CAT DBT FULL DIMENSION Continuous Haulage System Operation Manual A6474X251 - PDF DOWNLOAD

Operation Manual DBT-

FULL DIMENSION ® Continuous Haulage System

Doc. No.: A6474X251

DBT America ________________________________________________ 4041 Wurno Road Pulaski, VA 24301

Telephone: 540-980-4530 Fax: 540-994-3763

Internet: www.dbtamerica.com

__________________________________________________________

This manual is intended to provide GENERAL product information for the FULL DIMENSION® Continuous Haulage System. The illustrations, descriptions and procedures contained in this publication apply only to this system. DBT America reserves the right to revise models and designs without prior notice.

This haulage system was manufactured under the guidelines, procedures and requirements of the U. S. Federal Coal Mine Health and Safety Act, Code of Federal Regulations, Title 30, Chapter 1, Subpart 0, Part 75 for underground coal mines, and other applicable non-U. S. regulatory agency standards.

At the completion of the manufacturing process, this system 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 system, without the consent of DBT America, and these regulatory agencies, or any repair or replacement of parts contrary to DBT America's instructions, may invalidate these approvals and render this system unsafe to operate.

Strict compliance with all Federal and State Mining 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 system.

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

© DBT AMERICA 2006 ALL RIGHTS RESERVED

________________________________________________ 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

© DBT AMERICA 2007

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 _________________________________________________

Operation ................................................................................. 5.3 How to operate the continuous haulage system.................. 5.3 Who is allowed to operate the continuous haulage system?........................................................................... 5.3 When can conveying be started? ................................... 5.3 Controls and indicators ........................................................ 5.4 Operator’s compartment ................................................. 5.4 Starting procedure ..............................................................5.12 General ..........................................................................5.12 Checklist.........................................................................5.13 Operating procedures ....................................................5.15 Starting the pump motor ........................................5.15 Starting the conveyors (automatic mode)..............5.15 Starting the conveyors (individual mode) ..............5.16 Jogging the conveyors...........................................5.17 Tramming...............................................................5.17 Stopping the pump.................................................5.18 Pump motor reset ..................................................5.19 Conveyor lift ...........................................................5.19 Cab and canopy.....................................................5.19 Lights .....................................................................5.19 Instructions on the maintenance of the continuous haulage system...................................................................5.21 Important notes ..............................................................5.21 Before maintenance.......................................................5.21 lubricants........................................................................5.23 Instructions on the lubrication of the mobile bridge carrier (MBC)..................................................................5.24 Central lubrication system .....................................5.24 Specific lubrication procedures..............................5.27 Every 8 hours.........................................................5.27 Daily .......................................................................5.29 Every week ............................................................5.30 After first 50 hours of service .................................5.32 Every 2 weeks........................................................5.33 Every month...........................................................5.36 Every 3 months ......................................................5.39 Every 6 months ......................................................5.40 As required.............................................................5.41 Instructions on the lubrication of the piggyback conveyor (PIG) ...............................................................5.42 Specific lubrication procedures (PIG) ....................5.43 Daily .......................................................................5.43 Every week ............................................................5.44 Every 30 hours.......................................................5.45 Every 3 to 6 months...............................................5.46 Every 6 months ......................................................5.47 Instructions on the lubrication of the RFM tail dolly .......5.48 Specific lubrication procedures (RFM tail dolly) ....5.49 Every 8 hours.........................................................5.49 Every 24 hours.......................................................5.49

