________________________ Operation display

The display (Fig. 14) is located in the MBC operator’s compartment of each MBC. Fig. 14: Display location in MBC operator’s compartment Display unit

display

The display screens are accessed through the use of a handheld infrared (IR) remote (Fig. 15).

WARNING! The handheld IR remote is not permissible and shall not be used in any area where permissible electrical equipment is required.

Use of the IR remote in a permissible area may result in injury or death.

WARNING! The handheld IR remote is only to be used by maintenance personnel. The remote is used to put a MBC in stand alone operation (“MANUAL/MAINTENANCE”) mode for maintenance/ troubleshooting only. Under no circumstances should the MBC be used in production operations while in “MANUAL/MAINTENANCE” mode.

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Operation _______________________________________________________ Fig. 15: Infrared (IR) remote

“MENU/ON”

“PAGE UP”

“SET” LED (alive)

“PAGE DOWN” “UP” “DOWN”

The functions of the IR remote controls are (reference Fig. 15):

“MENU/ON”

LED

The “MENU/ON” button turns the IR remote on. After the IR remote is turned on, pressing the “MENU/ON” button will return the display to the default screen.

If there is no activity for thirty seconds, the IR remote will turn off. The button is also used to access four menu pages: 1 Programming Mode, 2 Time/Date, 3 Error Log, and 4 System Comm Stat.

The LED will illuminate red when the IR remote is turned on (alive).

“PAGE UP”

Pressing the “PAGE UP” button will toggle the display to the previous page.

“PAGE DOWN”

Pressing the “PAGE DOWN” button will toggle the display to the next page.

“UP”

The “UP” button is used to increase variable values. Note: The value is not recognized by the system unless the “SET” button is pressed.

“DOWN”

The “DOWN” button is used to decrease variable values. Note: The value is not recognized by the system unless the “SET” button is pressed.

“SET”

The “SET” button is used to verify to the system that the value changed on the current single variable is a legitimate value that is to be written to memory. If the “SET” button is not pressed, the value is not changed.

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_______________________________________________________ Operation Upon power-up, the display will show the system name and the software date (Fig. 16). After approximately five seconds, the screen will change to show the current date and time (Fig. 16).

Fig. 16: Start up screens

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Operation _______________________________________________________ Menu 1 - Programming Mode Programming Mode menus (Fig. 17) allow the user to set values for the following: PSW: This parameter is the amount of time, in seconds, that the PreStart Warning horn will sound to alert personnel that some function on the machine (pump, conveyor, etc.) is starting. After the horn sounds, the function will start. This parameter is adjustable in 0.1 second intervals from 2.0 to 5.0 seconds.

AUX CONTACT DELAY: This parameter is the amount of time MCU has to receive a return signal that the auxiliary contactor has closed after a command has been issued. This value is set in seconds: the smaller the value, the faster the MCU expects a return signal. This parameter is adjustable in 0.1 second intervals from 2.0 to 5.0 seconds.

CONV MOTOR STAGGER: This parameter is the amount of time (second), while in manual mode, between the start up conveyor motors.

This parameter is adjustable in 0.1 second intervals from 0.5 to 5.0 seconds.

WARNING! If an MBC is placed in “MANUAL/MAINTENANCE” mode using the IR remote and it is connected to other MBCs, it is a stand alone MBC and will not interact with other MBCs, therefore the “SYSTEM STOP” button on any other MBC will not shut down the system.

MANUAL MODE: This parameter allows the manual operation mode to be turned off or on.

The parameters are adjusted using the “UP” and “DOWN” buttons on the IR remote. Press “SET” to accept the new values.

Fig. 17: Programming Mode menus

WARNING! “MANUAL/MAINTENANCE” mode is for maintenance/ troubleshooting only. Under no circumstances should the MBC be used in production operations while in “MANUAL/MAINTENANCE” mode.

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_______________________________________________________ Operation Menu 2 - Modify Time/Date Modify Time/Date menus (Fig. 18) allow the user to adjust the date and time. The “PAGE UP” and “PAGE DOWN” buttons are used to toggle between the screens. The parameters are adjusted using the “UP” and “DOWN” buttons on the IR remote.

Fig. 18: Modify Time/Date menus

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Operation _______________________________________________________ Menu 3 - ERR Log The error log menu (Fig. 19) allow the user to toggle through the stored errors. The following information is displayed: REC # 0: Each fault incident is assigned it’s own record number. Do not confuse the record number with the fault identifier number. The list of the faults that have occurred on the machine are in numerical order by record number, with the first fault being REC # 0, the second REC # 1, etc. The “UP” and “DOWN” buttons on the IR remote are used to scroll through the list. Pressing the “SET” button five times while record 0, REC # 0, is displayed will clear the error log.

Note: Even if the error log is cleared, the “RESET” button on the CST or the radio remote must be pressed before the error is cleared from the system and operation can resume.

D00/00/00: Date, in MM/DD/YYYY format, that the error occurred.

T00:00:00: Time, in HH:MM:SS format, that the error occurred. (###) Description: Unique fault identifier and description. In the example shown in Fig. 18, the fault identifier is “(255)” and the description is “EMPTY FAULT LOCATION”. A complete list of faults is given in the Troubleshooting section of this manual.

The “PAGE UP” and “PAGE DOWN” buttons on the IR remote do not have a function on the Err Log menu.

Fig. 19: Error log display

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_______________________________________________________ Operation Menu 4 - System Comm Stat The system communication status screen (Fig. 20) displays the communication status. This is a read only screen and the “UP”/”DOWN” and “PAGE UP”/”PAGE DOWN” keys have no function.

Pressing the “MENU “button on the remote returns the display to Menu 1: Programming Mode.

Fig. 20: System Comm Stat display

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Operation _______________________________________________________ In addition to the CST or radio remote, the following controls and indicators are located in the operator’s compartment (reference Fig. 21): tape switch (panic bar)

The tape switch (panic bar) is located to the left of the operator. Pressing the tape switch will break the control circuit, stopping all motors.

After pressing the tape switch, the “SYSTEM RESET” button and the inposition switch (if equipped) must be pressed before the motors can be restarted.

in-position switch (if equipped)

The in-position switch (if equipped) (Fig. 21) is used to reset the safety circuit when the machine is powered on, when the “REMOTE/OFF/ MANUAL” setting is changed, or after the tape switch (panic bar) is pressed.

man-in-position foot pedal

The man-in-position foot pedal is a safety device. The pedal must be kept depressed at all times during operation. Releasing the man-inposition switch will break the control circuit, stopping all motors. A message will be displayed showing which man-in-position switch was opened.

WARNING! Check for correct operation of the man-in-position foot pedal at the beginning of every shift.

fire suppression remote actuator

The MBC is equipped with two fire suppression remote actuators, one on the operator’s left inside the operator’s compartment (Fig. 21) and the other near the left crawler drive opposite the operator (Fig. 22).

This particular suppression system is pneumatically actuated and extinguishes with dry chemicals. To actuate the system from either of the two actuators pull the safety pin and strike the plunger. Immediately after the plunger is struck, dry chemical will be dispensed throughout the machine.

WARNING! If either of the fire suppression actuator are actuated, the system must be completely recharged with dry chemicals and expellants.

gauge panel

The gauge panel is used to display the following hydraulic oil pressures: ■ ■ ■ ■

left and right tram main pressure charge pressure valve bank pressure valve bank pilot pressure

See the hydraulic schematic for your machine for correct hydraulic pressures.

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_______________________________________________________ Operation Fig. 21: Tape switch (panic strip), gauge panel, and man-in-position switch

Left tram main pressure

Charge pressure

Tape switch (panic strip)

Right tram main pressure

“IN POSITION” button (if equipped)

Valve bank pressure

Valve bank pilot pressure

Man-in-position foot pedal

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Operation _______________________________________________________ Fig. 22: Fire suppression actuators

Operator’s compartment actuator

Crawler drive actuator

Plunger

Pin

Actuation cartridge

Typical actuator

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_______________________________________________________ Operation The following controls are located on the electrical enclosure: “REMOTE/OFF/MANUAL” switch

The “REMOTE/OFF/MANUAL” operation switch is used to place the MBC in remote operation or manual (operator’s compartment CST) operation. If equipped, the “IN-POSITION” button must be pressed for remote operation to become active.

circuit breaker reset lever

The circuit breaker lever is used to turn the main circuit breaker on and off, or to reset if the circuit breaker has tripped.

circuit breaker reset button

The circuit breaker reset button is used to reset the 15 amp circuit breaker.

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Operation _______________________________________________________ Pre-operation check list Before operating the system, the following points should be inspected: ■

Clean and remove any foreign material from the operator’s compartment.

■

Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.

■

Visually inspect the condition and readability of all tags, labels and reflectors.

■

Check the hydraulic oil level by looking at the two sight glasses; the sight glasses should be full.

■

Check oil level in the tram reducers.

■

Check oil level in the conveyor drive reducers.

■

Inspect all electrical and hydraulic components for condition.

■

Check for proper conveyor chain tension.

■

Lubricate per the lubrication schedule.

■

Check to insure that crawler track tension is properly adjusted.

■

Check the proper function of all operating levers, linkages, cylinders, locking devices, springs, etc.

■

Check trailing cable to power source insuring that the voltage and breaker settings are correct.

■

Check that each cable handling device is intact and oriented correctly.

■

Check that all covers are installed and secure.

■

Check the tightness of all connecting elements.

■

Check that all units are connected together mechanically in the correct order with all pins secured insuring that the “master” MBC is positioned outby.

■

Check that lights are working and unobstructed.

■

Check dirt indicators on filters.

■

Man-in-position foot switch operation

■

Tape switch operation

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_______________________________________________________ Operation CAUTION! During inspection, report any damage, missing parts, or other faults to your immediate supervisor.

■

Inspect the following wear parts: ■

conveyor chain

■

conveyor chain flights

■

conveyor drive sprockets

■

conveyor tail shaft

■

conveyor wear plates

■

chain strippers

■

crawler pads

■

crawler drive sprockets

■

crawler idler rollers

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Operation _______________________________________________________ Operating Procedures Designating MBC identification When the system is initially set up, each MBC must be identified as to position (inby, outby 1, outby 2, etc.). This is done by setting a rotary switch on each MBC’s MCU (Fig. 23), located in the starter box.

The following example is for a three MBC system: MBC 1 (farthest MBC from face) - switch is set to position O3 (outby 3) MBC 2 (next MBC inby) - switch is set to position I1 (inby 1) MBC 3 (MBC closest to the face) - switch is set to position I2 (inby 2) Fig. 23: MCU

MBC identification setting

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_______________________________________________________ Operation The continuous haulage system may be operated from the CSTs inside the MBC operator’s compartments or from radio remotes. If using radio remotes, each radio remote and each MBC RF card must be configured to a unique mode that will allow each radio remote to operate only one MBC. WARNING! Failure to set radio remote unique modes on EACH MBC may result in inadvertent machine movement. Severe injury, death, or machine damage may result.

Radio remote unique mode configuration procedure To configure the radio remote: 1. Depress and hold the “MOTOR START ENABLE” button on the radio remote.

2. While holding the “MOTOR START ENABLE” button, use the “CANOPY” toggle switch to set the mode. Moving the toggle switch to the “UP” position will increase the mode number while moving the switch to the “DOWN” position will decrease the mode number.

3. The “MODE” LED on the radio remote will blink as follows to indicate mode: Mode 1: blink, pause, blink, pause, blink, pause Mode 2: blink blink, pause, blink blink, pause, blink blink, pause Mode 3: blink blink blink, pause, blink blink blink, pause, blink blink blink, pause Mode 4: blink blink blink blink, pause, blink blink blink blink, pause, blink blink blink blink, pause To configure the RF card (located in the starter box): 1. Move the dial on the RF card to the corresponding mode to which the radio remote was configured (Mode 1, 2, 3, or 4).

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Operation _______________________________________________________ Starting procedure After proper training, which includes reading the previous descriptions and locating each control, the operator is ready to operate the continuous haulage system. An experienced operator should monitor a new operator's indoctrination to the starting procedure.

Trial runs should be made with particular emphasis placed on operating the system in an open area before trying to operate in a production environment.

WARNING! If operating the system in “NORMAL” mode (from the operator’s compartment), do not operate any levers or pedals from outside the operator's compartment. Do not operate the system with any part of your body outside the operator's compartment. Severe injury may result.

CAUTION! This unit is equipped with a cab or canopy. Be careful not to hit your head when entering or leaving the operator's compartment.

This machine must not be operated without the canopy unless all appropriate approvals are received.

1. Ensure that the main circuit breaker is in the “ON” position.

2. Verify that the “REMOTE/OFF/MANUAL” selector switch, located on the starter box, is the desired position.

3. Press the “IN POSITION” button (if equipped) located above the panic strip.

4. If operating in “NORMAL” mode, sit in the operator's seat and adjust the seat position relative to the foot and hand controls.

WARNING! Never try to adjust the operator's seat while the continuous haulage system is in motion.

5. Move the “SYSTEM STOP” button to the reset position.

6. Start the pump motor: a. Depress the foot switch. This switch must be held in during operation. Releasing the foot switch will shut down all motors. b. Press and hold the “MOTOR START ENABLE” button. c.

Move the “MOTOR” toggle switch to the “START” position and continue to hold until the pre-start warning horn sounds.

d. Release the “MOTOR START ENABLE” button and the “MOTOR” start switch.

The display screen should now show a “ALL PUMPS RUNNING” message.

________________________________________________________________ 5.24 Continuous Haulage System

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_______________________________________________________ Operation The panic strip, machine stop, or system stop button may be pressed at any time to stop the pump motors.

NOTICE! At initial start-up of the system, allow sufficient time (5 to 10 minutes) for the units to “warm up” since cold hydraulic fluid may cause erratic operation. High pressures could result in damage.

Start conveyors (automatic mode- normal operation) The PIG conveyors and the MBC conveyors can only be started after all pump motors are running. In a detached system, each MBC controls its conveyor and the PIG conveyor directly outby the MBC. In an attached system, the most inby MBC controls both its inby and outby PIGs and all other MBCs control only their outby PIG. IMPORTANT! The MBCs must be started in order, as follows: ■ ■ ■ ■

Start the most outby MBC conveyor first.

Once the most outby MBC has been started, a message will be displayed on the next inby MBC that the outby conveyors are running.

That next inby MBC conveyor may be started.

This sequence continues until all conveyors in the system are running.

1. Ensure that the conveyor control, “CONV CNTRL”, toggle switch is set to “AUTOMATIC”. All operators in the system must have the switch set to automatic.

2. Ensure that the conveyor direction, “CONV DIR” toggle switch is set to forward, “FWD”. All operators in the system must have the switch set to forward.

3. Press and hold the “MOTOR START ENABLE” pushbutton.

4. Move the “MBC” toggle switch to the “START” position and continue to hold. The pre-start warning horn will sound, the outby PIG conveyor will start, and then the MBC conveyor will start. There will be a delay (delay time is pre-set on Menu 1 of the display) between the start of the PIG conveyor and the MBC conveyor.

5. Release the “MOTOR START ENABLE” button and the “MBC” start switch.

Moving the “MBC” toggle switch to the “STOP” position will stop that MBC’s conveyor, the outby PIG conveyor, and all conveyors inby to that MBC. All conveyors outby of the stopped PIG conveyor will continue to run.

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Operation _______________________________________________________ Start conveyors (“MANUAL/MAINTNENANCE” mode maintenance/troubleshooting ONLY) “MANUAL/MAINTENANCE” mode of operation allows each conveyor in the system to be started individually for maintenance and troubleshooting only . Conveyors must still be started from outby to inby. In a detached system, each MBC controls its conveyor and the PIG directly outby the MBC. In an attached system, the most inby MBC controls both its inby and outby PIGs and all other MBCs control only their outby PIG. WARNING! If an MBC is placed in “MANUAL/MAINTENANCE” mode using the IR remote and it is connected to other MBCs, it is a stand alone MBC and will not interact with other MBCs, therefore the “SYSTEM STOP” button on any other MBC will not shut down the system.

However if the stop strip tape switch is pressed, it will still stop all connected MBCs. Note: Previous to s/n: 53-1405 (MBC) & 44-1965 (PIG), neither the “STSTEM STOP” button nor the stop strip tape switch on any other MBC will shut down the MBC that is in “MANUAL/ MAINTENANCE” mode.

1. Ensure that the conveyor control, “CONV CNTRL”, toggle switch is set to “AUTOMATIC”. All operators in the system must have the switch set to “AUTOMATIC”.

2. Ensure that the conveyor direction, “CONV DIR” toggle switch is set to forward, “FWD”. All operators in the system must have the switch set to forward.

3. Press and hold the “MOTOR START ENABLE” pushbutton.

4. Move the “PIG #1” toggle switch to the “START” position and continue to hold until the pre-start warning horn sounds. It will sound for three seconds before the conveyor will start.

5. Release the “MOTOR START ENABLE” button and the “PIG #1” switch.

6. Press and hold the “MOTOR START ENABLE” pushbutton.

7. Move the “MBC” switch to the “START” position and continue to hold until the pre-start warning horn sounds. It will sound for three seconds before the conveyor will start.

8.

Release the “MBC” switch and the “MOTOR START ENABLE” but-

ton.

To stop a conveyor, move that conveyor’s (MBC, PIG #1, or PIG #2) toggle switch to the “STOP” position. This will stop that conveyor and all conveyors inby to that conveyor. All conveyors outby of the stopped conveyor will continue to run.

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_______________________________________________________ Operation Jogging the conveyors The “JOG” function allows a conveyor to be run for a short time for maintenance (example: to clear a jam) or troubleshooting. Because the “JOG” function is only active in “INDIVIDUAL” mode, it allows individual conveyors to be operated independent of the system.

WARNING! The “JOG” function is for use during maintenance and troubleshooting functions only.

1. Ensure that conveyor control toggle switch, “CONV CNTRL”, is in the “INDIVIDUAL” position.

2. Move the conveyor direction toggle switch, “CONV DIR”, to the desired direction, forward (FWD) or reverse (REV).

3. Start the pump motor (see Startup procedure).

4. Move the “JOG” toggle switch to the start position and hold.

5. Press and hold the MOTOR START ENABLE pushbutton.

6. Move the appropriate toggle switch, MBC or PIG, to “START”.

7. Allow the warning horn to sound. It will sound for three seconds before the conveyor will start.

8. Release the conveyor, MBC or PIG, start/stop toggle switch to stop the conveyor.

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Operation _______________________________________________________ Tramming To tram any MBC all pumps must be running on all MBCs. Each track, right and left, is controlled both proportionally and variably in both directions by analog control toggles .

IMPORTANT! Before tramming, take note of the position of the dolly and the amount of travel available to the dolly. Careful attention must be given to the amount of dolly travel available for tramming and it is the operator’s responsibility to maintain an adequate amount of travel in both directions to permit a continuous operation of the miner thus optimizing the system.

1. Ensure that all pumps on all MBCs are running.

2. Check that the tram handles are in the centered position.

WARNING! It is very important to ensure that the tram handles are in the centered position before trying to tram.

3. Press the TRAM ENABLE pushbutton.

4. Move the tram handles to the desired direction and speed of tramming.

IMPORTANT! The tram function disables if not used for eight seconds.

■

If the tram handles are not moved within eight seconds of the tram enable button being pushed, the operator will need to push the tram enable button in order to begin tramming.

■

If the tram handles are released to centered position and no more movement is detected in eight seconds, the operator will need to push the tram enable button in order to resume tramming.

________________________________________________________________ 5.28 Continuous Haulage System

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_______________________________________________________ Operation Stopping Any of the following controls can be used to stop the system: ■

“MOTOR” start/stop toggle switch: Moving the “MOTOR” toggle switch to “STOP” will break the control circuit, stopping all motors.

A message will be displayed indicating which MBC pump motor was turned off. All MBCs must be reset before any motors can restart. In “MANUAL/MAINTENANCE” mode, this function is only active on the MBC in “MANUAL/MAINTENANCE” mode; all other MBCs will show a communication fault and will not operate.

■

SYSTEM STOP reset/stop toggle switch: Moving the “SYSTEM STOP” toggle switch to “STOP” will break the control circuit, stopping all motors. This switch will stay in the “STOP” position until manually moved. A message will be displayed indicating which system was turned off. All MBCs must be reset before any motors can restart. In “MANUAL/MAINTENANCE” mode, this function is only active on the MBC in “MANUAL/MAINTENANCE” mode; all other MBCs will show a communication fault and will not operate.

■

“MACHINE STOP” pushbutton: Pressing the machine stop pushbutton will break the control circuit, stopping all motors. There will be a message displayed on all displays showing which machine stop on which MBC was pressed. All MBCs must be reset before any motors can restart. In “MANUAL/MAINTENANCE” mode, this function is only active on the MBC in “MANUAL/ MAINTENANCE” mode; all other MBCs will show a communication fault and will not operate.

■

Man-in-position switch (footswitch): Releasing the footswitch will break the control circuit, stopping all motors. There will be a message displayed on all displays showing which footswitch on which MBC was opened. All MBCs must be reset before any motors can restart. In “MANUAL/MAINTENANCE” mode, this function is only active on the MBC in “MANUAL/MAINTENANCE” mode; all other MBCs will show a communication fault and will not operate.

■

Tape switch (panic bar): Pressing the tape switch (panic bar) will break the control circuit, stopping all motors. All MBC “SYTEM RESET” switches must be activated and the tape switch reset button (if equipped) must be pressed before any motor can be restarted.

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Operation _______________________________________________________ Pump motor reset NOTICE: If electrical system is overloaded or shorted, all MBC pump and conveyor motors will stop. There will be a message displayed on all displays showing which circuit tripped on which MBC. All MBCs must be reset before any motors can restart.

If the pump motor has been stopped by any mechanism the system must be reset before operation can continue. The following reset action is the same for all pump stop mechanisms: 1. Move the “SYSTEM STOP” toggle switch to “RESET” and then release, allowing the switch to return to the centered position.

2. Once all MBCs have been reset, the pump motor can be started (see Start procedure in this chapter).

Power Fill Operation The MBC is equipped with a power fill system, to aid in quickly replenishing the hydraulic fluid.

All MBCs previous to s/n: FHZ01411 use the following procedure: 1. Connect a hose from a fresh oil source to the power fill flow divider.

2. With the pump running, turn the ball valve (located directly behind the Control Station) to divert pressure to the power fill flow divider.

3. From the Control Station, hold the toggle switch to Lower the inby conveyor lift cylinders. As long as the toggle switch is held down, suction will be created.

4. When finished remove the hose from the fresh oil source, cap the line, and stow the hose 5. Turn the ball valve back to the previous position, to regain inby conveyor lift cylinder capabilities.

All MBCs after s/n: FHZ01411 use the following procedure: 1. Connect a hose from a fresh oil source to the power fill flow divider.

2. With the pump running, pull the handle on the power fill diversion valve. This instantly diverts pressure from the valve bank to create suction for the power fill procedure and blocks all valve bank functions. As soon as the power fill diversion valve handle is released, it returns all valve bank functions.

3. When finished remove the hose from the fresh oil source, cap the line, and stow the hose.

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____________________________________________________ Maintenance Instructions on the maintenance of the continuous haulage system Maintenance at regular intervals increases the operational safety and prolongs the service life of the system. In particular, observe the safety instructions in chapter 2 “Your safety”.

Maintenance of the continuous haulage system includes: ■

Lubrication of the MBC, PIG, RFM tail dolly, RFM pulley support, and RFM intermediate sections in accordance with the lubrication schedule.

■

Inspection of the units for faults and proper function.

■

Inspection for wear parts.

Important notes Please observe the following: ■

In order to avoid individual components not being serviced or being only inadequately serviced during maintenance work on the system as a whole, we recommend that a general maintenance plan be drawn up. You can, for example, draw up a checklist using this operation manual and the manuals of the other components.

■

Inadequate maintenance can result in machine damage which leads to considerable costs.

■

Use only suitable and approved tools for maintenance work!

■

Use only original spare parts when replacing components.

■

All electrical work must be supervised and inspected by a certified electrician.

■

Anyone performing maintenance on this equipment must be trained to operate it and be familiar with this guide.

Before maintenance Please observe the following: ■

Shutdown the system on level ground.

■

Disconnect the electrical power. The circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source.

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Maintenance ____________________________________________________ WARNING! Before performing maintenance on the system, the circuit breaker must be in the “OFF” position and the power should be disconnected at the main power source. Electrical shock and accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

Test the controls to ensure that the unit will not move.

WARNING! Do not move any control lever unless you are certain that everyone is completely clear of any machine movement. Accidental machine movement can cause serious injuries or even death to you or the maintenance person.

■

During maintenance or servicing, if either of the tram drives are to be run, the side that is to be run must be jacked clear of the ground and securely blocked.

■

Do not perform maintenance on either boom while there is a load resting on the hydraulic cylinder. Booms must be securely blocked if maintenance is to be performed with either boom in the raised position.

WARNING! You could be seriously injured or even killed by falling loads. Observe the safe working load limits of lifting or blocking devices and keep a safe distance from suspended loads.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

■

Do not perform maintenance in a congested area. This could endanger the maintenance person or others in the vicinity.

■

Whenever a potential problem is uncovered during a periodic maintenance check, it is imperative that it be corrected immediately by a qualified maintenance technician.

■

Cleanliness can not be overemphasized as the essential ingredient of a good maintenance program. Machines should be kept as free as possible of dirt and debris which could impede performance or infiltrate systems and cause premature wear or failure.

________________________________________________________________ 5.32 Continuous Haulage System

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____________________________________________________ Maintenance Lubricants It is essential to the life of this system that the following lubrication schedule and quality of lubricants (Table 1) be followed.

A lubrication schedule is provided for each piece of equipment in this system. Check the lubrication point heading on each schedule to see which drawing figure applies.

Table 1: Lubricant chart Application

Lubricant

Electric motor bearings

Specification

Exxon Unirex N2

Grease points (except electric motor bearings)

Spec. 100-3

Gear boxes and wheel units

Spec. 100-13

LinkBelt gear box

Spec. 100-6

Fluid couplings (if equipped) Hydraulic fluid

Dextron II ATF Spec. 100-1

IMPORTANT! The lubricants listed above are recommended. However, other brand names of equivalent quality and grade may be used. (See lubrication specifications in chapter 6 of this manual)

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Maintenance ____________________________________________________ Instructions on the lubrication of the mobile bridge carrier (MBC) IMPORTANT! The mobile bridge carrier (MBC) is equipped with a central lubrication system that allows several lubrication points to be lubricated from one central point.

See the following section.

Central lubrication system The central lubrication system (Fig. 24) allows the following to be easily lubricated from a central point; operator's side conveyor bearing, offside drive seal, discharge boom pivot (near and far), and receiving boom pivot (near and far).

Fig. 24: Central lubrication (mobile bridge carrier) 3 2

4 5

6 1 1.

2.

3.

4.

5.

6.

conveyor drive shaft bearing (operator’s side) conveyor reducer drive seal discharge section pivot (near) discharge section pivot (far) receiving section pivot (near) receiving section pivot (far)

________________________________________________________________ 5.34 Continuous Haulage System

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____________________________________________________ Maintenance Table 2: Lubrication schedule, mobile bridge carrier (MBC) Lube point

Description

Places

Lubricant

Specification

Every 8 hours of operation 3 8 7

Drive shaft bearing PIG (PBC) dolly Hydraulic oil tank: Check oil level

1 4

Spec. 100-3 Spec. 100-3

1

Spec. 100-1

1

Spec. 100-13

2

Spec. 100-13

Spec. 100-3 Spec. 100-3

Daily 6 10

Conveyor reducer: Check oil level Tram reducer (left and right): Check oil level

Every week 1 4

Tail shaft

4 1

2

Conveyor reducer

1

Spec. 100-3

1

Tram reducer

1

Spec. 100-3

2

Spec. 100-13

Conveyor pivot pins

First 50 hours of service 10

Tram reducer (left and right): Change oil

Every 2 weeks 13 14 15 16 21

Hydrostatic filter: Change element Hydraulic fluid: Sample Pressure filter: Change element Return filter: Change element Charge filter: Change element

2 1 1 1 1

Every month 9

Idler roller (left and right)

2

Spec. 100-3

11

Cab tilt cylinder

2

Spec. 100-3

18

Conveyor lift, inby (left and right)

4

Spec. 100-3

19

Conveyor lift, outby (left and right)

4

Spec. 100-3

12

Magnetic filter: Clean

1

Every 3 months 5 17

Electric Motors (tram) Electric Motors (conveyor drive)

1 1

6

Conveyor reducer: Change oil

1

Spec. 100-13

10

Tram reducer (left and right): Change oil

2

Spec. 100-13

20

Control panel slide bracket

1

Spec. 100-3

Exxon Unirex N-2 Exxon Unirex N-2

Every 6 months

As required

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Maintenance ____________________________________________________ Fig. 25: Lubrication chart, mobile bridge carrier (MBC)

4 8

Tail dolly

19

13

13 15 21 19

5 10

7

18 9 18

12

20

1 3

16

11

17

2 6

________________________________________________________________ 5.36 Continuous Haulage System

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____________________________________________________ Maintenance Specific lubrication procedures (MBC) Every 8 hours of operation: drive shaft bearing

Lubricate the drive shaft bearing through the grease fitting located on the central lubrication panel (Fig. 26) in front of the operator’s compartment. Pump grease into the fitting until new grease can be observed coming out of the bearing.

Fig. 26: Drive shaft bearing lubrication

Central lubrication panel

pig (PBC) dolly

Drive shaft bearing

Lubricate the 4 grease fittings (2 per side) located on the pig (PBC) dolly (Fig. 27). Pump grease into the fitting (4) until new grease can be observed coming out from around the pin.

Fig. 27: Pig (PBC) dolly lubrication points Grease fitting

Grease fitting

Grease fitting

Grease fitting

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Maintenance ____________________________________________________ hydraulic oil tank

Check the temperature and hydraulic oil level by looking at the sight glasses located on the side of the oil tank (Fig. 28). The oil level should not be allowed to drop below the bottom sight glass. If the hydraulic oil level is low, add oil through the fill cap located on top of the tank Fig. 28: Hydraulic oil check/add points

Sight glass

Oil filler cap

Thermometer and sight glass

________________________________________________________________ 5.38 Continuous Haulage System

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____________________________________________________ Maintenance Daily: conveyor reducer

Check the breather and oil level in the conveyor drive reducer (Fig. 29): clean all dirt and debris from and around the breather. remove the dipstick and add oil as required per reading.

Fig. 29: Conveyor reducer oil level Oil fill Breather

Oil drain

tram reducer

Check the breather and oil level in both tram reducer drive gear boxes (Fig. 30): remove the oil level/fill plug. the oil level should be kept at the level of the level/fill plug. should it be necessary to add oil, add oil through the fill plug hole until it begins to flow out of the hole.

Do not overfill the reducer

Fig. 30: Tram reducer

Oil level/fill plug

Magnetic drain plug

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Maintenance ____________________________________________________ Every week: conveyor pivot pins

Lubricate the conveyor pivot pins through the four grease fittings located on the central lubrication panel (Fig. 31) near the front of the operator’s compartment. Pump grease into the fittings until new grease can be observed coming out of the pin.

Fig. 31: Conveyor pivot pin lubrication

Central lubrication Pivot pin location (both sides)

tail shaft

Pivot pin location (both sides)

Lubricate the tail shaft through the grease fitting located on the operator’s side of the machine (Fig. 32). Pump grease into the fitting until new grease can be observed coming out of the relief fitting located on opposite end of tail shaft. Relief fitting is to protect the caterpillar seals.

Fig. 32: Tail shaft lubrication

Grease fitting

Relief fitting

________________________________________________________________ 5.40 Continuous Haulage System

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____________________________________________________ Maintenance conveyor reducer

Lubricate the two seal grease fittings on the conveyor reducer (Fig. 33).

Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 33: Conveyor reducer lubrication To central lubrication panel fitting

Central lubrication panel fitting

Grease fitting

tram reducer

Lubricate the seal grease fitting on the tram reducers (Fig. 34). Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 34: Tram reducer lubrication Grease fitting

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Maintenance ____________________________________________________ After first 50 hours of service: tram reducer

Change the oil in both tram reducer drive gear boxes (Fig. 35): Clean all dirt and debris from and around the oil level/fill plug.

Remove the drain plug and allow the oil to completely drain.

Replace the drain plug and tighten.

Fill the gear box until oil begins to flow from the oil level/fill plug hole.

Do not overfill the reducer Fig. 35: Tram reducer oil change

Oil level/fill plug

Magnetic drain plug

________________________________________________________________ 5.42 Continuous Haulage System

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____________________________________________________ Maintenance Every 2 weeks: hydrostatic filter

Change the filter elements on both hydrostatic filters (Fig. 36): Remove the access cover from the machine.

Rotate the cap counter clockwise (ccw) to remove the old element.

The bowl can be cleaned using kerosene and a soft brush and dried thoroughly.

Insert the new element into the bowl.

Place cap onto bowl and rotate clockwise (cw).

Use wrench to tighten securely.

Replace the access cover Fig. 36: Hydrostatic filter element replacement

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Maintenance ____________________________________________________ pressure filter

Change the filter element in the pressure filter (Fig. 37): Rotate the cup counter clockwise (ccw) to remove the old element.

The bowl can be cleaned using kerosene and a soft brush and dried thoroughly.

Insert the new element into the bowl.

Place cup onto bowl assembly and rotate clockwise (cw).

Use wrench to tighten securely.

return filter

Change the filter element in the return filter (Fig. 37): Remove the access cover from the machine.

Rotate the cup counter clockwise (ccw) to remove the old element.

The bowl can be cleaned using kerosene and a soft brush and dried thoroughly.

Insert the new element into the bowl.

Place cup onto bowl assembly and rotate clockwise (cw).

Use wrench to tighten securely.

Fig. 37: Pressure filter and return filter element replacement

Return Filter Pressure Filter

________________________________________________________________ 5.44 Continuous Haulage System

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____________________________________________________ Maintenance charge filter

Change the filter elements on the three charge filters (Fig. 38): Rotate the bowl counter clockwise (ccw) to remove the old element.

The bowl can be cleaned using kerosene and a soft brush and dried thoroughly.

Insert the new element into the bowl.

Place bowl onto head assembly and rotate clockwise (cw).

Hand-tighten securely.

Fig. 38: Charge filter element replacement

hydraulic fluid

Take a sample of the hydraulic fluid from the hydraulic tank after each filter change for the first three months of operation to make sure that the elements are being changed on a timely basis.

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Maintenance ____________________________________________________ Every month: idler roller

Lubricate both right and left side idler rollers (Fig. 39): Clean dirt and debris from around fittings.

Pump grease into the fittings until new grease can be observed coming out of the fittings.

Fig. 39: Idler roller lubrication

Grease fitting

cab tilt cylinder

Lubricate grease fittings on the rod and base end of the cab tilt cylinder (Fig. 40). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 40: Cab tilt cylinder lubrication Grease fitting

Grease fitting

________________________________________________________________ 5.46 Continuous Haulage System

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____________________________________________________ Maintenance conveyor lift cylinders, inby

Lubricate grease fittings on both of the rod and base ends of the conveyor lift (inby) cylinders (Fig. 41). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 41: Conveyor lift cylinder lubrication (inby)

Grease fitting Typical both sides

Grease fitting

Optional inby lift cylinder grease fitting block.

conveyor lift cylinders, outby

Lubricate grease fittings on both of the rod and base ends of the conveyor lift (outby) cylinders (Fig. 42). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 42: Conveyor lift cylinder lubrication (outby)

Grease fitting

Typical both sides

Grease fitting

Optional outby lift cylinder grease fitting block.

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Maintenance ____________________________________________________ magnetic filter

Clean the magnetic filter located in the oil tank (Fig. 43).

Clean dirt and debris from around the magnetic filter.

Remove the filter from the tank.

The filter can be cleaned using kerosene and a soft brush and dried thoroughly.

Fig. 43: Magnetic filter cleaning

Magnetic filter

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____________________________________________________ Maintenance Every 3 months: electric motor (tram)

Lubricate the electric tram motors (Fig. 44): Clean dirt and debris from around the two plugs, one is located on each end of motor.

Remove the plugs.

Install grease fittings and grease sparingly.

Remove grease fitting, clean and reinstall plugs.

electric motor (conveyor)

Lubricate the electric conveyor motor (Fig. 44): Clean dirt and debris from around the two plugs, one is located on each end of motor.

Remove the plugs.

Install grease fittings and grease sparingly.

Remove grease fitting, clean and reinstall plugs.

NOTICE! The plugs must always be reinstalled in the electric motors.

Incorrect grease or over greasing may occur and cause serious damage to the motor.

Fig. 44: Electric motor lubrication

Conveyor motor

Tram motor

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Maintenance ____________________________________________________ Every 6 months: conveyor reducer

Change the oil in the conveyor reducer while the reducer is at operating temperature (Fig. 45): Clean all dirt and debris from and around the dipstick and drain plug.

Remove the drain plug and allow the reducer to completely drain.

Clean and reinstall drain plug.

Remove the dipstick and add oil as required per reading.

Fig. 45: Conveyor reducer oil change

Oil fill

Breather

Oil drain

tram reducer

Change the oil in the tram reducer while the reducer is at operating temperature (Fig. 46): Clean all dirt and debris from and around the oil level/fill and drain plug.

Remove the drain plug and allow the reducer to completely drain.

Clean and reinstall drain plug.

Fill the reducer until oil begins to flow from the oil level/fill plug hole.

Do not overfill the reducer

________________________________________________________________ 5.50 Continuous Haulage System

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____________________________________________________ Maintenance Fig. 46: Tram reducer oil change

Oil level/fill plug

Magnetic drain plug

As required: control panel slide bracket

The control panel slide bracket (Fig. 47) was lubricated prior to shipment from the factory and should not require lubrication under normal operating conditions. If under severe operating conditions lubrication is required, grease the fitting sparingly.

Fig. 47: Control panel slide bracket lubrication

Grease fitting

_____________________________________________________________ A6474X251 REV 08 5.51

BI016242

Maintenance ____________________________________________________ Instructions on the lubrication of the Piggyback Bridge Conveyor (PIG) Table 3: Lubrication schedule, PIG Lube point

Description

Places

Lubricant

Specification

Daily 4

Conveyor reducer: Check oil level

2

Spec. 100-13

1 2

Spec. 100-3 Spec. 100-3

2

Spec. 100-3

Every week 1 5

Tail shaft Conveyor reducer seal

2

Drive shaft

Every 30 hours of operation Every 3 to 6 months 3

4

Electric motors

Exxon Unirex N-2

Every 6 months 4

2

Conveyor reducer: Change oil

Spec. 100-13

Fig. 48: Lubrication points, PIG

2

4

3

5

5 2

4

3

1

________________________________________________________________ 5.52 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Specific lubrication procedures (PIG) Daily: conveyor reducer

Check the conveyor drive gear box oil level by looking at the sight glass (Fig. 49). Oil must visible through the sight glass. If the oil level is low, add oil through the plug located on top side of the gear case until oil fills to the centerline of the sight glass.

Fig. 49: PIG, Conveyor reducer level check

Sight glass Sight glass

_____________________________________________________________ A6474X251 REV 08 5.53

BI016242

Maintenance ____________________________________________________ Every week: tail shaft

Lubricate the tail shaft with through the grease fitting located on the operator’s side of the machine (Fig. 50). Pump grease into the fitting until new grease can be observed coming out of the relief fitting located on opposite end of tail shaft. Relief fitting is to protect the caterpillar seals.

Fig. 50: PIG, tail shaft lubrication

Grease point

conveyor reducer

Lubricate the two seal grease fittings on each conveyor reducer (Fig. 51). Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 51: PIG, conveyor reducer seal lubrication

Grease fitting

________________________________________________________________ 5.54 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Every 30 hours of operation: drive shaft

Lubricate the drive shaft splines through the grease fittings located on each side of the conveyor (Fig. 52).

Fig. 52: PIG, drive shaft lubrication

Grease fitting

_____________________________________________________________ A6474X251 REV 08 5.55

BI016242

Maintenance ____________________________________________________ Every 3 to 6 months: electric motors

Lubricate the two electric motors (Fig. 53): Clean dirt and debris from around the two plugs, one is located on each end of motor.

Remove the plugs.

Install grease fittings and grease sparingly.

Remove grease fitting, clean and reinstall plugs.

NOTICE! The plugs must always be reinstalled in the electric motors.

Incorrect grease or over greasing may occur and cause serious damage to the motor.

Fig. 53: PIG, electric motor lubrication

Grease fitting Grease fitting

________________________________________________________________ 5.56 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Every 6 months: conveyor reducer

Change the oil in the conveyor reducer while the reducer is at operating temperature (Fig. 54): Clean all dirt and debris from and around the dipstick and drain plug.

Remove the drain plug and allow the reducer to completely drain.

Clean and reinstall drain plug.

Remove the dipstick and add oil as required per reading.

Fig. 54: PIG, conveyor reducer oil change

Oil fill

Breather

Oil drain

_____________________________________________________________ A6474X251 REV 08 5.57

BI016242

Maintenance ____________________________________________________ Instructions on the lubrication of the RFM tail dolly Table 4: Lubrication schedule, RFM tail dolly Lube point

Description

Places

Lubricant

Specification

Every 8 hours of operation 2

Belt trainer roller

4

Exxon Lidok EP-2

Spec. 100-3

2

Exxon Lidok EP-2

Spec. 100-3

Every 24 hours of operation 1

Dolly wheels

Fig. 55: Lubrication points, tail dolly

Belt trainer 6” or 9” wheels Junction box mounting plate Bolt-on yoke plate Cable tray

2

1

________________________________________________________________ 5.58 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Specific lubrication procedures (RFM tail dolly) Every 8 hours of operation: belt trainer roller

Lubricate the belt trainer roller through the grease fitting located on the inside of the belt trainer roller (Fig. 56). Pump grease into the fitting until new grease can be observed coming out of the rollers.

Fig. 56: RFM belt trainer lubrication

Grease point

Every 24 hours of operation: dolly wheels

Lubricate the tail shaft through the grease fitting located on the operator’s side of the machine (Fig. 57). Pump grease into the fitting until new grease can be observed coming out of the relief fitting located on opposite end of tail shaft. Relief fitting is to protect the caterpillar seals.

Fig. 57: RFM tail dolly lubrication

Grease point

Grease point

_____________________________________________________________ A6474X251 REV 08 5.59

BI016242

Maintenance ____________________________________________________ Instructions on the lubrication of the RFM pulley support section Table 5: Lubrication schedule, RFM pulley support section Lube point

Description

Places

Lubricant

Specification

Every 8 hours of operation 1

Pulley bearing

2

Exxon Lidok EP-2

Spec. 100-3

6

Exxon Lidok EP-2

Spec. 100-3

Every 6 months 2

Carrying rolls

Fig. 58: Lubrication points, RFM pulley support section Plow type belt wiper

Pull plate

Carrying roll

12” or 14” dia. Pulley with 3 15/16 or 4 7/16 brgs.

2 2

Pulley cover

1

Alignment bolts, each side

Skid foot, varies from 3” to 10”

________________________________________________________________ 5.60 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Specific lubrication procedures (RFM pulley support section) Every 8 hours of operation: pulley bearing

Remove pulley cover and lubricate each side of the pulley bearing (Fig. 59).

Fig. 59: RFM pulley support carrying roll lubrication

Pulley bearing

Every 6 months: carrying rolls

Lubricate each side of the 3 carrying rolls located on RFM pulley support section (Fig. 60).

Fig. 60: RFM pulley support carrying roll lubrication Carrying roll grease points

Carrying roll grease points

_____________________________________________________________ A6474X251 REV 08 5.61

BI016242

Maintenance ____________________________________________________ Instructions on the lubrication of the intermediate RFM section

Table 6: Lubrication schedule, RFM intermediate section Lube point

Description

Places

Lubricant

Specification

Every 6 months 1

Carrying rolls

12

Exxon Lidok EP-2

Spec. 100-3

Fig. 61: Lubrication points, RFM intermediate section Carrying roll

Carrying roll

Carrying roll

Dolly track

1

Skid foot varies from 3” to 10”

1

1

Skid foot varies from 3” to 10”

________________________________________________________________ 5.62 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Specific lubrication procedures (intermediate RFM section) Every 6 months: carrying rolls

Lubricate each side of the 6 carrying rolls located on each intermediate RFM section (Fig. 62).

Fig. 62: RFM intermediate section carrying roll lubrication

Note: Figure shows multiple RFM sections in storage

Carrying roll grease points

_____________________________________________________________ A6474X251 REV 08 5.63

BI016242

Maintenance ____________________________________________________ Inspection of the mobile bridge carrier (MBC) CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected: ■

Clean and remove any foreign material from the operator’s compartment.

■

Inspect all electrical cables, conduits, hydraulic hoses, fittings and warning devices for signs of wear or damage.

■

Visually inspect the condition and readability of all tags, labels and reflectors.

■

Check the hydraulic oil level by looking at the two sight glasses.

The oil level should be kept at the level of the top sight glass.

■

Check oil level in the tram reducers.

■

Check oil level in the conveyor drive reducer.

■

Inspect all electrical and hydraulic components for condition.

■

Check for proper conveyor chain tensioning.

■

Lubricate per the lubrication schedule.

■

Check to insure that crawler tracks are snug and ready for tramming.

■

Check the proper function of all operating levers, linkages, cylinders, locking devices, springs, etc.

■

Check trailing cable to power source insuring that the voltage and breaker settings are correct.

■

Check that the cable handling device is intact and oriented correctly.

■

Check that all covers are installed and secure.

■

Check the tightness of all connecting elements.

________________________________________________________________ 5.64 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Inspection of wear parts on the mobile bridge carrier (MBC) 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 : ■

conveyor chain

■

conveyor chain flights

■

conveyor drive sprockets

■

conveyor tail shaft

■

conveyor wear plates

■

chain strippers

■

crawler pads

■

crawler drive sprockets

■

crawler idler rollers

Inspection of fire suppression system on the mobile bridge carrier (MBC) To provide maximum assurance that your fire suppression system will operate effectively and safely, the following points should be inspected weekly (Fig. 57).

■

Note general appearance for mechanical damage or corrosion.

■

Check nameplate for readability, corrosion or looseness.

■

Remove fill cap assembly.

■

Examine gaskets for elasticity, clean and coat lightly with a good grade of high heat resistant grease.

■

Inspect threads on fill cap and in fill opening for nicks, burrs, cross threading, rough or feathered edges.

■

Check pressure relief vent in fill opening threads for obstruction.

■

Make certain extinguisher is filled with free flowing Ansul dry chemical to a level of not more than 3” from bottom of fill opening.

■

Secure fill cap, hand tight.

■

Remove extinguisher cartridge guard assembly.

■

Unscrew cartridge and weigh (replace if weight is ½ oz. less than stamped on cartridge).

_____________________________________________________________ A6474X251 REV 08 5.65

BI016242

Maintenance ____________________________________________________ ■

Check pressure vents in receiver/actuator for obstruction.

■

Examine cartridge receiver gasket for elasticity, clean and coat lightly with a good grade of high heat resistant grease. Return cartridge to receiver/actuator, hand tighten.

■

Examine cartridge receiver gasket for elasticity, clean and coat lightly with a good grade of high heat resistant grease. Return cartridge to receiver/actuator, hand tighten.

■

Disengage bursting disc union and open bracket clamp.

■

Lift extinguisher partially out of bracket and examine bursting disc; should be installed with full disc side facing extinguisher, properly seated and undamaged (scored or ruptured).

■

Reposition extinguisher, engage bursting disc union (wrench tighten) and close bracket clamp.

■

Check hoses, fittings and nozzles for mechanical damage.

■

Check nozzle openings; slot should be closed (capped) with silicone grease.

■

Check remote actuator (dashboard type).

■

Remove cartridge and weigh (replace if weight is ¼ oz. less than stamped on cartridge).

■

Inspect threads on cartridge and in actuator for nicks, burrs, cross threading, rough or feathered edges.

■

Check pressure safety vent in actuator body for obstruction.

■

Examine actuator cartridge gasket for elasticity, clean and lightly coat with a good grade of high heat resistant grease.

■

Pull ring pin and operate actuator button several times to check for free movement.

■

Seal ring pin to puncture lever with lead and wire seal. Return cartridge to remote actuator, hand tighten.

■

Record date of maintenance and notify operating personnel that system is back in service.

________________________________________________________________ 5.66 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Recharge of fire suppression system on the mobile bridge carrier (MBC) To return your fire suppression system to service after use (Fig. 63).

■

Pull ring on safety valve to relieve actuator system pressure.

■

Disconnect actuation system hose at cartridge receiver/actuator assembly.

■

Open bursting disc union assembly.

■

Remove extinguisher from bracket.

■

Replace ruptured bursting disc with new disc. (Full disc side must face extinguisher).

■

Fill extinguisher to rated capacity with Ansul dry chemical specified on nameplate.

■

Clean fill opening threads and gasket seating surface.

■

Secure fill cap, hand tighten.

■

Remove cartridge guard assembly.

■

Remove empty cartridge.

■

Make certain that the receiver/actuator puncture pin is fully retracted.

■

Screw full charged cartridge into receiver/actuator assembly, hand tighten.

■

Replace cartridge guard.

■

Secure extinguisher in bracket.

■

Assemble bursting disc union, wrench tighten.

■

Connect actuation system hose at cartridge receiver/actuator assembly, wrench tighten.

■

Replace cartridge in remote actuator (dashboard type). Pull out button, insert ring pin and remove empty cartridge. Screw fully charged cartridge into actuator, hand tighten. Seal ring pin to actuator button stem with lead and wire seal.

■

Clean and repack nozzles with silicone grease.

■

Record date of recharge and notify operating personnel that system is back in service.

_____________________________________________________________ A6474X251 REV 08 5.67

BI016242

Maintenance ____________________________________________________ Recharge inspection of fire suppression system on the mobile bridge carrier (MBC) To provide maximum assurance that your fire suppression system will operate effectively and safely after recharging, the following points should be inspected weekly (Fig. 63).

■

Make certain that extinguisher is in its designated place.

■

Note general appearance for mechanical damage or corrosion.

■

Check nameplate (s) for readability.

■

Remove fill cap assembly.

■

Make certain that extinguisher is filled with free flowing dry chemical to a level of not more than 3” from the bottom of the fill opening.

■

Secure fill cap, hand tighten.

■

Remove cartridge from extinguisher and examine disc. Seal should be unruptured.

■

Return cartridge to cartridge receiver/actuator assembly, hand tighten.

■

Check hoses, fittings and nozzles for mechanical damage and cuts.

■

Remove cartridge from remote actuator and examine disc. Disc should be un-ruptured.

■

Return cartridge to remote actuator assembly, hand tighten.

■

Replace any broken or missing lead and wire seals.

■

Record date of inspection.

________________________________________________________________ 5.68 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Fig. 63: Typical fire suppression system (MBC)

Remote actuator

Extinguisher

Spray nozzle (Typical 7 places)

Extinguisher

Remote actuator

_____________________________________________________________ A6474X251 REV 08 5.69

BI016242

Maintenance ____________________________________________________ Inspection of the piggyback bridge conveyor (PIG) CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected: ■

Clean and remove any foreign material.

■

Inspect all electrical cables, conduits, and fittings or signs of wear or damage.

■

Visually inspect the condition and readability of all tags, labels and reflectors.

■

Check oil level in the conveyor drive reducers.

■

Inspect all electrical components for condition.

■

Check for proper conveyor chain tensioning.

■

Lubricate per the lubrication schedule.

■

Check the proper function of all linkages, cylinders, locking devices, springs, etc.

■

Check trailing cable to power source insuring that the voltage and breaker settings are correct.

■

Check that the cable handling device is intact and oriented correctly.

■

Check that all covers are installed and secure.

■

Check the tightness of all connecting elements.

Inspection of wear parts on the piggyback bridge conveyor (PIG) 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 as to their degree of wear.

■

conveyor chain

■

conveyor chain flights

■

conveyor drive sprockets

■

conveyor tail shaft

■

conveyor wear plates

■

chain strippers

________________________________________________________________ 5.70 Continuous Haulage System

BI016242

____________________________________________________ Maintenance Inspection of the RFM CAUTION! During inspection, report any damage, missing parts or other faults to your immediate supervisor.

Prior to each shift the following points should be inspected: ■

Clean and remove any foreign material.

■

Inspect all electrical cables, conduits, fittings and warning devices for signs of wear or damage.

■

Visually inspect the condition and readability of all tags, labels and reflectors.

■

Inspect all electrical components for condition.

■

Check for proper conveyor chain tensioning.

■

Lubricate per the lubrication schedule.

■

Check the proper function of all linkages, locking devices, springs, etc.

■

Check that the cable handling device is intact and oriented correctly.

■

Check that all covers are installed and secure.

■

Check the tightness of all connecting elements.

_____________________________________________________________ A6474X251 REV 08 5.71

BI016242

Maintenance ____________________________________________________

________________________________________________________________ 5.72 Continuous Haulage System

BI016242

___________________________________________ Adjustment procedures Instructions on the adjustment procedures on the mobile bridge carrier (MBC) It is essential that adjustments be made periodically to the conveyor chain and crawler tracks, otherwise damage can be caused to other parts of the machine or to the assembly itself. Inspect the adjustments at regular intervals.

WARNING! Failure to follow applicable guidelines described in Chapter 2, "Your Safety" before performing maintenance or service on this machine could result in severe personal injury or potential death.

Conveyor chain The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 64): 1. Loosen bleeder fitting 2 – 3 turns.

2. Attach a grease gun to the grease fitting on the rod end of the cylinder housing and apply grease until desired tension is achieved on both sides. Correct tension is achieved when conveyor chain can be lifted approximately 1” at the center of conveyor with conveyor empty.

Note: Receiving and discharge booms must be fully raised when adjustment is checked.

3. Close bleeder fitting.

4. Remove cover plate.

5. Install or remove the required amount of shims to fill the shim area.

Make certain that the same amounts of shims are used on both sides to prevent chain from stretching unevenly. Spare shims are located in a storage pocket in front of the conveyor chain take-up cylinder.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly.

Incorrect tension or adjustment can cause premature wear of sprockets and chain.

_____________________________________________________________ A6474X251 REV 08 5.73

BI016242

Adjustment procedures ___________________________________________ 6. Release pressure on the grease cylinder on both sides by first loosening the grease fitting and then opening the bleeder valve.

WARNING! Due to grease cylinder being under high pressure, do not stand in direct line of grease fitting or bleeder valve.

WARNING! Due to grease cylinder being under high pressure, do not stand in direct line of grease fitting or bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.

7. Allow tail shaft pressure to rest completely on shims, close bleeder fitting and tighten grease fitting.

8. Replace shim cover plate and secure with the four bolts and lock washers.

Fig. 64: Conveyor chain adjustment

Take-up cylinder

Lug

Tailshaft end

Rod end

Bleeder fitting

Grease fitting

Shim set

Cover

Bolts and lock washers

________________________________________________________________ 5.74 Continuous Haulage System

BI016242

___________________________________________ Adjustment procedures Crawler track The crawler track is a complete assembly and should be checked for wear and correct tension at regular intervals. Chain sag should be 2” to 2 ½” at the center of the crawler.

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 65): 1. Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

2. With the bleeder fitting closed, pump grease (Spec. 100-3) into the grease fitting. Pump grease into the fitting until the correct adjustment is achieved. Chain sag should be 2” to 2 ½” at the center of the crawler.

DANGER! Raise both sides of machine: both crawlers off ground when adjusting the track (ALWAYS). Otherwise, moving the control lever could cause the machine to move and fall off its supports. You could be seriously injured or even killed by falling loads.

3. Run crawler in forward direction for 3 minutes at slow speed.

4. Run crawler in reverse direction for 3 minutes at slow speed.

5. Shutdown machine.

6. If necessary, re-adjust chain sag.

7. Add or remove required amount of shims to maintain correct tension.

8. Slowly open the bleeder fitting to release the grease pressure in the cylinder, allowing the shims to maintain the correct tension.

WARNING! Due to grease cylinder being under high pressure, do not visually inspect to see is grease is released while the bleeder fitting is open. You could be seriously injured from high pressure grease.

9. Close bleeder fitting

_____________________________________________________________ A6474X251 REV 08 5.75

BI016242

Adjustment procedures ___________________________________________ Fig. 65: Crawler track adjustment

Shim storage

2” to 2 ½” sag

Grease take-up with shim lock

Shims

Crawler track

________________________________________________________________ 5.76 Continuous Haulage System

BI016242

___________________________________________ Adjustment procedures Instructions on the adjustment procedures on piggyback bridge conveyor (PIG) It is essential that adjustments be made periodically to the conveyor chain, otherwise damage can be caused to other parts of the machine or to the assembly itself. Inspect the adjustments at regular intervals.

WARNING! Failure to follow applicable guidelines described in Chapter 2, "Your Safety" before performing maintenance or service on this machine could result in severe personal injury or potential death.

Conveyor chain The conveyor chain is a complete assembly and should be checked for correct tension at regular intervals.

To adjust tension on the conveyor chain with the take-up cylinders proceed as follows (Fig. 66): 1. Loosen bleeder fitting 2 – 3 turns.

2. Attach a grease gun to the grease fitting on the rod end of the cylinder housing and apply grease until desired tension is achieved on both sides. Correct tension is achieved when conveyor chain can be lifted approximately 1” at the center of conveyor with conveyor empty.

3. Close bleeder fitting.

4. Remove cover plate.

5. Install or remove the required amount of shims to fill the shim area.

Make certain that the same amounts of shims are used on both sides to prevent chain from stretching unevenly. Spare shims are located in a storage pocket in front of the conveyor chain take-up cylinder.

NOTICE! Make certain that the same amounts of shims are used on both sides of the conveyor to prevent chain from stretching unevenly.

Incorrect tension or adjustment can cause premature wear of sprockets and chain.

6. Release pressure on the grease cylinder on both sides by first loosening the grease fitting and then opening the bleeder valve.

WARNING! Due to grease cylinder being under high pressure, do not stand in direct line of grease fitting or bleeder valve when releasing pressure. You could be seriously injured from high pressure grease.

_____________________________________________________________ A6474X251 REV 08 5.77

BI016242

Adjustment procedures ___________________________________________ 7. Allow tail shaft pressure to rest completely on shims, close bleeder fitting and tighten grease fitting.

8. Replace shim cover plate and secure with the four bolts and lock washers.

Fig. 66: Conveyor chain adjustment

Take-up cylinder

Tailshaft end

Lug

Bleeder fitting

Rod end

Grease fitting

Shim set

Cover Bolts and lock washers

________________________________________________________________ 5.78 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts Instructions on the replacement of wear parts on the mobile bridge carrier (MBC) 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.

Conveyor drive The conveyor drive assembly transmits torque to the conveyor drive chain from the electric drive motor via a torque limiter, drive reducer and conveyor drive shaft. As soon as any component of the conveyor drive is worn or damaged the component must be replaced.

The conveyor drive assembly (Fig. 67) consists of the following main components: ■ ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer drive shaft connecting tube

Fig. 67: Conveyor drive main components

Torque Limiter Connecting tube

Coupling

Reducer Drive motor

Drive shaft

_____________________________________________________________ A6474X251 REV 08 5.79

BI016242

Replacement of wear parts ________________________________________ Drive shaft The drive shaft transmits the torque of the gear box to the conveyor chain assembly. It is part of a complete assembly. As soon as the chain sprockets are worn the sprockets must be replaced.

The drive shaft assembly (Fig. 68) consists of the following main components: ■ ■ ■ ■

drive shaft sprockets spacer tubes bearing

Fig. 68: Drive shaft main components

1 2 3 4 5 6 7

drive shaft sprocket spacer tube spacer tube key screw pilot bearing

NOTICE! Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

________________________________________________________________ 5.80 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts How to remove the drive shaft To remove the drive shaft assembly from the discharge boom proceed as follows: Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain and fold back to clear drive shaft (see Conveyor chain replacement in this chapter).

Remove the motor and reducer cover.

Remove the bolts and washers that secure the reducer guard to the frame (Fig. 69). The guard is hinged to swing out of the way for easy access to reducer.

Remove the bolts, nuts, and washers that secure the chain stripper and remove chain stripper (Fig. 69).

Fig. 69: Remove chain stripper Reducer guard

Nuts, bolts, and washers

Chain stripper

_____________________________________________________________ A6474X251 REV 08 5.81

BI016242

Replacement of wear parts ________________________________________ Remove the locking wire, bolt, and lock washer that secure the retainer cap to the drive shaft and remove the retainer cap (Fig. 70).

Fig. 70: Remove the retainer cap Locking wire, bolt, and lock washer

Retainer cap

Remove the 3 bolts and lock washers that secure the bearing cover and remove cover (Fig. 71).

Fig. 71: Remove the bearing cover

Bearing cover

Three bolts and lock washers

________________________________________________________________ 5.82 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts Remove the 4 bolts and lock washers that secure the bearing adapter and remove adapter and bearing (Fig. 72).

Fig. 72: Remove the bearing adapter and bearing

Bearing adapter and bearing

Four bolts and lock washers

Pull the drive shaft assembly from bearing end and key from the reducer.

_____________________________________________________________ A6474X251 REV 08 5.83

BI016242

Replacement of wear parts ________________________________________ How to install the drive shaft To install the drive shaft assembly into the discharge boom assembly proceed as follows: Coat drive shaft with grease (Spec. 100-3).

Insert the drive shaft through the opening in discharge boom and push shaft into reducer. Make certain that the key is installed and lined up correctly (Fig. 73)

Fig. 73: Installing drive shaft

Drive shaft assembly

________________________________________________________________ 5.84 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts Install the bearing adapter and bearing on the end of the drive shaft. Secure with the four bolts and lock washers and torque to 170 ft-lb (Fig. 74).

Fig. 74: Install the bearing adapter and bearing

Bearing adapter and bearing

Four bolts and lock washers

Install the bearing cover and secure with the three bolts and lock washers. Torque the bolts to 170 ft-lb (Fig. 75).

Fig. 75: Install the bearing cover

Bearing cover

Three bolts and lock washers

_____________________________________________________________ A6474X251 REV 08 5.85

BI016242

Replacement of wear parts ________________________________________ Install the retainer cap and secure with the bolt and lock washer.

Torque the bolt to 280 ft-lb (Fig. 76). Install locking wire.

Fig. 76: Retainer cap installation Locking wire, bolt, and lock washer

Retainer cap

Install the chain stripper and secure with the twelve bolts, nuts, and washers, insert bolts from the top of the chain stripper. Torque bolts to 80 ft-lb (Fig. 77).

Fig. 77: Chain stripper installation

Twelve nuts, bolts, and washers

Chain stripper

________________________________________________________________ 5.86 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts Swing the reducer guard back to the correct position and secure with the two bolts and washers (Fig. 78). Install motor and reducer cover.

Fig. 78: Reducer guard Reducer guard

Bolts and washers

Connect the conveyor chain (see Conveyor chain replacement in this chapter).

Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).

_____________________________________________________________ A6474X251 REV 08 5.87

BI016242

Replacement of wear parts ________________________________________ Drive shaft sprocket The drive shaft sprocket transmits the torque of the gear box to the conveyor chain assembly. It is part of a complete assembly. As soon as the sprockets are worn they must be replaced. The sprockets can be replaced with the original sprocket or a field replacement is available which can be installed without removing the drive shaft.

The drive shaft assembly (Fig. 79) consists of the following main components: ■ ■ ■ ■

drive shaft sprockets spacer tubes bearing

Fig. 79: Drive shaft main components

1 drive shaft 2 sprocket 3 spacer tube 7 pilot bearing

4 spacer tube 5 key 6 screw

NOTICE! Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

________________________________________________________________ 5.88 Continuous Haulage System

BI016242

________________________________________ Replacement of wear parts How to remove the drive shaft sprockets To remove the drive shaft sprockets from the drive shaft assembly proceed as follows (Fig. 80): Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).

Remove the two set screws from each sprocket.

Slide spacers and both sprockets from the drive shaft.

Remove old keys.

Inspect all components of the drive shaft for wear and damage. See parts manual for replacement parts list.

How to install the drive shaft sprockets To install the drive shaft sprockets on the drive shaft assembly proceed as follows (Fig. 80): Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.

Slide one of the short spacers onto the shaft.

Insert one of the keys into the shaft keyway and slide first sprocket onto shaft and tighten the two set screws to secure the sprocket.

Slide the long spacer onto the shaft.

Insert the other key into the shaft keyway and slide second sprocket onto shaft and tighten the two set screws to secure the sprocket.

Slide the second short spacer onto the shaft.

Install the drive shaft assembly in the discharge boom. See drive shaft installation in this chapter.

Fig. 80: Drive shaft sprockets Sprocket Short spacer Key (2) Set screw 2 per sprocket

Long Spacer

Short spacer

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Replacement of wear parts ________________________________________ How to remove the drive shaft sprockets for field replacement To remove the drive shaft sprockets without removing the drive shaft from the discharge boom for field replacement sprockets proceed as follows: Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain and fold back to clear drive shaft (see Conveyor chain replacement in this chapter).

Burn off old sprocket, being careful not to burn spacers or drive shaft.

Remove old key.

Clean drive shaft thoroughly.

Install new key.

Position both halves of sprocket over shaft, align keyway and tack weld. Use smallest tacks possible to hold sprocket during preheat (Fig. 81).

NOTICE! Be careful not to weld sprockets to shaft or spacer.

________________________________________________________________ 5.90 Continuous Haulage System

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________________________________________ Replacement of wear parts Preheat thoroughly to 300° F. Take care to preheat slowly. Do not go over 350° F. Weld using stringer bead method. Interpass temperature must not go below 300° F NOTICE! Be careful not to weld sprockets to shaft or spacer.

Be sure to clean each pass of all slag and splatter. No undercut is allowed.

Allow to cool slowly.

Install and tighten set screws in sprocket.

Connect the conveyor chain (see Conveyor chain replacement in this chapter).

Fig. 81: Field replacement sprocket

Welding filler material Diameter Current -

E8018C3 1/8” DCEP (Reverse polarity)

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Replacement of wear parts ________________________________________ Conveyor drive module The conveyor drive module transmits torque to the conveyor drive shaft via a drive motor, torque limiter, and a speed reducer. The module must be removed as a complete assembly. As soon as any component of the drive module is worn damaged, the component must be replaced.

The conveyor drive module (Fig. 82) consists of the following main components: ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer connecting tube

Fig. 82: Conveyor drive module components

Torque limiter

Connecting tube Coupling

Reducer Drive motor

________________________________________________________________ 5.92 Continuous Haulage System

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________________________________________ Replacement of wear parts How to remove the conveyor drive module To remove the conveyor drive module from the receiving boom proceed as follows: Remove the motor and reducer cover.

Remove the bolts and lock washers that secure the reducer and motor guards and swing both out of the way to allow easy access to the drive.

If required, remove grease hose assemblies from reducer.

Disconnect all electrical wiring to the drive motor.

DANGER! Ensure that electrical power has been disconnected at the main power source before performing any electrical maintenance on machine. You could be seriously injured or killed from electrical shock.

Connect an additional lifting device (e.g. lifting tackle or winch with an adequate load limit) to the lifting eyes located on the motor and reducer. Only apply enough lifting pressure to support the drive module until the module is disconnected from the frame.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Remove the locking wire, bolt, and lock washer that secure the retainer cap to the drive shaft and remove the retainer cap (Fig. 83).

Disconnect reducer bearing seal lubrication hoses, if applicable.

Remove the four bolts and lock washers that secure the reducer to the frame (Fig. 83). With the aid of the lifting device, slide the drive module assembly carefully off of the drive shaft and move module to desired work area.

Remove key from reducer.

Disconnect lifting device.

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Replacement of wear parts ________________________________________ How to install the conveyor drive module To install the conveyor drive module on the receiving boom proceed as follows: Connect an additional lifting device (e.g. lifting tackle or winch with an adequate load limit) to the lifting eyes located on the motor and reducer.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Clean drive shaft and coat shaft with anti-seize lubricant.

With the aid of the lifting device, slide the drive module assembly carefully onto the drive shaft and align reducer mounting holes up with mounting holes of discharge frame.

NOTICE! Do not force the reducer onto drive shaft. Forcing the reducer onto the reducer shaft may cause damage to the shaft or reducer.

Secure reducer to discharge boom with the four bolts and lock washers.

Install retainer cap on end of drive shaft, secure with bolt, and lock washer and install locking wire.

Connect reducer bearing seal lubrication hoses, if applicable.

Connect all electrical wiring to the drive motor.

DANGER! All electrical maintenance must be supervised and inspected by a certified electrician.

Install motor and reducer guards and secure with bolts and lock washers.

Install the motor and reducer cover.

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________________________________________ Replacement of wear parts Fig. 83: Conveyor drive module removal and installation Retainer cap ,locking wire, bolt and lock

Bolts and lock washers (Typical 4 places)

How to disassemble the conveyor drive module To disassemble the conveyor drive module proceed as follows (Fig. 84): Remove the connecting tube cover.

Reach through connecting tube and loosen set screw on coupling.

Remove the bolts and lock washers that secure the motor to the connecting tube and move the motor back until it is free of the connecting tube and coupling.

Remove key from motor shaft.

Reach through opening located on the motor end of the connecting tube and pull the coupling, torque limiter, and bushing out of the connecting tube.

Remove bolts and lock washers that secure coupling to torque limiter and remove coupling.

Remove the bolts and lock washers that secure the bushing to the torque limiter and remove bushing.

Remove key from reducer shaft.

Reaching through opening in connecting tube, remove the eight bolts and lock washers that secure the connecting tube to the reducer.

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Replacement of wear parts ________________________________________ How to assemble the conveyor drive module To assemble the conveyor drive module proceed as follows (Fig. 84): Reaching through opening in connecting tube, install the bolts and lock washers to secure the connecting tube to the reducer.

Clean reducer shaft and coat shaft with anti-seize lubricant.

Install key on reducer shaft.

Insert bushing into torque limiter and secure with bolts and lock washers.

Secure coupling to torque limiter with bolts and lock washers.

Reach through opening located at the motor end of the connecting tube and slide the assembled bushing, torque limiter, and coupling onto the reducer shaft, make sure the key is in place on the reducer shaft. Do not force. Forcing the torque limiter into the reducer shaft may cause damage to the shaft or torque limiter.

NOTICE! Do not force the torque limiter onto reducer shaft. Forcing the torque limiter onto the reducer shaft may cause damage to the shaft or torque limiter.

Insert key on motor shaft and slide motor shaft into coupling. Ensure that key is lined up with keyway in coupling.

Secure motor to connecting tube with the bolts and lock washers.

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________________________________________ Replacement of wear parts Visually inspect for correct alignment of the assembly through the connecting tube opening.

After correct alignment is achieved, reach through the connecting tube opening and tighten coupling set screw.

Install the connecting tube cover with bolts and lock washers.

Fig. 84: Conveyor drive module disassembly and assembly

Bushing Torque limiter Connecting tube

Coupling

Motor Reducer

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Replacement of wear parts ________________________________________ Tail shaft The tail shaft provides friction free transition from the return to the conveying deck and has a take up which allows for even adjustments to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced.

The tail shaft assembly (Fig. 85) consists of the following main components: ■ ■ ■ ■ ■ ■ ■

shaft roller assembly face seal o-ring retaining ring bushing bearing

Fig. 85: Tail shaft main components

1 2 3 4 5 6

tail shaft roller assembly face seal slide lug slide lug o-ring

7 8 9 10 11 12

grease fitting slide block retainer bar slide plate bolt lock washer

13 14 15 16 17

bolt lock washer retaining ring relief fitting bushing

________________________________________________________________ 5.98 Continuous Haulage System

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________________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 86): Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Remove the bolts and lock washers that secure the bumper and remove bumper.

Remove the bolts and lock washers that secure the guide plates and remove guide plates from both sides.

Separate conveyor chain and fold back to clear tail shaft (see Conveyor chain replacement in this chapter).

Slide tail shaft out through opening.

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 86): Slide tail shaft in receiving boom through opening.

Fold the conveyor back over tail shaft.

Align rollers and chain.

Align flight bolts with access holes in conveyor side plates.

Connect conveyor chain (see Conveyor chain replacement in this chapter).

Install both guide plates and secure with bolts and lock washers.

Install the bumper with bolts and lock washers.

Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).

Lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.

With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

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Replacement of wear parts ________________________________________ Fig. 86: Tail shaft removal and installation

MBC frame

Bumper

Tail shaft

Guide plates

________________________________________________________________ 5.100 Continuous Haulage System

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________________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 88): Remove the tail shaft assembly from the receiving boom (see How to remove the tail shaft in this chapter).

Remove the socket head bolts, Item 13, lock washers, Item 14, and retainer bar, Item 9.

Remove slide block, Item 8, from the tail shaft, Item 1.

Remove the retaining ring, Item 15. To remove ring, put screw driver into ring slot and pry free end of ring out. Begin spiraling ring out of groove. Remove ring from shaft.

Remove the bolts, Item 11, and lock washers, Item12, that secure the slide plate, item 10, and remove plate.

Slide attaching lug, Item 4, off of shaft, Item 1.

Inspect exposed caterpillar seal, item 3, for wear (Fig. 87).

- The special lapped faces of the mating seal rings form a sealing band approximately .063 inches (1.6 mm) wide which retains the oil lubricant and seals out all foreign material. As wear occurs, the contact band broadens (Fig. 81) slightly, moving slowly inward until the inside diameter is reached.

Fig. 87: Wear inspection for caterpillar seals Broadened contact band

New

Partially worn

Inspect o-ring, Item 6, and replace if necessary.

Slide roller, Item 2, off of shaft, Item 1.

Inspect roller, Item 2, and bushing, Item 17, for wear or damage.

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Replacement of wear parts ________________________________________ How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 88): Thoroughly clean any parts that will be re-installed.

Grease shaft, Item 1, with Spec. 100-3 grease.

Insert bushings, Item 17, into roller, Item 2.

Slide roller, Item 2, onto of shaft, Item 1.

Slide o-ring, Item 6, onto shaft, Item 1.

Slide caterpillar seal, Item 3, onto slide block, Item 4. Be careful not to damage seal.

Insert slide block, Item 4, onto shaft, Item 1. Be careful not to damage seal when it is inserted into the roller, Item 2.

Install retaining ring, Item 15.

Install slide plate, Item 10, onto slide lugs, Items 4 and 5, secure with bolts, Item 11, and lock washers, Item 12.

Install slide block, Item 8, onto shaft, Item1.

Install retainer bar, Item 9, and secure with socket head bolts, item 13 and lock washers, Item 14.

After tail shaft is completely assembled, lubricate through grease fitting, Item 7, with Spec. 100-3 grease until grease flows from relief fitting, Item 16, on opposite end of shaft.

NOTICE! Relief fitting is to protect caterpillar seals from over pressure. Do not replace relief fitting with plug or grease fitting or damage to seals or tail shaft assembly may occur.

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________________________________________ Replacement of wear parts Fig. 88: tail shaft assembly and disassembly

1 2 3 4 5 6

tail shaft roller assembly face seal slide lug slide lug o-ring

7 8 9 10 11 12

grease fitting slide block retainer bar slide plate bolt lock washer

13 14 15 16 17

bolt lock washer retaining ring relief fitting bushing

Conveyor chain The conveyor chain assembly carries mined material along the conveyor trough from the receiving boom to the discharge boom. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop. As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

Each conveyor chain section (Fig. 83) consists of the following main components: ■ ■ ■ ■

chain chain connector flight nut (top lock)

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Replacement of wear parts ________________________________________ Fig. 89: Conveyor chain components T-pin Threaded stud

Connecting pin

9/16 NF lock nut

Flight

How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 90): Lay conveyor chain sections on a clean flat surface.

Position a flight on the threaded studs on the chain..

Secure the flight with 9/16 NF lock nuts, using a thin wall socket, universal joint, and impact wrench to tighten.

CAUTION! Do not use elastic stop nut on chain connector pins. Damage to the machine or conveyor chain could occur due to the elastic nuts vibrating off.

Tack weld the lock nuts to the studs.

IMPORTANT! During assembly, turn two flights upside down (evenly spaced within the conveyor chain assembly) to aid in cleaning return line.

Connect the next chain section by pressing the connecting pin through the chain links, using a piece of tubing or pipe to keep the side bars from bending.

Secure the connecting pin with the T-pin.

Repeat the previous assembly instructions until the complete chain has been assembled.

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________________________________________ Replacement of wear parts How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows (Fig. 90): Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain (Fig. 90).

To separate the conveyor chain proceed as follows (Fig. 90): Tension must be released (see previous instructions).

Align chain connector with access holes in conveyor side plates.

Remove nuts and chain connectors from each side.

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the conveyor chain and slowly pull the conveyor chain completely out of the machine.

DANGER! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

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Replacement of wear parts ________________________________________ How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows (Fig. 90): Check to ensure that the conveyor tail shaft is completely retracted.

If not retracted, see Conveyor chain adjustment in this chapter to retract take-up cylinders.

Run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the conveyor chain completely through the bottom conveyor pan.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.

DANGER! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain.

The connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.

Pull chain through top conveyor pan. Ensure that the chain is below the chain hold downs.

Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft roller.

Align chain connection point with access holes in conveyor side plates.

Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).

Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is not sliding across tail shaft.

________________________________________________________________ 5.106 Continuous Haulage System

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________________________________________ Replacement of wear parts Fig. 90: Conveyor chain installation

Chain travel

Tail shaft Drive shaft

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Replacement of wear parts ________________________________________ Crawler track The crawler track assembly (left and right) carries the machine via torque received from the tram drive reducer. The crawler track is made up of one basic crawler pad assembly, which repeats sequentially along the entire pad loop. As soon as any component of the crawler track is worn the component or complete crawler track assembly must be replaced.

Each crawler track (Fig. 91) consists of the following main components: ■ ■ ■

Crawler pad spiral pin connector pin

Fig. 91: Crawler track components

Forged pad

Pin

________________________________________________________________ 5.108 Continuous Haulage System

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________________________________________ Replacement of wear parts How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 91): Lay crawler track pads on a clean flat surface.

Each crawler pad connection requires one of the following connections per side (Fig. 91).

Insert connector pin through crawler pads from the outside. A hammer may be required to drive connector pin through pad and connector pin provisions.

Ensure that spiral pin holes are correctly aligned in connector pin.

Insert spiral pin through aligned holes in pad and connecting pin. A hammer will be required to drive spiral pin flush with outside edge of pad.

Repeat above procedure for other side of crawler pad and remainder of crawler pads.

How to remove the crawler track pad assembly To remove the crawler track pad assembly proceed as follows (Fig. 91): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Crawler track tension must be released (see Crawler track adjustment in this chapter).

Separate the crawler pads.

To separate the crawler pads proceed as follows (Fig. 91) IMPORTANT! Heating connections with a torch may be required to ease the removal of spiral pins and connecting pins.

Drive both spiral pins from crawler pad connection using hammer and punch.

Separate crawler track assembly.

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Replacement of wear parts ________________________________________ Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the crawler track assembly and slowly pull the crawler track completely out from under the machine.

DANGER! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the crawler track, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the crawler track.

Inspect the crawler drive sprockets and idler rollers for wear or damage. Replace if necessary.

How to install the crawler track pad assembly To install the crawler track pad assembly proceed as follows (Fig. 91): Remove old crawler track pad assembly (see previous section, How to remove crawler track pad assembly) DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Check to ensure that crawler track tension cylinder is completely retracted (see Crawler track adjustment in this chapter).

Slide crawler track pad assembly under crawler assembly.

Fold pad assembly over both ends of crawler assembly. Ensure that pad assembly meshes with drive sprockets and idler rollers.

Connect crawler track pad assembly (see How to assemble crawler track pad assembly in this chapter for proper connection).

Adjust tension on the crawler track pad assembly (see Crawler track pad adjustment procedure in this chapter for proper adjustment).

________________________________________________________________ 5.110 Continuous Haulage System

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________________________________________ Replacement of wear parts Crawler drive module The crawler drive module transmits torque to the crawler track via a hydraulic drive motor coupled to the tram drive gear case. The complete module must be disassembled before removing components from frame. As soon as any component of the drive module is worn or damaged, the component must be replaced.

The crawler drive module (Fig. 92) consists of the following main components: ■ ■ ■

hydraulic drive motor tram drive gear case o-ring

Fig. 92: Crawler drive module main components

Tram drive gear case

Hydraulic drive motor (not shown)

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Replacement of wear parts ________________________________________ How to disassemble the crawler drive module To disassemble the crawler drive module proceed as follows (Fig. 92): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Crawler track tension must be released (see Crawler track adjustment in this chapter).

Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear drive module.

Disconnect hydraulic hoses to drive motor and tag for reassembly.

Remove the bolts and lock washers that secure the drive motor to the connecting tube and remove drive motor.

Remove bolts from tie plate and move it to an out of the way location.

Remove the bolts and lock washers that secure the gear case to the frame and slide gear box clear of frame.

Inspect all components for wear or damage.

________________________________________________________________ 5.112 Continuous Haulage System

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________________________________________ Replacement of wear parts How to assemble the crawler drive module To assemble the crawler drive module proceed as follows (Fig. 92): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground so the crawler will be free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Inspect all components for wear or damage prior to assembly.

Slide tram gear case into the rear of the crawler drive frame and secure with the bolts and lock washers. Torque bolts in an alternating pattern to the recommended specification (based on size).

Install o-ring on hydraulic motor pilot.

Install tie plate– torque fasteners properly.

Insert the drive motor shaft into the reducer, being careful not to force them together. Otherwise, damage to the shaft or adapter may occur. Secure motor with the bolts and lock washers.

Connect the hydraulic hoses to the drive motor and purge hydraulic system of air.

Connect crawler track pad assembly (see How to install crawler track pad assembly in this chapter).

Adjust crawler track pad tension (see how to adjust crawler track in this chapter).

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Replacement of wear parts ________________________________________ Crawler take-up and idler The crawler idler allows for friction free transition and even adjustment of crawler chain slack. As soon as any part of the crawler idler is worn or damaged, the complete idler or component must be replaced.

The crawler take-up and idler (Fig. 93) consists of the following main components: ■ ■ ■

idler assembly shims grease take-up cylinder

Fig. 93: Crawler take-up and idler main components

Idler assembly

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________________________________________ Replacement of wear parts How to remove the crawler take-up and idler To remove the crawler take-up and idler proceed as follows (Fig. 93): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground with the crawler free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Crawler track tension must be released (see Crawler track adjustment in this chapter).

Separate the crawler pads (see How to remove the crawler track assembly in this chapter) and fold pads back to clear idler.

Remove needle valve, relief fitting and grease tubing from idler piston.

Slide idler assembly out of the crawler frame.

Inspect all components for wear or damage.

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Replacement of wear parts ________________________________________ How to install the crawler take-up and idler To install the crawler take-up and idler proceed as follows (Fig. 93): Raise complete crawler assembly off ground and securely block under the machine. The machine must be securely supported off the ground so the crawler will be free to turn.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the lifting devices and keep a safe distance away from suspended loads.

Inspect all components for wear or damage prior to assembly.

Slide idler assembly into the crawler frame.

Install needle valve, relief fitting and grease tubing onto idler piston.

Do not replace relief fitting with standard type grease fitting.

DANGER! Do not replace relief fitting with standard type grease fitting or high pressure build up will occur in take-up cylinder. You could be seriously injured from high pressure grease.

Connect the crawler pads (see How to assemble the crawler track assembly in this chapter).

Adjust crawler track tension (see How to adjust crawler track tension in this chapter).

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________________________________________ Replacement of wear parts Instructions on the replacement of wear parts on the piggyback bridge conveyor (PIG) 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.

Conveyor drive There are two conveyor drive assemblies, one on each side, that transmit torque to the conveyor drive chain from the electric drive motors via a torque limiter, drive reducer, and conveyor drive shaft. As soon as any component of the conveyor drive is worn or damaged the component must be replaced.

The conveyor drive assembly (Fig. 94) consists of the following main components: ■ ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer drive shaft connecting tube

Fig. 94: Conveyor drive main components

Torque Limiter Connecting tube

Coupling

Reducer Drive motor

Drive shaft

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Replacement of wear parts ________________________________________ Drive shaft The drive shaft transmits the torque of the gear boxes to the conveyor chain assembly. It is part of a complete assembly. As soon as the chain sprockets are worn the sprockets must be replaced.

The drive shaft assembly (Fig. 95) consists of the following main components: ■ ■ ■

drive shaft sprockets spacer tubes

Fig. 95: Drive shaft main components

5 6

4

4

5 6

3

1 2 1 drive shaft 2 sprocket 3 spacer tube

2 4 spacer tube 5 key 6 screw

NOTICE! Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

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________________________________________ Replacement of wear parts How to remove the drive shaft To remove the drive shaft assembly from the discharge boom proceed as follows: Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain and fold back to clear drive shaft (see Conveyor chain replacement in this chapter).

Remove the motor and reducer cover.

Remove drive module guard to access the reducer by removing the bolts and washers that secure the guard to the frame (Fig. 96).

Remove the bolts, nuts, and washers that secure the chain stripper and remove chain stripper (Fig. 96).

Fig. 96: Remove chain stripper Drive module guard

Bolts and washers

Chain stripper

Nuts, bolts, and washers

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Replacement of wear parts ________________________________________ Remove the locking wire, bolt, and lock washer that secure the retainer cap to the drive shaft and remove the retainer caps on each side of the PIG (Fig. 97).

Fig. 97: Remove the retainer cap Locking wire, bolt, and lock washer

Locking wire, bolt, and lock washer

Retainer cap

Retainer cap

Remove the conveyor drive assembly from one side of the PIG (see How to remove the conveyor drive module in this chapter).

Remove the set screws and keys that secure the sprockets to the drive shaft.

Remove the drive shaft through the hole in the PIG frame on the side of the removed conveyor drive assembly. As the drive shaft is pulled through the frame, remove the spacers and sprockets from the drive shaft.

Reassemble the drive shaft assembly if necessary.

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________________________________________ Replacement of wear parts How to install the drive shaft To install the drive shaft assembly into the discharge boom assembly proceed as follows: Disassemble the drive shaft assembly, if necessary.

Remove the motor and reducer cover, drive module guard, and conveyor drive assembly if necessary.

Coat drive shaft with grease (Spec. 100-3).

Insert the drive shaft. Slide the spacers and sprockets onto the drive shaft as the drive shaft is pushed through the hole in the PIG frame. Push shaft into reducer on opposite side. (Fig. 98) Fig. 98: Installing drive shaft

Drive shaft assembly

Secure the sprockets to the drive shaft with the keys and set screws.

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Replacement of wear parts ________________________________________ Install the retainer cap and secure with the bolt and lock washer.

Torque the bolt to 280 ft-lb (Fig. 99). Install locking wire.

Fig. 99: Retainer cap installation Locking wire, bolt, and lock washer

Retainer cap

Install the chain stripper and secure with bolts, nuts, and washers, insert bolts from the top of the chain stripper. Torque bolts to 80 ftlb (Fig. 100).

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________________________________________ Replacement of wear parts Fig. 100: Chain stripper installation Chain stripper

Nuts, bolts, and washers

Install the conveyor drive module assembly over the drive shaft. (see How to install the conveyor drive module in this chapter).

Install the drive module guard (Fig. 101).

Fig. 101: Drive module guard

Drive module guard

Bolts and washers

Install motor and reducer cover.

Connect the conveyor chain (see Conveyor chain replacement in this chapter).

Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).

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Replacement of wear parts ________________________________________ Drive shaft sprockets The drive shaft sprockets transmits the torque of the gear box to the conveyor chain assembly. It is part of a complete assembly. As soon as the sprockets are worn they must be replaced. The sprockets can be replaced with the original sprocket or a field replacement is available which can be installed without removing the drive shaft.

The drive shaft assembly (Fig. 102) consists of the following main components: ■ ■ ■

drive shaft sprockets spacer tubes

Fig. 102: Drive shaft main components

5 6

4

4

5 6

3

1 2 1 drive shaft 2 sprocket 3 spacer tube

2 4 spacer tube 5 key 6 screw

NOTICE! Due to the high abrasion forces the chain sprockets are subject to a very high level of wear.

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________________________________________ Replacement of wear parts How to remove the drive shaft sprockets To remove the drive shaft sprockets from the drive shaft assembly proceed as follows (Fig. 103): Remove the drive shaft assembly from the discharge boom (see Drive shaft removal in this chapter).

Remove the set screws from each sprocket.

Slide spacers and both sprockets from the drive shaft.

Remove old keys.

Inspect all components of the drive shaft for wear and damage. See parts manual for replacement parts list.

How to install the drive shaft sprockets To install the drive shaft sprockets on the drive shaft assembly proceed as follows (Fig. 103): Thoroughly clean and lubricate the drive shaft with Spec. 100-3 grease.

Slide one of the short spacers onto the shaft.

Insert one of the keys into the shaft keyway and slide first sprocket onto shaft and tighten the set screws to secure the sprocket.

Slide the long spacer onto the shaft.

Insert the other key into the shaft keyway and slide second sprocket onto shaft and tighten the set screws to secure the sprocket.

Slide the second short spacer onto the shaft.

Install the drive shaft assembly in the discharge boom. See drive shaft installation in this chapter.

Fig. 103: Drive shaft sprockets Short spacer

Sprocket Key (2)

Long Spacer

Set screw 2 per sprocket

Short spacer

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Replacement of wear parts ________________________________________ How to remove the drive shaft sprockets for field replacement To remove the drive shaft sprockets without removing the drive shaft from the discharge boom for field replacement sprockets proceed as follows: NOTICE! Field replacement of sprockets is for temporary use only. Replace sprocket properly (see How to install the drive shaft sprockets in this chapter) at next maintenance shift.

Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain and fold back to clear drive shaft (see Conveyor chain replacement in this chapter).

Burn off old sprocket, being careful not to burn spacers or drive shaft.

Remove old key.

Clean drive shaft thoroughly.

Install new key.

Position both halves of sprocket over shaft, align keyway and tack weld. Use smallest tacks possible to hold sprocket during preheat (Fig. 104).

NOTICE! Be careful not to weld sprockets to shaft or spacer.

Preheat thoroughly to 300° F. Take care to preheat slowly. Do not go over 350° F. Weld using stringer bead method (Fig. 104). Interpass temperature must not go below 300° F Be sure to clean each pass of all slag and splatter. No undercut is allowed.

Allow to cool slowly.

Install and tighten set screws in sprocket.

Connect the conveyor chain (see Conveyor chain replacement in this chapter).

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________________________________________ Replacement of wear parts Fig. 104: Field replacement sprocket

Welding filler material Diameter Current -

E8018C3 1/8” DCEP (Reverse polarity)

Conveyor drive module There are two conveyor drive modules, one on each side of the PIG, that transmit torque to the conveyor drive shaft via a drive motor, torque limiter, and a speed reducer. The modules must be removed as a complete assembly. As soon as any component of one of the drive modules is worn or damaged, the component must be replaced.

The conveyor drive module (Fig. 105) consists of the following main components: ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer connecting tube

Fig. 105: Conveyor drive module components

Torque Limiter Connecting tube

Drive motor

Reducer

Coupling

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Replacement of wear parts ________________________________________ How to remove the conveyor drive module To remove a conveyor drive module from the PIG proceed as follows: Remove the motor and reducer cover (Fig. 106).

Remove drive module guard (Fig. 106) to access the reducer by removing the bolts and washers that secure the reducer guard to the frame.

If required, remove grease hose assemblies from reducer.

Disconnect all electrical wiring to the drive motor.

DANGER! Ensure that electrical power has been disconnected at the main power source before performing any electrical maintenance on machine. You could be seriously injured or killed from electrical shock.

Connect an additional lifting device (e.g. lifting tackle or winch with an adequate load limit) to the lifting eyes located on the motor and reducer. Only apply enough lifting pressure to support the drive module until the module is disconnected from the frame.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Remove the locking wire, bolt, and lock washer that secure the retainer cap to the drive shaft and remove the retainer cap (Fig. 100).

Disconnect reducer bearing seal lubrication hoses, if applicable.

Remove the bolts and lock washers that secure the reducer to the frame. With the aid of the lifting device, slide the drive module assembly carefully off of the drive shaft and move module to desired work area.

Disconnect lifting device.

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________________________________________ Replacement of wear parts How to install the conveyor drive module To install the conveyor drive module on the PIG proceed as follows: Connect an additional lifting device (e.g. lifting tackle or winch with an adequate load limit) to the lifting eyes located on the motor and reducer.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Clean drive shaft and coat shaft with anti-seize lubricant.

With the aid of the lifting device, slide the drive module assembly carefully onto the drive shaft and align reducer mounting holes up with mounting holes of discharge frame.

NOTICE! Do not force the reducer onto drive shaft. Forcing the reducer onto the reducer shaft may cause damage to the shaft or reducer.

Secure reducer to discharge boom with bolts and lock washers.

Install retainer cap on end of drive shaft, secure with bolt, and lock washer and install locking wire (Fig. 106).

Connect reducer bearing seal lubrication hoses, if applicable.

Connect all electrical wiring to the drive motor.

DANGER! All electrical maintenance must be supervised and inspected by a certified electrician.

Install the drive module guard (Fig. 106).

Install the motor and reducer cover (Fig. 106).

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Replacement of wear parts ________________________________________ Fig. 106: Conveyor drive module removal and installation Retainer cap ,locking wire, bolt and lock

Conveyor drive module

Motor and reducer cover

Drive module guard

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________________________________________ Replacement of wear parts How to disassemble the conveyor drive module To disassemble the conveyor drive module proceed as follows (Fig. 107): Remove the connecting tube cover.

Reach through connecting tube and loosen set screw on coupling.

Remove the bolts and lock washers that secure the motor to the connecting tube and move the motor back until it is free of the connecting tube and coupling.

Remove key from motor shaft.

Reach through opening located on the motor end of the connecting tube and pull the coupling, torque limiter, and bushing out of the connecting tube.

Remove the bolts and lock washers that secure coupling to torque limiter and remove coupling.

Remove the bolts and lock washers that secure the bushing to the torque limiter and remove bushing.

Remove key from reducer shaft.

Reaching through opening in connecting tube, remove the bolts and lock washers that secure the connecting tube to the reducer.

How to assemble the conveyor drive module To assemble the conveyor drive module proceed as follows (Fig. 107): Reaching through opening in connecting tube, install bolts and lock washers to secure the connecting tube to the reducer.

Clean reducer shaft and coat shaft with anti-seize lubricant.

Install key on reducer shaft.

Insert bushing into torque limiter and secure with bolts and lock washers.

Secure coupling to torque limiter with bolts and lock washers.

Reach through opening located at the motor end of the connecting tube and slide the assembled bushing, torque limiter, and coupling onto the reducer shaft, make sure the key is in place on the reducer shaft.

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Replacement of wear parts ________________________________________ NOTICE! Do not force the torque limiter onto reducer shaft. Forcing the torque limiter onto the reducer shaft may cause damage to the shaft or torque limiter.

Insert key on motor shaft and slide motor shaft into coupling. Ensure that key is lined up with keyway in coupling.

Secure motor to connecting tube with bolts and lock washers.

Visually inspect for correct alignment of the assembly through the connecting tube opening.

After correct alignment is achieved, reach through the connecting tube opening and tighten coupling set screw.

Install the connecting tube cover with bolts and lock washers.

Fig. 107: Conveyor drive module disassembly and assembly

Bushing Connecting tube

Torque limiter Coupling Motor

Reducer

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________________________________________ Replacement of wear parts Tail shaft The tail shaft allows for even adjustments friction free transition to the conveyor chain assembly. As soon as any component of the tail shaft is worn the component or complete tail shaft assembly must be replaced.

The tail shaft assembly (Fig. 108) consists of the following main components: ■ ■ ■ ■ ■ ■

shaft roller assembly face seal o-ring retaining ring bushing

Fig. 108: Tail shaft main components

1 2 3 4 5 6

tail shaft roller assembly face seal slide lug slide lug o-ring

7 8 9 10 11 12

grease fitting slide block retainer bar slide plate bolt lock washer

13 14 15 16 17

bolt lock washer retaining ring relief fitting bushing

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Replacement of wear parts ________________________________________ How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 109): Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Remove the bolts and lock washers that secure the bumper plate and swing plate out of the way.

Remove the bolts and lock washers that secure the guide plates and remove guide plates from both sides.

Separate conveyor chain and fold back to clear tail shaft (see Conveyor chain replacement in this chapter).

Slide tail shaft out through opening.

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 109): Slide tail shaft in receiving boom through opening.

Fold the conveyor back over tail shaft.

Align rollers and chain.

Align flight bolts with access holes in conveyor side plates.

Connect conveyor chain (see Conveyor chain replacement in this chapter).

Install both guide plates and secure with bolts and lock washers.

Swing bumper plate back into position and secure with bolts and lock washers.

Adjust tension on the conveyor chain (see Conveyor chain adjustment in this chapter).

Lubricate tail shaft and slide plate bearings with Spec. 100-3 grease.

With machine running, visually inspect tail shaft to ensure that the shaft is turning and conveyor chain is not sliding across tail shaft.

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________________________________________ Replacement of wear parts Fig. 109: Tail shaft removal and installation

bumper plate

PIG frame

Tail shaft

Guide plate

How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (items numbers refer to Fig. 111): Remove the tail shaft assembly from the receiving boom (see How to remove the tail shaft in this chapter).

Remove the socket head bolts, Item 13, lock washers, Item 14, and retainer bar, Item 9.

Remove slide block, Item 8, from the tail shaft, Item 1.

Remove the retaining ring, Item 15. To remove ring, put screw driver into ring slot and pry free end of ring out. Begin spiraling ring out of groove. Remove ring from shaft.

Remove the bolts, Item 11, and lock washers, Item12, that secure the slide plate, item 10, and remove plate.

Slide attaching lug, Item 4, off of shaft, Item 1.

Inspect exposed caterpillar seal, item 3, for wear (Fig. 110).

-

The special lapped faces of the mating seal rings form a sealing band approximately .063 inches (1.6 mm) wide which retains the oil lubricant and seals out all foreign material. As wear occurs, the contact band broadens (Fig. 104) slightly, moving slowly inward until the inside diameter is reached.

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Replacement of wear parts ________________________________________ Fig. 110: Wear inspection for caterpillar seals Broadened contact band

New

Partially worn

Inspect o-ring, Item 6, and replace if necessary.

Slide roller, Item 2, off of shaft, Item 1.

Inspect roller, Item 2, and bushing, Item 17, for wear or damage.

How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (item numbers refer to Fig. 111): Thoroughly clean any parts that will be re-installed.

Grease shaft, Item 1, with Spec. 100-3 grease.

Insert bushings, Item 17, into roller, Item 2.

Slide roller, Item 2, onto of shaft, Item 1.

Slide o-ring, Item 6, onto shaft, Item 1.

Slide caterpillar seal, Item 3, onto slide block, Item 4. Be careful not to damage seal.

Insert slide block, Item 4, onto shaft, Item 1. Be careful not to damage seal when it is inserted into the roller, Item 2.

Install retaining ring, Item 15.

Install slide plate, Item 10, onto slide lugs, Items 4 and 5, secure with bolts, Item 11, and lock washers, Item 12.

Install slide block, Item 8, onto shaft, Item1.

Install retainer bar, Item 9, and secure with socket head bolts, item 13 and lock washers, Item 14.

After tail shaft is completely assembled, lubricate through grease fitting, Item 7, with Spec. 100-3 grease until grease flows from relief fitting, Item 16, on opposite end of shaft.

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________________________________________ Replacement of wear parts NOTICE! Relief fitting is to protect caterpillar seals from over pressure. Do not replace relief fitting with plug or grease fitting or damage to seals or tail shaft assembly may occur.

Fig. 111: Tail shaft assembly and disassembly

1 2 3 4 5 6

tail shaft roller assembly face seal slide lug slide lug o-ring

7 8 9 10 11 12

grease fitting slide block retainer bar slide plate bolt lock washer

13 14 15 16 17

bolt lock washer retaining ring relief fitting bushing

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Replacement of wear parts ________________________________________ Conveyor chain The conveyor chain assembly (Fig. 112) carries mined material along the PIG conveyor trough. The conveyor chain is made up of one basic chain assembly, which repeats sequentially along the entire chain loop.

As soon as any component of the conveyor chain is worn the component or complete conveyor chain assembly must be replaced.

Fig. 112: Conveyor chain

T-pin Threaded stud

Connecting pin

9/16 NF lock nut

Flight

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________________________________________ Replacement of wear parts How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 112): Lay conveyor chain sections on a clean flat surface.

Position a flight on the threaded studs on the chain..

Secure the flight with 9/16 NF lock nuts, using a thin wall socket, universal joint, and impact wrench to tighten.

CAUTION! Do not use elastic stop nut on chain connector pins. Damage to the machine or conveyor chain could occur due to the elastic nuts vibrating off.

Tack weld the lock nuts to the studs.

IMPORTANT! During assembly, turn two flights upside down (evenly spaced within the conveyor chain assembly) to aid in cleaning return line.

Connect the next chain section by pressing the connecting pin through the chain links, using a piece of tubing or pipe to keep the side bars from bending.

Secure the connecting pin with the T-pin.

Repeat the previous assembly instructions until the complete chain has been assembled.

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Replacement of wear parts ________________________________________ How to remove the conveyor chain assembly To remove the conveyor chain assembly proceed as follows (Fig. 113): Release tension on the conveyor chain by releasing grease in both of the conveyor chain take-up cylinders (see Conveyor chain adjustment in this chapter).

Separate conveyor chain. To separate the conveyor chain proceed as follows (Fig. 113): -

Tension must be released (see previous instructions).

-

Align chain connector with access holes (Fig. 113) in conveyor side plates.

-

Remove access hole covers from the conveyor side plates.

-

Remove nuts and chain connectors from each side.

-

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to either end of the conveyor chain and slowly pull the conveyor chain completely out of the machine.

DANGER! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain, the connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

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________________________________________ Replacement of wear parts How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows (Fig. 114): Check to ensure that the conveyor tail shaft is completely retracted.

If not retracted, see Conveyor chain adjustment in this chapter to retract take-up cylinders.

Run a cable or pull rope with an adequate load limit through the bottom conveyor pan and connect to the conveyor chain.

Connect an additional pulling or lifting device (e.g. winch or lifting tackle with adequate load limit) to the other end of the cable or pull rope and slowly pull the conveyor chain completely through the bottom conveyor pan.

IMPORTANT! If old conveyor chain is still on machine, installation can be facilitated by connecting the new conveyor chain to the old conveyor chain via the chain connectors and pulling it through the bottom conveyor pan.

DANGER! When using an additional pulling device (e.g. winch or lifting tackle with adequate load limit) for pulling the conveyor chain.

The connection could fracture under the load. You could be seriously injured or killed by the recoiling chain or cable.

Use only approved lifting equipment for connecting pulling devices to the conveyor chain.

Fold conveyor chain back over the tail shaft and drive shaft and slowly pull the chain along the conveyor ensuring that the chain is under the chain hold downs.

Pull chain through top conveyor pan. Ensure that the chain is below the chain hold downs.

Ensure that the chain is properly meshed with the drive sprockets and aligned with the tail shaft roller.

Align chain connection point with access holes in conveyor side plates.

Connect conveyor chain (see How to assemble the conveyor chain sections in this chapter for proper connection).

Adjust tension on the conveyor chain (see Conveyor chain adjustment procedure in this chapter).

With machine running, visually inspect tail shaft to ensure that that the shaft is turning and conveyor chain is not sliding across tail shaft.

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Replacement of wear parts ________________________________________ Fig. 114: Conveyor chain installation

Chain travel

Drive shaft

Tail shaft

Access hole

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______________________________ Replacement of hydraulic components Instructions on the replacement of hydraulic components on the mobile bridge carrier (MBC) It is essential that hydraulic components are replaced before they reach the lowest wear or use limit, as otherwise damage can be caused to other parts of the machine. Inspect the hydraulic components at regular intervals for premature noise or fluid leakage.

DANGER! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

DANGER! All adjustable pressures are preset at the factory; do not change the pressure settings from what is stated on the hydraulic schematic located in the hydraulic section of your parts manual.

NOTICE! The hydraulic system must be purged of air anytime a hydraulic hose or component is disconnected or changed. Failure to do so can cause damage to any part of the hydraulic system.

Hydraulic components (MBC) The Mobile Bridge Carrier (MBC) has the following hydraulic components: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

tram hydrostatic pump (2) tram motor (2) cross port relief valve (2) hydrostatic filter (2) pressure filter (1) return/charge filter (2) flow divider (1) inby conveyor lift cylinder (2) outby conveyor lift cylinder (2) canopy cylinder (1) cab lift cylinder (1) valve bank (1) heat exchanger (1) ball valve (1) pressure gauge, 6000 psi (3) gauge (1) gauge, 600 psi (2) shuttle valve (2)

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Replacement of hydraulic components ______________________________ Fig. 114: Hydraulic component locator (MBC)

89

3 4 5

4 1

18 2 16 12

12

17

2 16 11

8

6

14

98

15

10 13

1.

2.

3.

4.

5.

6.

7.

hydrostatic pump tram motor charge filter hydrostatic filter pressure filter return filter flow divider

8.

9.

10.

11.

12.

13.

14.

inby conveyor lift cylinder outby conveyor lift cylinder canopy cylinder cab lift cylinder detented 3-way valve heat exchanger ball valve

15.

16.

17.

18.

pressure gauges shuttle valve valve bank hydraulic oil tank

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______________________________ Replacement of hydraulic components Tram hydrostatic pump The MBC has two hydrostatic pumps that are driven by one 75 HP electric motors for the left and right tram assemblies.

The hydrostatic pump drive (Fig. 115) consists of the following main components: ■ ■ ■ ■

hydrostatic pump electric motor connecting tube coupling

Fig. 115: Tram hydrostatic pump drive main components

Hydrostatic pump

Electric motor Hydrostatic pump

Electric motor Connecting tube

Connecting tube Coupling

Coupling

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Replacement of hydraulic components ______________________________ How to disassemble the hydrostatic pump drive To disassemble the hydrostatic pump drive proceed as follows (Fig. 115): Disconnect all electrical wiring to the drive motor.

DANGER! Ensure that electrical power has been disconnected at the main power source before performing any electrical maintenance on machine. You could be seriously injured or killed from electrical shock.

Disconnect and tag hydraulic hoses at the pump.

DANGER! Never disconnect a hydraulic hose if the circuit is pressurized.

Release of pressurized fluid can cause serious injury or death to you or other workers.

Remove the bolts and lock washers that secure the connecting tube cover and remove cover.

Remove the bolts and lock washers that secure the pump to the connecting tube and remove pump.

Reach through access hole in connecting tube and pull coupling off of motor shaft.

Remove the bolts, lock washers and nuts that secure the connecting tube to the motor and remove connecting tube.

Remove the bolts and lock washers that secure the motor to the frame.

With the aid of an additional lifting device, lift motor from frame.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Disconnect lifting device.

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______________________________ Replacement of hydraulic components How to assemble the hydrostatic pump drive To assemble the hydrostatic pump drive proceed as follows (Fig. 115): With the aid of an additional lifting device, lift motor into frame and secure with the bolts and lock washers.

DANGER! When using an additional lifting device (e.g. winch or lifting tackle with adequate load limit) for lifting the drive module. The connection could fracture under the load. You could be seriously injured or killed by the falling load.

Use only approved lifting equipment for connecting lifting devices to the drive module.

Disconnect lifting device.

Attach the connecting tube (with access hole turned to the top) to the motor and secure with the bolts, lock washers and nuts.

Reach through access hole in connecting tube and slide coupling onto the motor shaft.

Install the pump onto the connecting tube, be careful not to force the pump shaft into the connecting tube or damage to the splines may occur.

Secure the pump to the connecting tube with all bolts and lock washers.

Install the connecting tube cover and secure with the bolts and lock washers.

Fill all cases on hydraulic pump and tram motor prior to start up.

Connect all electrical wiring to the drive motor.

NOTICE! All electrical maintenance must be performed or inspected by a certified electrical technician.

Connect all hydraulic hoses to the pump and purge hydraulic system of air.

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Replacement of hydraulic components ______________________________ Tram motor The MBC has two tram motors for the left and right tram assemblies. If either of the tram motors need replaced, they are available as service exchange components only.

How to remove the tram motor To remove the tram motor proceed as follows (Fig. 116): Disconnect hydraulic hoses to drive motor and tag for reassembly.

DANGER! Never disconnect a hydraulic hose if the circuit is pressurized.

Release of pressurized fluid can cause serious injury or death to you or other workers.

Remove the bolts and lock washers that secure the drive motor to the connecting tube and remove drive motor.

How to install the tram motor To install the tram motor proceed as follows (Fig. 116): Insert the tram motor shaft into the connecting tube, being careful not to force or damage the shaft or adapter. Secure motor with the bolts and lock washers.

Connect the hydraulic hoses to the tram motor and purge hydraulic system of air.

Fig. 116: Tram motor removal and installation

Tram motor

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______________________________ Replacement of hydraulic components Conveyor lift cylinders (inby and outby) The MBC has two inby and two outby conveyor lift cylinders for the left and right sides of the receiving and discharge boom assemblies. If either of the cylinders need replaced or repaired, seal kits and counter balance valves are available.

How to remove the conveyor lift cylinders To remove either of the cylinders proceed as follows: Lower boom until the cylinder is completely retracted and no load is resting on the cylinder.

Securely block and support under the boom with an appropriate blocking device.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the blocking devices and keep a safe distance away from suspended and blocked loads.

Disconnect hydraulic hoses to cylinder and tag for reassembly.

DANGER! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

Remove cotter pins from the top and bottom cylinder pins and remove cylinder pins.

Remove cylinder from machine.

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Replacement of hydraulic components ______________________________ How to install the conveyor lift cylinders To install either of the cylinders proceed as follows: Ensure that the boom is securely blocked and supported under the boom with an appropriate blocking device.

DANGER! You could be seriously injured or even killed by falling loads. Observe the safe working load of the blocking devices and keep a safe distance away from suspended and blocked loads.

Insert cylinder into cylinder lugs of main frame and boom frame.

Cylinder base goes in the lower main frame lug and rod end goes boom lug.

Align pin holes and insert cylinder pins.

Insert cotter pins in both cylinder pins and bend.

Connect hydraulic hoses as previously tagged.

Purge hydraulic system of air.

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______________________________ Replacement of hydraulic components Canopy cylinder The MBC has one canopy lift cylinder located in the rear of the operator’s compartment. If the cylinders need replaced or repaired, seal kits and counter balance valves are available.

How to remove the canopy cylinder To remove the cylinder proceed as follows (Fig. 117): Lower cylinder until it is completely retracted and no load is resting on the cylinder.

Disconnect hydraulic hoses to cylinder and tag for reassembly.

DANGER! Never disconnect a hydraulic hose if the circuit is pressurized or if there is a load on the circuit. If a hose is disconnected while the circuit is pressurized or a load is on the circuit, the load will fall causing damage to the machine or serious injury or death to you or other workers.

Remove the bolt and elastic stop nut from the rod end of cylinder.

Remove the bolts and lock washers that secure the cylinder and cylinder cover guard to the side of the operator’s compartment.

Remove cylinder from machine.

How to install the canopy cylinder To install the cylinder proceed as follows (Fig. 117): Insert cylinder and cylinder cover guard into appropriate location of operator’s compartment and align the mounting holes.

Secure cylinder and guard with the bolts and lock washers.

Place cylinder cap on rod end of cylinder and secure with the bolt and elastic stop nut.

Connect hydraulic hoses as previously tagged.

Purge hydraulic system of air.

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Replacement of hydraulic components ______________________________ Fig. 117: Canopy cylinder removal and installation Mounting bolts and lock washers

Bolt and elastic stop nut

Cylinder cap

Canopy cylinder

Cylinder cover

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_________________________________________________ Troubleshooting Troubleshooting procedures The following section lists possible problems encountered when operating and servicing the continuous haulage system and can aid in locating and correcting these problems.

This section covers basic hydraulic components, with each listed in a trouble-cause-remedy format.

WARNING! Some procedures must be carried out with the cover of the electrical controller removed and some procedures require the controller to be energized during the tests. It is extremely important that you take all necessary precautions to prevent accidental electrical shock while working within the controller. An MSHA-certified electrician must supervise and inspect all work performed.

For maintenance procedures and tests that DO NOT require the controller to be energized, these precautions include: Before removing the controller cover, remove power from the system by switching the circuit breaker off.

Use insulated gloves and tools where possible.

All connections must be tight and care must be taken to prevent bolts, nuts, washers and other small metal fasteners from being dropped or lost inside the controller. These lost fasteners could cause electrical shorts inside the controller.

For procedures that DO require that the controller be energized while the cover is off: At no time should you reach inside the controller while it is energized. If it becomes necessary to make adjustments or to replace parts inside the controller, the machine circuit breaker must be turned to the “OFF” position. Once the circuit breaker is in the “OFF” position adjustments or parts replacements can be made.

WARNING! Never disconnect a hydraulic hose if the circuit is pressurized or there is a load on the circuit. If a hose is disconnected while the cylinder is supporting a load, the load will fall.

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Troubleshooting _________________________________________________ Hydraulic system (general) Table 7: Hydraulic system (general) troubleshooting Trouble, symptom, or cause

Probable cause

Test, check and/or remedy

Dirty oil Components not properly cleaned Disassemble components after servicing. and reclean parts.

Air breather left off.

Replace breather.

Hose lines not properly covered after servicing machine.

Clean hose lines after servicing.

Filter elements not replaced at proper intervals or when indicated.

Replace elements at proper intervals.

Foaming oil Return of tank lines not below fluid level.

Check oil level. Replace broken hoses or lines.

Oil contaminated with incompatible foreign matter.

Drain out oil and replace with clean oil.

Suction leak to pump aerating oil.

Replace or tighten fittings and lines.

Moisture in oil Soluble oil solution splashing into poorly gasketed tanks or fill holes left open.

Moisture in cans or used replacement oil.

Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.

Replace with new cans of oil.

Extreme temperature differential in certain geographical locations.

Replace with recommended oil for correct temperature range. overheating of system Fluid viscosity too high.

Check fluid specs.

Excessive slippage or internal leakage past pump or cylinders.

Fluid viscosity too low.

Improper air circulation around reservoir.

Check to see if the area around the reservoir is clear.

System relief valve set too high or Reset the relief valve to too low. specifications.

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_________________________________________________ Troubleshooting Table 7 (continued): Hydraulic system (general) troubleshooting Trouble, symptom, or cause

Probable cause

foreign matter sources Sealing compound (pipe dope, in the circuit Teflon tape).

Test, check and/or remedy Clean or replace seals.

Burrs inside piping components. Disassemble piping components and remove any burrs.

Lines left unprotected and dirty, repaired components.

Drain and replace oil.

Repair parts not properly protected while stored.

Clean parts thoroughly before installation.

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Troubleshooting _________________________________________________ Hydraulic cylinders Table 8: Hydraulic cylinder troubleshooting Trouble, symptom or cause

Probable cause

Cylinder drifts Piston seal leak.

Control cartridge by-passing.

Test, check and/or remedy Repair seals or replace cylinder.

Replace cartridge or cylinder as required.

Correct leaks.

Other circuit leaks.

Cylinder fails to move the Pressure too Iow. load when actuated

Check pressure at cylinder to make circuit requirements.

Piston seal leak.

Repair seals or replace cylinder.

Piston rod broken at piston end.

Repair as required or replace cylinder.

Replace cylinder.

Contamination in hydraulic system resulting in scored cylinder bore.

Erratic or chatter in opera- Excessive friction due to mistion alignment and/or side loading.

Air in circuit.

Correct cylinder to load alignment.

Cycle cylinder to full stop positions to purge air.

Excessive or rapid piston Excessive system pressure due Correct pressure adjustment to seal wear to over adjustment. rated limits.

Excessive friction due to misalignment and/or side loading.

Cylinder body seal leak Excessive pressure.

Correct cylinder to load alignment.

Reduce pressure to rated limits.

Seal is pinched or extruded.

Replace cylinder body seal.

Seal deterioration (soft or gummy).

Check compatibility of seal material with operating fluid. Replace oil.

Piston is leaking Dirt has scored the piston or the Replace piston or rod. rod.

Piston freezes to the tube Scoring in the piston.

Replace.

Packing and gasket leaks Excessive heat. develop

Replace packing and gasket.

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_________________________________________________ Troubleshooting Hydraulic pump Table 9: Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

Pump makes excessive noise Vacuum leaks in suction line.

Test, check and/or remedy Check for leaks in fittings or damaged suction lines.

Vacuum leaks in the pump shaft Check pump. seal.

Poor alignment with drive mechanism.

Align pump and pump motor.

Incorrect fluid in system.

Check fluid specs.

Relief valve set too high.

Check relief pressure.

Seal deterioration (hard or loss of elasticity).

Replace seal.

Seal deterioration (loss of radial Replace seal . squeeze due to flat spots or wear on O.D. or I. D.).

Seal leak Torn or worn seals.

Replace seal.

Gland bearing worn.

Replace gland and seals.

Seal deterioration (soft or gummy).

Replace seal.

Seal deterioration (hard or loss of elasticity).

Replace seal.

Seal deterioration (flat spots on I.D.).

Replace seal.

Aeration of fluid in reservoir.

Correct air leak.

Worn or damaged gears and housing.

Replace gears and housing.

Worn or faulty bearing.

Replace faulty bearing.

Reversed rotation.

Check pump motor wiring.

Plugged or restricted suction line or suction strainer.

Clean by removing the plugged area.

Plugged reservoir filter breather .

Clean reservoir. Clean breather.

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Troubleshooting _________________________________________________ Table 9 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

Seal leak (continued) Oil viscosity too high or operating temperature too low.

Test, check and/or remedy

Replace with recommended oil.

Air leak in suction line or fittings. Replace lines or fittings if badly worn.

Loose or worn pump parts.

Replace worn pump parts.

Air leak at pump shaft seal.

Replace pump shaft seals.

Oil level too low and drawing air Check oil level. in through inlet pipe opening.

Air bubbles in intake oil.

Check oil level and tighten any loose fittings.

Pump housing bolts loose or not Tighten the housing bolts and re -torque bolts. properly torqued.

Pump failure to deliver oil Low oiI Ievel in reservoir.

Fill to proper level.

Oil intake hose suction strainer plugged.

Clean or replace strainer.

Air leak in suction line and preventing priming.

Tighten or replace suction lines.

Pump shaft turning too slowly.

Gears are worn and need replacing.

Oil viscosity too high.

Replace with recommended oil.

Wrong shaft rotation.

Check pump motor wiring.

Pump shaft or parts broken.

Replace shaft or broken parts.

Dirt in pump.

Clean pump .

Oil leakage around pump Shaft seal worn.

Replace seals.

Head of oil on suction hose con- Tighten bolts. Tighten or replace nection leaking. connections.

Pump housing bolts loose or improperly torqued.

Tighten bolts.

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_________________________________________________ Troubleshooting Table 9 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause

Probable cause

Test, check and/or remedy

Excessive pump wear Abrasive dirt in hydraulic oil being Replace oil with clean hydraulic circulated through the system. oil.

OiI viscosity too Iow. System pressure exceeding pump rating.

Replace with recommended oil.

Relief valve out of adjustment.

Pump misalignment.

Realign pump.

Pump parts inside the housing Seizure due to lack of oil. are broken Excessive system pressure above maximum pump rating.

Check oiI level.

Relief vaIve out of adjustment.

Excessive torqueing to housing bolts.

Loosen bolts and then retorque.

Solid matter being drawn in from reservoir and wedged in pump.

Remove and clean clogged area.

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Troubleshooting _________________________________________________ Valves Table 10: Valve troubleshooting Trouble, symptom or cause

Probable cause

Operating pressure can- Valve spring broken. not be changed Open valve in the system.

Test, check and/or remedy Replace the spring.

Find and close open valve.

Valve piston sticks Dirt in the system.

Remove the valve and clean it thoroughly; flush the system as necessary.

Certain passages are Dirt in the system. blocked or pressure fluctuates

Remove the valve and clean it thoroughly; flush the system as necessary.

Pressure fluctuates and Air in the system. there is extreme noise in the valve Pressure or volume too high.

Check for leaks.

Valve leaks internally Valve piston and body worn.

Replace the valve.

Excessive leakage or Valve excessively hot. sticking pistons occurs Dirt in the system.

Adjust the pressure or volume.

Remove the valve and clean it thoroughly; flush the system.

Replace oil.

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_________________________________________________ Troubleshooting Error codes The continuous haulage system will display and log error codes. There are two basic types of error codes: ■ ■ Fault log codes

Fault log codes Real time codes

Fault log error codes (Table 12) are sequentially numbered and are stored in the fault log only when they result in a system shutdown.

They normally do not appear on the display. The infra red transmitter is used to access the fault error log.

Communication errors between MCU will result in fault log codes, numbers 5 through 16.

IMPORTANT Since communication is both ways, the error codes help to narrow down the cause. Cable problems will most often result in error code numbers 5, 6, or 7. Codes 8-16 are return message problems which usually indicates an internal MCU problem, as wiring must be intact for the outgoing messages to have been received.

Real time codes

Real time error codes (Tables 12 and 13) will appear on the display immediately. They are almost always displayed on the fourth line replacing “STATUS OK”. They are numbered and transferred to the fault log if a motor shutdown resulted when they occurred.

IMPORTANT Most error codes are common between the fault log and real time codes.

Communication faults

Errors indicating a communication fault or an initialization error (Table 12) on the part of the control station (CST) are not numbered and will appear during normal operation (real time). They will typically appear on the fourth line of the display.

When the CST is powered up, it scans its switches for the “off” position.

If any switches are found to be “on”, including tram joysticks, the CST will not transmit to the machine control unit (MCU), and the MCU will indicate a “CST COMM error”.

The “EST POWER” LED on the CST will not be blinking and the “SW ACTIVE” LED will be constantly illuminated. The “EST POWER” LED must be blinking for transmission back to the MCU. Keep connections between the CST and the MCU tight.

This is most likely due to a cable problem, but may also indicate trouble with the barrier.

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Troubleshooting _________________________________________________ Table 11: Communication faults Fault log No.

Communication fault

Displayed

1

OUTBY CONTROL STATION COMM FAULT

OUTBY CST COMM ERROR (MBC NO.1)

2

INBY1 CONTROL STATION COMM FAULT

INBY 1 CST COMM ERROR (MBC NO.2)

3

INBY2 CONTROL STATION COMM FAULT

INBY 2 CST COMM ERROR (MBC NO.3)

4

INBY3 CONTROL STATION COMM FAULT

INBY 3 CST COMM ERROR (MBC NO.4)

Table 12: Fault log codes (assumes an 8 unit system) Fault log No.

Fault log code

Real time code (displayed)

5

COMM FAULT OUTBY TO INBY1

COMM ERR OUTBY-INBY1

6

COMM FAULT OUTBY TO INBY2

COMM ERR OUTBY-INBY2

7

COMM FAULT OUTBY TO INBY3

COMM ERR OUTBY-INBY3

8

COMM FAULT INBY1 TO OUTBY

COMM ERR INBY1-OUTBY

9

COMM FAULT INBY1 TO INBY2

COMM ERR INBY1-INBY2

10

COMM FAULT INBY1 TO INBY3

COMM ERR INBY1-OUTBY3

11

COMM FAULT INBY2 TO OUTBY

COMM ERR INBY2-OUTBY

12

COMM FAULT INBY2 TO INBY1

COMM ERR INBY2-INBY1

13

COMM FAULT INBY2 TO INBY3

COMM ERR INBY2-INBY3

14

COMM FAULT INBY3 TO OUTBY

COMM ERR INBY3-OUTBY

15

COMM FAULT INBY3 TO INBY1

COMM ERR INBY3-INBY1

16

COMM FAULT INBY3 TO INBY2

COMM ERR INBY3-INBY2

17

OUBY FOOTSWITCH TRIP

OUTBY FOOTSWITCH OPEN

18

INBY1 FOOTSWITCH TRIP

INBY1 FOOTSWITCH OPEN

19

INBY2 FOOTSWITCH TRIP

INBY2 FOOTSWITCH OPEN

20

INBY3 FOOTSWITCH TRIP

INBY3 FOOTSWITCH OPEN

21

OUTBY PUMP OVERLOAD

OUTBY PMP MTR OVLOAD

22

INBY1 PUMP OVERLOAD

INBY1 PMP MTR OVLOAD

23

INBY2 PUMP OVERLOAD

INBY2 PMP MTR OVLOAD

24

INBY3 PUMP OVERLOAD

INBY3 PMP MTR OVLOAD

25

OUTBY PIG#1 OVERLOAD

OUTBY PG1 MTR OVLOAD

26

INBY1 PIG#2 OVERLOAD

INBY1 PG1 MTR OVLOAD

27

INBY2 PIG#1 OVERLOAD

INBY2 PG1 MTR OVLOAD

28

INBY3 PIG#1 OVERLOAD

INBY3 PG1 MTR OVLOAD

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_________________________________________________ Troubleshooting Table 12 (continued): Fault log codes (assumes an 8 unit system) Fault log No.

Fault log code

Real time code (displayed)

29

OUTBY MBC OVERLOAD

OUTBY MBC MTR OVLOAD

30

INBY1 MBC OVERLOAD

INBY1 MBC MTR OVLOAD

31

INBY2 MBC OVERLOAD

INBY2 MBC MTR OVLOAD

32

INBY3 MBC OVERLOAD

INBY3 MBC MTR OVLOAD

33

OUTBY PIG#2 OVERLOAD

OUTBY PG2 MTR OVLOAD

34

INBY1 PIG#2 OVERLOAD

INBY1 PG2 MTR OVLOAD

35

INBY2 PIG#2 OVERLOAD

INBY2 PG2 MTR OVLOAD

36

INBY3 PIG#2 OVERLOAD

INBY3 PG2 MTR OVLOAD

37

OUTBY PUMP CONTACTOR FROZEN OPEN

OUBY PUMP FZ OPEN

38

INBY#1 PUMP CONTACTOR FROZEN OPEN

INBY1 PUMP FZ OPEN

39

INBY#2 PUMP CONTACTOR FROZEN OPEN

INBY2 PUMP FZ OPEN

40

INBY#3 PUMP CONTACTOR FROZEN OPEN

INBY3 PUMP FZ OPEN

41

OUTBY PUMP CONTACTOR FROZEN CLOSED

OUTBY PUMP FZ CLOSED

42

INBY#1 PUMP CONTACTOR FROZEN CLOSED

INBY1 PUMP FZ CLOSED

43

INBY#2 PUMP CONTACTOR FROZEN CLOSED

INBY2 PUMP FZ CLOSED

44

INBY#3 PUMP CONTACTOR FROZEN CLOSED

INBY3 PUMP FZ CLOSED

45

OUTBY PIG1 FWD CONTACTOR FROZEN OPEN

OUTBY PIG1 FZ OPEN

46

INBY#1 PIG1 FWD CONTACTOR FROZEN OPEN

INBY1 PIG1 FZ OPEN

47

INBY#2 PIG1 FWD CONTACTOR FROZEN OPEN

INBY2 PIG1 FZ OPEN

48

INBY#3 PIG1 FWD CONTACTOR FROZEN OPEN

INBY3 PIG1 FZ OPEN

49

OUTBY PIG1 FWD CONTACTOR FROZEN CLOSED

OUTBY PIG1 FZ CLOSED

50

INBY#1 PIG1 FWD CONTACTOR FROZEN CLOSED

INBY1 PIG1 FZ CLOSED

51

INBY#2 PIG1 FWD CONTACTOR FROZEN CLOSED

INBY2 PIG1 FZ CLOSED

52

INBY#3 PIG1 FWD CONTACTOR FROZEN CLOSED

INBY3 PIG1 FZ CLOSED

53

OUTBY PIG1 REV CONTACTOR FROZEN OPEN

OUTBY PIG1 REV FZ OPEN

54

INBY#1 PIG1 REV CONTACTOR FROZEN OPEN

INBY1 PIG1 REV FZ OPEN

55

INBY#2 PIG1 REV CONTACTOR FROZEN OPEN

INBY2 PIG1 REV FZ OPEN

56

INBY#3 PIG1 REV CONTACTOR FROZEN OPEN

INBY3 PIG1 REV FZ OPEN

57

OUTBY PIG1 REV CONTACTOR FROZEN CLOSED

OUTBY PIG1 REV FZ CLOSED

58

INBY#1 PIG1 REV CONTACTOR FROZEN CLOSED

INBY1 PIG1 REV FZ CLOSED

59

INBY#2 PIG1 REV CONTACTOR FROZEN CLOSED

INBY2 PIG1 REV FZ CLOSED

60

INBY#3 PIG1 REV CONTACTOR FROZEN CLOSED

INBY3 PIG1 REV FZ CLOSED

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Troubleshooting _________________________________________________ Table 12 (continued): Fault log codes (assumes an 8 unit system) Fault log No.

Fault log code

Real time code (displayed)

61

OUTBY MBC FWD CONTACTOR FROZEN OPEN

OUTBY MBC FZ OPN

62

INBY#1 MBC FWD CONTACTOR FROZEN OPEN

INBY1 MBC FZ OPEN

63

INBY#2 MBC FWD CONTACTOR FROZEN OPEN

INBY2 MBC FZ OPEN

64

INBY#3 MBC FWD CONTACTOR FROZEN OPEN

INBY3 MBC FZ OPEN

65

OUTBY MBC FWD CONTACTOR FROZEN CLOSED

OUTBY MBC FZ CLOSED

66

INBY#1 MBC FWD CONTACTOR FROZEN CLOSED

INBY1 MBC FZ CLOSED

67

INBY#2 MBC FWD CONTACTOR FROZEN CLOSED

INBY2 MBC FZ CLOSED

68

INBY#3 MBC FWD CONTACTOR FROZEN CLOSED

INBY3 MBC FZ CLOSED

69

OUTBY MBC REV CONTACTOR FROZEN OPEN

OUTBY MBC REV FZ OPEN

70

INBY#1 MBC REV CONTACTOR FROZEN OPEN

INBY1 MBC REV FZ OPEN

71

INBY#2 MBC REV CONTACTOR FROZEN OPEN

INBY2 MBC REV FZ OPEN

72

INBY#3 MBC REV CONTACTOR FROZEN OPEN

INBY3 MBC REV FZ OPEN

73

OUTBY MBC REV CONTACTOR FROZEN CLOSED

OUTBY MBC REV FZ CLOSED

74

INBY#1 MBC REV CONTACTOR FROZEN CLOSED

INBY1 MBC REV FZ CLOSED

75

INBY#2 MBC REV CONTACTOR FROZEN CLOSED

INBY2 MBC REV FZ CLOSED

76

INBY#3 MBC REV CONTACTOR FROZEN CLOSED

INBY3 MBC REV FZ CLOSED

77

OUTBY PIG2 FORWARD CONTACTOR FROZEN OPEN OUTBY PIG2 FZ OPEN

78

INBY#1 PIG2 FWD CONTACTOR FROZEN OPEN

INBY1 PIG2 FZ OPEN

79

INBY#2 PIG2 FWD CONTACTOR FROZEN OPEN

INBY2 PIG2 FZ OPEN

80

INBY#3 PIG2 FWD CONTACTOR FROZEN OPEN

INBY3 PIG2 FZ OPEN

81

OUTBY PIG2 FWD CONTACTOR FROZEN CLOSED

OUTBY PIG2 FZ CLOSED

82

INBY#1 PIG2 FWD CONTACTOR FROZEN CLOSED

INBY2 PIG1 FZ CLOSED

83

INBY#2 PIG2 FWD CONTACTOR FROZEN CLOSED

INBY2 PIG2 FZ CLOSED

84

INBY#3 PIG2 FWD CONTACTOR FROZEN CLOSED

INBY3 PIG2 FZ CLOSED

85

OUTBY PIG2 REV CONTACTOR FROZEN OPEN

OUTBY PIG2 REV FZ OPEN

86

INBY#1 PIG2 REV CONTACTOR FROZEN OPEN

INBY1 PIG2 REV FZ OPEN

87

INBY#2 PIG2 REV CONTACTOR FROZEN OPEN

INBY2 PIG2 REV FZ OPEN

88

INBY#3 PIG2 REV CONTACTOR FROZEN OPEN

INBY3 PIG2 REV FZ OPEN

89

OUTBY PIG2 REV CONTACTOR FROZEN CLOSED

OUTBY PIG2 REV FZ CLOSED

90

INBY#1 PIG2 REV CONTACTOR FROZEN CLOSED

INBY1 PIG2 REV FZ CLOSED

91

INBY#2 PIG2 REV CONTACTOR FROZEN CLOSED

INBY2 PIG2 REV FZ CLOSED

92

INBY#3 PIG2 REV CONTACTOR FROZEN CLOSED

INBY3 PIG2 REV FZ CLOSED

________________________________________________________________ 5.164 Continuous Haulage System

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_________________________________________________ Troubleshooting Table 13: Real time codes (assumes an 8 unit system) Fault

Displayed

Machine stopped on outby MBC

OUTBY MACHINE STOP

Machine stopped on Inby MBC #1

INBY1 MACHINE STOP

Machine stopped on Inby MBC #2

INBY2 MACHINE STOP

Machine stopped on Inby MBC #3

INBY3 MACHINE STOP

System stopped on outby MBC

OUTBY SYSTEM STOP

System stopped on Inby MBC #1

INBY1 SYSTEM STOP

System stopped on Inby MBC #2

INBY2 SYSTEM STOP

System stopped on Inby MBC #3

INBY3 SYSTEM STOP

Pump motor stopped on outby MBC

OUTBY PUMP MTR STOP

Pump motor stopped on Inby MBC #1

INBY1 PUMP MTR STOP

Pump motor stopped on Inby MBC #2

INBY2 PUMP MTR STOP

Pump motor stopped on Inby MBC #3

INBY3 PUMP MTR STOP

Conveyor stopped on outby MBC

OUTBY MBC CONV STOP

Conveyor stopped on Inby MBC #1

INBY1 MBC CONV STOP

Conveyor stopped on Inby MBC #2

INBY2 MBC CONV STOP

Conveyor stopped on Inby MBC #3

INBY3 MBC CONV STOP

Conveyor stopped on outby PIG #1

OUTBY PIG1 CONV STOP

Conveyor stopped on outby PIG #2

OUTBY PIG2 CONV STOP

Conveyor stopped on inby #1 PIG #1

INBY1 PIG1 CONV STOP

Conveyor stopped on inby #1 PIG #2

INBY1 PIG2 CONV STOP

Conveyor stopped on inby #2 PIG #1

INBY2 PIG1 CONV STOP

Conveyor stopped on inby #2 PIG #2

INBY2 PIG2 CONV STOP

Conveyor stopped on inby #3 PIG #1

INBY3 PIG1 CONV STOP

Conveyor stopped on inby #3 PIG #2

INBY3 PIG2 CONV STOP

Reset required on outby MBC

OUTBY RESET REQUIRED

Reset required on inby MBC #1

INBY1 RESET REQUIRED

Reset required on inby MBC #2

INBY2 RESET REQUIRED

Reset required on inby MBC #3

INBY3 RESET REQUIRED

Miner has been shut down (attached system only)

MINER SHUT DOWN

______________________________________________________________ A6474X251 REV 08 5.165

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Troubleshooting _________________________________________________ Table 13 (continued): Real time codes (assumes an 8 unit system) Fault, error

Displayed

Conveyor direction switch was changed from “FWD” CONV DIR SW CHANGE to “REV” or from “REV” to “FWD” while conveyors motors were running. Note: all conveyors will shut down.

Conveyor control switch was changed from “auto” to CONV CNTRL SW CHANGE “individual” or from “individual” to “auto” while the conveyor was running Jog switch was changed from “FWD” to “REV” or from “REV” to “FWD”

JOG SWITCH CHANGED

Attempt was made to jog while the control switch was in auto.

JOG SW WHILE AUTO

Attempt was made to auto sequence start with the direction switch in reverse

NO CNV REV WITH AUTO

Conveyor start attempts were made without the 120VAC inputs that indicates that the overload contact is closed.

MBC START W/O OVLOAD

Conveyor start attempts were made without the 120VAC inputs that indicates that the overload contact is closed.

PG1 START W/O OVLOAD

Conveyor start attempts were made without the 120VAC inputs that indicates that the overload contact is closed.

PG2 START W/O OVLOAD

Conveyor start attempts were made without the 120VAC inputs that indicates that the overload contact is closed.

PG3 START W/O OVLOAD

Attempted to tram without all pump motors running.

ALL PUMPS ON TO TRAM

Display is not receiving any messages form the MCU.

SERIAL COMMUNICATION FAULT WITH MCU

MCU is receiving incoming messages from the MCU COMMUNICATION ERROR DISPLAY TO MCU but the MCU is not receiving the response back from the display.

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_______________________________________________________________

6

Technical data

________________________________________________________________

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_______________________________________________________________

________________________________________________________________

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___________________________________________________ Technical data

Technical data This chapter contains the most important technical data on the continuous haulage system. Further data can be found in the spare parts lists. At the end of this chapter you will find information on the bolt tightening torques, HFA fluids, greases, etc. Read this chapter through carefully and pay particular attention in particular to the safety instructions.

IMPORTANT The technical data listed in this chapter is for stock machines only.

Customer specials may not be listed.

Components of the continuous haulage system Technical data sheet Mobile Bridge Carrier (MBC) Dimensions

Overall length: approx. 29’ Overall width: approx. 9’ 6” Overall height (max. @ midpoint): approx. 28” Stack-up height (over bridges): Receiving end (w/o sideboards): approx. 28” Discharge end (w/o sideboards): approx. 28” Length, mine reach (pivot to pivot): approx. 26’ Dolly travel: approx. 5’ Weight: Empty: approx. 40,000 lb.

With two bridges attached: approx. 60,000 lb.

Ground clearance: approx. 6” Voltage: 950 volt AC Conveyor width: approx. 30” Conveyor depth: approx. 6” to 10” Conveyor drive 1@40 HP Chain speed: approx. 300 FPM Flight spacing: approx. 16” approx. 15 TPM Capacity (based on product at 65 lb/ft3): Conveyor chain take-up: grease w/manual shim locks Crawler length (center to center): approx. 80.5” Crawler width: approx. 14” Tram drive Internal Tram drive motor: 2@40 HP Tram speed: approx. 65 FPM Ground pressure (empty): approx. 20 psi Crawler take-up adjustment: grease w/manual shim locks Oil tank capacity: approx. 65 gal.

Hydraulic pressure: approx. 3900 psi Fire suppression: ABC dry chemical

_____________________________________________________________ A6474X251 REV 08 6.3

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Technical data ___________________________________________________ Gear pump: Tram motor: Inby conveyor lift cylinder: Outby conveyor lift cylinder: Canopy lift cylinder: Cab lift cylinder: Pressure filter: Valve bank:

2@15 GPM 2@105 cc 2@8” Stroke 2@5.25” Stroke 15” Stroke 5.25” Stroke Pall 12 Micron Absolute 4 Section

Piggyback bridge Conveyor (PBC) Dimensions

Overall length: Without 9’ intermediate section: approx. 32’ 6” With 9’ intermediate section: approx. 41’ 6” Overall width at motors: approx. 6’ 3” Overall height receiving end: approx. 28” Length, pivot to pivot (actual mine reach): Without 9’ intermediate section: approx. 0’ With 9’ intermediate section: approx. 39’ Swing (each side of center line): approx. 90° Weight: Empty: approx. 20,000 lb.

Conveyor width: approx. 30” Conveyor depth: approx. 6” - 10” Conveyor drive: 2@30 HP Voltage: 950 volt AC Reducer: 10:1 ratio Chain speed: approx. 300 FPM Flight spacing: approx. 16” Capacity (continuous/peak at 65 lb/ft3): approx. 15 TPM Conveyor chain take-up: Grease w/manual shim lock

________________________________________________________________ 6.4 Continuous Haulage System

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___________________________________________________ Technical data Piggyback bridge Conveyor (PBC - liquid cooled) Dimensions

Overall length: Without 9’ intermediate section: approx. 32’ 6” With 9’ intermediate section: approx. 41’ 6” Overall width at motors: approx. 6’ 3” Overall height receiving end: approx. 28” Length, pivot to pivot (actual mine reach): Without 9’ intermediate section: approx. 30’ With 9’ intermediate section: approx. 39’ Swing (each side of center line): approx. 90° Weight: Empty: approx. 20,000 lb.

Conveyor width: approx. 30” Conveyor depth: approx. 6” - 10” Conveyor drive: 1@40 HP Voltage: 950 volt AC Reducer: 10:1 Chain speed: approx. 300 FPM Flight spacing: approx. 16” approx. 15 TPM Capacity (continuous/peak at 65 lb/ft3): Conveyor chain take-up: Grease w/manual shim lock MBC dolly

Dimensions

Overall length: Overall width: Adjustment:

approx. 76” approx. 56” approx. 4” maximum

RFM pulley section Dimensions

Overall length: Overall width: Overall height: Rollers (3):

approx. 242” approx. 56” approx. 16” 4” dia.

RFM intermediate section Dimensions

Overall length: Overall width: Overall height: Rollers (6):

approx. 222” approx. 56” approx. 16” 4” dia.

Tail dolly Dimensions

Overall length: Overall width: Overall height:

approx. 150” approx. 87” approx. 24”

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Technical data ___________________________________________________

________________________________________________________________ 6.6 Continuous Haulage System

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_______________________________________________ Tightening torques Tightening torques IMPORTANT! Due to the application of fasteners being subject to great stresses and heavy or extreme vibration, it is imperative that all bolts be applied with an adequate amount of torque. For this reason this list of recommended torque settings for different types and sizes of fasteners used has been compiled.

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

IMPORTANT! The tightening torques stated in the spare parts lists must be observed, as well, for installation and maintenance.

Set screws Table 14: Set screws (Socket long-lok) Nominal diameter

Recommended torque setting

#6

6 in-lbs

#8

9 in-lbs

#10

13 in-lbs

1/4”

30 in-lbs

5/16”

5 ft-lbs

3/8”

8 ft-lbs

7/16”

11 ft-lbs

1/2”

16.7 ft-lbs

Table 15: Set screws (Socket standard steel) Nominal diameter

Recommended torque setting

#6

9 in-lbs

#8

16 in-lbs

#10

30 in-lbs

1/4”

6 ft-lbs

5/16”

12 ft-lbs

3/8”

18 ft-lbs

7/16”

29 ft-lbs

1/2”

43 ft-lbs

5/8”

100 ft-lbs

3/4”

146 ft-lbs

7/8”

199 ft-lbs

1”

262 ft-lbs

_____________________________________________________________ A6474X251 REV 08 6.7

BI016242

Tightening torques _______________________________________________ Table 16: FSR hex bolts (SAE 5 and 325 steel) Nominal diameter

Recommended torque setting

1/4”

9 ft-lbs

5/16”

18 ft-lbs

3/8”

31 ft-lbs

7/16”

50 ft-lbs

1/2”

75 ft-lbs

9/16”

110 ft-lbs

5/8”

150 ft-lbs

3/4”

250 ft-lbs

7/8”

378 ft-lbs

1”

583 ft-lbs

1 1/8”

782 ft-lbs

1 1/4”

1,097 ft-lbs

1 3/8”

1,461 ft-lbs

1 1/2”

1,748 ft-lbs

1 3/4”

3,114 ft-lbs

2”

4,504 ft-lbs

2 1/4”

6,497 ft-lbs

2 1/2”

7,144 ft-lbs

2 3/4”

12,092 ft-lbs

3”

15,744 ft-lbs

Table 17: Socket, flat and button head cap screws (Steel only) Nominal diameter #6 #8 #10 1/4” 5/16” 3/8” 7/16” 1/2” 5/8” 3/4” 7/8” 1” 1 1/8” 1 1/4” 1 3/8” 1 1/2”

Recommended torque setting 26 in-lbs 52 in-lbs 6 ft-lbs 14 ft-lbs 30 ft-lbs 50 ft-lbs 81 ft-lbs 121 ft-lbs 240 ft-lbs 395 ft-lbs 629 ft-lbs 964 ft-lbs 1,523 ft-lbs 2,121 ft-lbs 2,843 ft-lbs 3,402 ft-lbs

________________________________________________________________ 6.8 Continuous Haulage System

BI016242

_______________________________________________ Tightening torques Table 18: Untreated screw, black finish (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.60

1.37

2.70

4.5

7.8

11

22

Ft-lbs

0.44

1.01

1.99

3.3

5.6

8.1

16

Nm

1.37

3.10

6.15

10.5

17.5

26

61

Ft-lbs

1.01

2.29

4.54

7.7

12.9

19

37

Nm

1.92

4.40

8.55

15

25

36

72

Ft-lbs

1.42

3.25

6.38

11

18.4

26

53

Nm

2.30

5.25

10.4

18

29

43

87

Ft-lbs

1.70

3.87

7.6

13

21.3

31

64

Table 19: Untreated screw, black finish (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nominal diameter M18

M20

M22

M24

Nm

39

62

85

130

184

250

315

Ft-lbs

28

45

70

95

135

184

232

Nm

89

141

215

295

420

570

725

Ft-lbs

65

103

158

217

308

420

634

Nm

125

198

305

420

690

800

1020

Ft-lbs

92

146

224

309

435

590

752

Nm

150

240

365

500

710

960

1220

Ft-lbs

110

177

269

368

523

708

899

Table 20: Untreated screw, black finish (Coarse thread, continued) Property class

Torque Ma

5.6 8.8 10.9 12.9

Recommended torque setting M27 M30

Nominal diameter M33

M36

M39

Nm

470

635

865

1111

1440

Ft-lbs

346

468

637

819

1062

Nm

1070

1450

1970

2630

3290

Ft-lbs

789

1069

1452

1885

2428

Nm

1510

2050

2770

3560

4620

Ft-lbs

1113

1511

2042

2625

3407

Nm

1810

2450

3330

4280

5550

Ft-lbs

1334

1606

2455

3156

4093

_____________________________________________________________ A6474X251 REV 08 6.9

BI016242

Tightening torques _______________________________________________ Table 21: Untreated screw, black finish (Fine thread) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M8 X 1 M10 X 1.25 M12 X 1.25

Nm

27

52

95

Ft-lbs

19

38

70

Nm

38

73

135

Ft-lbs

28

53

99

Nm

45

88

160

Ft-lbs

33

64

118

Table 22: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8 10.9 12.9

Recommended Nominal diameter torque setting M14 X 1.5 M16 X 1.5 M18 X 1.5

Nm

150

225

325

Ft-lbs

110

165

239

Nm

210

315

460

Ft-lbs

154

232

339

Nm

260

380

550

Ft-lbs

184

280

405

Table 23: Untreated screw, black finish (Fine thread, continued) Property class

Torque Ma

8.8

Nm

Recommended Nominal diameter torque setting M20 X 1.5 M22 X 1.5 M24 X 2 399

Ft-lbs 10.9 12.9

610

780

449

575

Nm

640

860

1100

Ft-lbs

472

634

811

Nm

770

1050

1300

Ft-lbs

567

774

958

________________________________________________________________ 6.10 Continuous Haulage System

BI016242

_______________________________________________ Tightening torques Table 24: Electrically zinc plated (Coarse thread) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M3 M4 M5

Nominal diameter M6

M7

M8

M10

Nm

0.56

1.28

2.50

4.3

7.1

10.5

21

Ft-lbs

0.41

0.94

1.84

3.1

5.2

7.7

15

Nm

1.28

2.90

5.75

9.9

16.5

24

48

Ft-lbs

0.94

2.14

4.24

7.3

12.1

17.7

35

Nm

1.80

4.10

8.10

14

23

34

67

Ft-lbs

1.33

3.02

5.97

10.3

16.9

25

49

Nm

2.15

4.95

9.70

16.5

27

40

81

Ft-lbs

1.59

3.65

7.15

12.1

19.9

29

59

Table 25: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended torque setting M12 M14 M16

Nm

36

Ft-lbs

26

42

54

89

126

169

Nm

83

132

200

275

390

530

Ft-lbs

61

97

147

202

287

390

58

88

Nominal diameter M18

M20

M22

121

171

230

Nm

117

185

285

390

550

745

Ft-lbs

86.2

136

210

287

405

549

Nm

140

220

340

470

660

890

Ft-lbs

103

162

250

346

486

656

Table 26: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8

10.9 12.9

Torque Ma

Recommended torque setting M24 M27 M30

Nominal diameter

Nm

295

435

590

800

1030

1340

Ft-lbs

217

320

435

590

759

988

Nm

675

995

1350

1830

2360

3050

Ft-lbs

497

733

995

1349

1740

2249

Nm

960

1400

1900

2680

3310

4290

Ft-lbs

708

1032

1401

1902

2441

3163

Nm

1140

1680

2280

3090

3980

5150

Ft-lbs

840

1239

1661

2278

2935

3798

_____________________________________________________________ A6474X251 REV 08 6.11

BI016242

Tightening torques _______________________________________________ Table 27: Electrically zinc plated (Fine thread) Property class 8.8 10.9 12.9

Torque Ma Nm Ft-lbs Nm Ft-lbs Nm Ft-lbs

Recommended torque setting M8 X 1 25 18 35 25 42 30

Nominal diameter M10 X 1.25 49 36 68 50 82 60

M12 X 1.25 88 84 125 92 150 110

Table 28: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M14 X 1.5

Nominal diameter M16 X 1.5

M18 X 1.5

Nm

140

210

305

Ft-lbs

103

154

224

Nm

195

295

425

Ft-lbs

143

217

313

Nm

235

350

510

Ft-lbs

173

258

376

Table 29: Electrically zinc plated (Fine thread, continued) Property class 8.8 10.9 12.9

Torque Ma

Recommended torque setting M20 X 1.5

Nominal diameter M22 X 1.5

M24 X 2

Nm

425

570

720

Ft-lbs

313

420

531

Nm

600

800

1000

Ft-lbs

442

590

737

Nm

720

960

1200

Ft-lbs

531

708

885

________________________________________________________________ 6.12 Continuous Haulage System

BI016242

_______________________________________________ Permissible media Permissible media Lubrication fluids and greases NOTICE! Use only approved lubrication fluids and greases! These fluids and greases have been tested and guarantee reliable operation of the mechanical and hydraulic functions of the machine.

IMPORTANT! The lubrication fluids and 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 fluids and 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 and fluids having the same specification base but different origins.

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

IMPORTANT! The approval of the listed products relates only to the pure technical use in our mechanical and hydraulic systems. The responsibility for the constituents used in the hydraulic concentrates lies solely with the respective manufacturer.

IMPORTANT! Be sure to observe the manufacturer’s instructions for use.

NOTICE! When performing maintenance on the continuous haulage system, all used oil and lubricants should be disposed of per your local EPA standards.

_____________________________________________________________ A6474X251 REV 08 6.13

BI016242

Permissible media _______________________________________________ Approved suppliers: Table 30: Anti-wear hydraulic oil (Spec 100-1) Supplier

Brand name

1

Amoco Oil Company

Amoco AW oil No.68

2

Gulf oil

Harmony 68 AW

3

Mobil Oil Corporation

Mobil DTE-16

4

Chevron U.S.A.

5

Sun Oil Company

Chevron hydraulic Oil Aw ISO 68 Sunvis 868

6

Unocal 76

Unax AW 68

7

Shell Oil company

Shell Hydraulic Oil #33

8

Century Lubricating Oils, Inc.

Hyldraulic AW 68

9

Atlantic Richfield Company

Duro AW S-315 Oil

10

Texaco Lubricants Company

Texaco Rando Oil HD 68

11

Exxon

Nuto 68

12

Pennzoil

Pennzbell AW 68 Hydraulic Oil

13

14

Standard Oil Company Standard Oil Co. of Ohio Boron Oil Company BP Oil Inc. Lubricating Engineers

Industron 54 Industron 53 Energol HLP-C68 6120 Monolec Hydraulic Oil

15

Conoco Inc.

Super Hydraulic oil 68

16

Hydrotex

Systems 5K 68

17

Phillips

Maginus A Oils 81350

18

Miners Oil

Hydraulic Oil 68AW

________________________________________________________________ 6.14 Continuous Haulage System

BI016242

_______________________________________________ Permissible media Table 31: Extreme pressure gear oils (Spec. 100-2) Supplier

Brand name

1

Amoco Oil Company

Amoco Permagear EP 460

2

Gulf oil

EP Lubricant HD 460

3

Mobil Oil Corporation

4

Chevron U.S.A.

5

Sun Oil Company

Mobil Gear 634 Mobil Gear 636 Chevron Gear Compound EP ISO 460 Sunep 460

6

Unocal 76

7

Shell Oil company

8

Century Lubricating Oils, Inc.

9

Texaco Lubricants Company

Hulbest EP-7 Powergear 460 Meropa 680

10

Exxon

Spartan EP 460

11

Pennzoil

Super Maxol EP 460 Gear Lube Super Maxol EP 460 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

608 Almosal Vari-Purpose Gear Lubricant Gear oil 460

14

Hydrotex

933 Industrial Gear Lubricant

15

Phillips

16

Miners Oil

All Purpose Gear Oil 85W-90 5EP Gear Oil EP460

Extra Duty NL Gear Lube 7 EP Extra Duty NL Gear Lube 8 EP Shell Omala 680

_____________________________________________________________ A6474X251 REV 08 6.15

BI016242

Permissible media _______________________________________________ Table 32: Extreme pressure motor bearing grease (Spec. 100-3) Supplier

Brand name

1

Amoco Oil Company

2 3 4

Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7 8

Sun Oil Company Unocal 76 Shell Oil company Century Lubricating Oils, Inc.

9 10 11 12

Texaco Lubricants Company Exxon Pennzoil Lubricating Engineers

13

Conoco Inc.

14 15 16

Hydrotex Phillips Atlantic Richfield

Amolith grease 2 EP Rykon Premium Grease 2 EP Gulfcrown grease EP#2 Mobilux EP-2 Chevron Dura-Lith Grease EP-2 NLGI 2 Sun Prestige 742EP Multiplex EP2 Alvania EP-2 Hullith EP2 Multipurpose Grease or Replex2 or Uniwrl 2 or Uniwrl EMB or Hullith GP 2 or Hullith EP 2 Texaco Multifak EP 2 Lidok EP 2 Pennlith EP 712 Grease 3752 Almagard Vari-Purpose Lubricant EP Conolith grease No. 2 or Super Sta Grease No. 2 LC-65 Hyplex Philube EP Grease Litholine H EP-2 Grease

Table 33: Semi-fluid grease (Spec. 100-4)

1 2 3 4 5 6

Supplier Texaco Lubricants Company Century oils Limited Hydrotex Pennzoil Unocal Exxon

Brand name Novatex EP 000 Joy Loader Semi-Fluid grease MPD-60 Ultra E.P. 000 Semi-Fluid 760 Grease MM Grease Lidok E.P. 000

________________________________________________________________ 6.16 Continuous Haulage System

BI016242

_______________________________________________ Permissible media Table 34: Invert emulsion hydraulic fluid (Spec. 100-5)

1 2 3 4

Supplier Unocal 76 Conoco Inc. Atlantic Richfield Company Brooks Oil Company

5 6

Cincinnati – Vulcon Company Cities Service Oil company

7 8

10 11

Century Oils limited Fiske Bros. Refining Company Getty Oil company (Veedol, Tidewater) Gulf Oil Company E.F. Houghton

12 13 14 15 16 17

Century Lubricating Oils Imperial Oil and Grease Mobil Oil Corporation National Oil and chemical Co. Pennzoil Quaker Chemical Company

18

Henery E. Sanson and Sons MFGE Company Southwest Grease and Oil Company, Inc. Southwest Petroleum Corp.

9

19 20 21

22 23

Standard Oil Company of Ohio (Boron Sohio) Sun Oil company Tower Oil Company

24 25

Wynn Oil company Lubrication Engineers

26

Hydrotex

Brand name FR Fluid FR Hydraulic Fluid Duro FR-HD Brooks fire Resistant Hydraulic Fluid B Vulcon FR Fluid #1 Citgo Pacemaker Invert FR Fluid Aquacent Light Lubriplate HO-Retard Veedol Auburn FRH FR Fluid Houghto-Safe 5046 Houghto-Safe 5046W Hulsafe 600 Astrol 587 Pyrogard D Erifon 1, 2, and 3 Maxmul FRP/G Quintolubric 958 Series Quintolubric 958 Series Hydra-Mul Premium Emulsion Fluid Invert Emulsion fire resistant Hydraulic Fluid Swepco Fire Resistant Hydraulic oil #718 Staysol FR

Sunsafe F Safoil Anti-Wear Hydraulic Fluid Hydra-Safe heavy Medium 6455 Monolec Fire Resistant hydraulic Fluid HY-Guard

_____________________________________________________________ A6474X251 REV 08 6.17

BI016242

Permissible media _______________________________________________ Table 35: Extreme pressure gear oil, SAE 90 (Spec. 100-6) Supplier

Brand name

1

Amoco Oil Company

Amoco Premagear EP 320

2

Gulf oil

EP Lubricant HD 320

3

Mobil Oil Corporation

Mobil gear 632

4

Chevron U.S.A.

5

Sun Oil Company

Chevron gear compound EP ISO 320 Sunep 320

6

Unocal 76

Extra Duty NL Gear Lube 6EP

7

Shell Oil company

Omala 75

8

Century Lubricating Oils, Inc.

Hulbest EP-6

9

Texaco Lubricants Company

Meropa 320

10

Exxon

Spartan EP 320

11

Pennzoil

Super Maxol EP 220 Gear Lube

12

Lubricating Engineers

13

Conoco Inc.

605 Almasol Vari-Purpose Gear Lubricant Gear Oil 320

14

Hydrotex

932 Industrial Gear Lube

15

Phillips

16

Atlantic Richfield

Philube All Purpose Gear Oil 85W-90 Pennant NL S-1000

17

Cities Service

Citgo EP Compound 110

18

Pennzoil

Pen Gear #320

19

Miner Oil

Gear Oil EP220

20

Texaco, Lubricants Company

Texaco Multigear EP 80W-90

________________________________________________________________ 6.18 Continuous Haulage System

BI016242

_______________________________________________ Permissible media Table 36: Hydraulic and general purpose oil medium-heavy/R&O inhibited (Spec. 100-7) Supplier

Brand name

1 2 3

Amoco Oil Company Gulf oil Mobil Oil Corporation

American Industrial Oil No. 68 Harmony 68 DTE Heavy – Medium

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Turbine Oil ISO 68 or Chevron Machine Oil R&O ISO 68 Sunvis 754

6

Unocal 76

7

Shell Oil Company

Unax RX68 or Turbine Oil 68 Turbo 68

8

Century Lubricating Oils, Inc.

Centraulic R&O 68

9

Texaco Lubricants Company

Regal Oil R&O N-68

10

Exxon

Tresstic 68

11

Pennzoil

Pennzbell RO 68

12

Lubricating Engineers

6120 Monolec Turbine Oil

13

Conoco Inc.

14

Hydrotex

Detol R&O 68 or Turbine Oil 68 Systems 1, System 5K 68

15

Atlantic Richfield

Duro 5.315

16

Cities Service

Citgo Pacemaker A/W68

17

Miner Oil

Hydraulic Oil AW68

18

Texaco, Lubricants Company

TDH 1893

_____________________________________________________________ A6474X251 REV 08 6.19

BI016242

Permissible media _______________________________________________ Table 37: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name 1

Amoco Oil Company

American Industrial oil No. 150

2

Gulf Oil

Harmony 150

3

Mobil Oil Corporation

DTE Oil EX. Heavy

4

Chevron U.S.A.

5

Sun Oil Company

Chevron Machine Oil AW ISO 150M or Chevron Machine Oil R&O ISO 150 Sunvis 961

6

Unocal 76

7

Shell Oil company

Unax RX 700 or Turbine Oil 700 Turbo 150

8

Century Lubricating Oils, Inc.

Centraulic R&O 150

9

Atlantic Richfield Company

10

Texaco Lubricants Company

Duro 600 or S-700 Regal Oil R&O 150

11

Exxon

Teresstic 150

12

Pennzoil

Pennzbell RO 150

13

Cities Service

Citgo Pacemaker 150

14

Lubrication Engineers

6405 Monolec Turbine Oil

15

Conoco Inc.

Dectol R&O 76

16

Hydrotex

System 1 150, System 5k 150

17

Phillips

Magnus Oils 700

18

Miner Oil

ISO 150

Table 38: Worm gear lubricant, compounded cylinder oil (Spec. 100-9) Supplier Brand name 1 Amoco Oil Company Cylinder oil No. 1000 2 Mobil Oil Corporation Extra Hecla Super Cylinder Oil 3 Chevron U.S.A. Chevron Cylinder Oil W ISO 1000 4 Sun Oil Company Sun Steam Cylinder Oil 5 Unocal 76 Worm gear Lube 250 or Stevalc 6 Century Lubricating Oils, Inc. Garwal 680 7 Atlantic Richfield Company Modoc 195 8 Texaco Lubricants Company 650 T Cylinder Oil 1000 9 Exxon Cylesstic TK-1000 10 Pennzoil Cylinder Oil #1000 11 Conoco Inc. Inca Oil 1000

________________________________________________________________ 6.20 Continuous Haulage System

BI016242

_______________________________________________ Permissible media Table 39: Light gear oil, SAE 40 motor oil (Spec. 100-10)

1 2 3 4

Supplier Amoco Oil Company Gulf oil Mobil Oil Corporation Chevron U.S.A.

5 6 7

Sun Oil Company Unocal 76 Shell Oil company

8 9 10

Century Texaco Lubricants Company Exxon

11 12 13

Pennzoil Lubricating Engineers Conoco Inc.

14 15

Hydrotex Phillips

Brand name Amoco 300 SAE 40 Super Duty 40 Delvac 1340 Chevron RPM Heavy Duty Motor Oil 15W-40 Sunoco Super C 40 Guardol Motor Oil SAE 40 Rotella Oil 40 (Automotive) Turbo Oil 150 (Industrial) Rimula CT40 (Foreign) Rotela SX40 (Foreign) Flexe SAE 40 Ursa Super plus SAE 40 XD-3 Extra SAE 40 or XD-3 SAE 40 Long Life SAE 40 Motor Oil 8440 Monolex GFS Engine Oil Fleet Heavy Duty Motor Oil SAE 40 Hyfilm SAE 40 Super HD II Motor Oil SAE 15W-40

Table 40: Synthetic EP gear lubricants (Spec. 100-11)

1

Supplier Century Lubricants Company

Brand name Synthetic EP Gear Lubricants

Table 41: Multi-purpose tractor hydraulic fluid (Spec. 100-12)

1 2 3 4

Supplier Exxon / Mobil Century / Fuchs Shell Chevron

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid

5 6 7

BP Lubricants Quaker State Conoco

Tractran UTH Quaker State FCI HD Powertran Fluid

_____________________________________________________________ A6474X251 REV 08 6.21

BI016242

Permissible media _______________________________________________ Table 42: Synthetic EP gear lubricants (Spec. 100-13) specification Limit ISO Viscosity Grade (ASTM D-2422)

680

AGMA Grade (AGMA 9005)

8 EP

API Gravity (ASTM D-1298)

25.0

Type

Viscosity SUS @ 100° F 283-347

236 calculated

SUS @ 210° F 50-58

3564 calculated

CST @ 40° C (ASTM D-445)

671 cst

CST @ 100° C (ASTM D-445)

48 cst

Viscosity Index (ASTM D-2270)

125

Flash Point (ASTM D-92)

450° F (232° C)

Pour Point (ASTM D-97)

15° F (-9° C)

Timken OK Load (ASTM D-2782)

80 lbs

Four Ball EP, Weld Point (ASTM D-2783)

315 kgf

Four Ball LWI (ASTM D-2783)

51 kgf

Falex (ASTM D-4172)

3000 lbs typ,

FZG Pass Stages (ASTM D-5182)

13

Copper Corrosion (ASTM D-130)

1 lb

Rust Protection, Dist. Water (ASTM D-665)

Pass

Rust Protection, Sea Water (ASTM D-665)

Pass

Emulsibility (ASTM D-1401M) Water-Millimeters

1 hour

Water-Millimeters

15 24 hours

Water-Millimeters

30 48 hours

Foam Suppression (ASTM D-892) 5 minutes

75 mls/max

10 mls/max Oxidation Stability (ASTM D-2893)

7% inc.

Table 43: Synthetic EP gear lubricants (Spec. 100-13) approved suppliers

1

Supplier Fuchs

Brand name Powergear H680

________________________________________________________________ 6.22 Continuous Haulage System