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System

© DBT AMERICA 2007

5. Operation

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© DBT AMERICA 2007

Instructions on the lubrication of the RFM pulley support section...............................................................5.50 Specific lubrication procedures (RFM pulley support section) .....................................................5.51 Every 8 hours.........................................................5.51 Every 6 months ......................................................5.51 Instructions on the lubrication of the intermediate RFM section............................................................................5.52 Specific lubrication procedures (intermediate RFM section) ..................................................................5.53 Every 6 months ......................................................5.53 Inspection of the mobile bridge carrier...........................5.54 Inspection of wear parts on the mobile bridge carrier....5.55 Inspection of fire suppression system on the mobile bridge carrier..................................................................5.55 Recharge of fire suppression system on the mobile bridge carrier..................................................................5.57 Recharge inspection of fire suppression system on the mobile bridge carrier ......................................................5.58 Inspection of the piggyback bridge conveyor.................5.61 Inspection of wear parts on the piggyback bridge conveyor.........................................................................5.60 Inspection of the RFM....................................................5.61 Instructions on the adjustment procedures on the mobile bridge carrier..................................................................5.63 Conveyor chain ......................................................5.63 Crawler track..........................................................5.65 Instructions on the adjustment procedures on the piggyback bridge conveyor ............................................5.67 Conveyor chain ......................................................5.67 Instructions on the replacement of wear parts on the mobile bridge carrier (MBC)...........................................5.69 Conveyor drive.......................................................5.69 Drive shaft..............................................................5.70 How to remove the drive shaft ........................5.71 How to install the drive shaft ...........................5.74 Drive shaft sprocket ...............................................5.78 How to remove the drive shaft sprocket..........5.79 How to install the drive shaft sprocket.............5.79 How to remove the drive shaft sprocket for field replacement .............................................5.80 Conveyor drive module..........................................5.82 How to remove the conveyor drive module.....5.83 How to install the conveyor drive module........5.84 How to disassemble the conveyor drive module.............................................................5.85 How to assemble the conveyor drive module .5.86 Tail shaft ................................................................5.88 How to remove the tail shaft............................5.89 How to install the tail shaft ..............................5.89 How to disassemble the tail shaft....................5.91 How to assemble the tail shaft ........................5.92

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Conveyor chain ..................................................... 5.93 How to assemble the conveyor chain sections........................................................... 5.94 How to remove the conveyor chain assembly 5.95 How to install the conveyor chain assembly... 5.96 Crawler track ......................................................... 5.98 How to assemble the crawler track pads........ 5.99 How to remove the crawler track pad assembly......................................................... 5.99 How to install the crawler track pad assembly........................................................5.100 Crawler drive module ...........................................5.101 How to disassemble the crawler drive module ..........................................................5.102 How to assemble the crawler drive module ..5.103 Crawler take-up and idler .....................................5.104 How to remove the crawler take-up and idler ................................................................5.105 How to install the crawler take-up and idler...5.106 Instructions on the replacement of wear parts on the piggyback bridge conveyor...........................................5.107 Conveyor drive .....................................................5.107 Drive shaft ............................................................5.108 How to remove the drive shaft .......................5.109 How to install the drive shaft..........................5.111 Drive shaft sprockets............................................5.114 How to remove the drive shaft sprockets ......5.115 How to install the drive shaft sprockets .........5.115 How to remove the drive shaft sprockets for field replacement ...........................................5.116 Conveyor drive module ........................................5.117 How to remove the conveyor drive module ...5.118 How to install the conveyor drive module ......5.119 How to disassemble the conveyor drive module ...........................................................5.121 How to assemble the conveyor drive module 5.121 Tail shaft...............................................................5.123 How to remove the tail shaft ..........................5.124 How to install the tail shaft .............................5.124 How to disassemble the tail shaft ..................5.125 How to assemble the tail shaft.......................5.126 Conveyor chain ....................................................5.128 How to assemble the conveyor chain sections..........................................................5.129 How to remove the conveyor chain assembly........................................................5.130 How to install the conveyor chain assembly..5.131

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System

© DBT AMERICA 2007

Table of contents _________________________________________________

________________________________________________ Table of contents

© DBT AMERICA 2007

Instructions on the replacement of hydraulic components on the mobile bridge carrier (MBC).............................. 5.133 Hydraulic components (MBC).............................. 5.133 Tram hydrostatic pump ........................................ 5.135 How to disassemble the hydrostatic pump drive............................................................... 5.136 How to assemble the hydrostatic pump drive 5.137 Tram motor .......................................................... 5.138 How to remove tram motor ............................ 5.138 How to install tram motor ............................... 5.138 Conveyor lift cylinders (inby and outby)............... 5.139 How to remove conveyor lift cylinders .......... 5.139 How to install conveyor lift cylinders ............. 5.140 Canopy cylinder ................................................... 5.141 How to remove canopy cylinder .................... 5.141 How to install canopy cylinder ....................... 5.141 Troubleshooting procedures ........................................ 5.143 Hydraulic system (general) .................................. 5.144 Hydraulic cylinders............................................... 5.146 Hydraulic pump .................................................... 5.147 Valves .................................................................. 5.150 Error codes .......................................................... 5.151 Communication faults .................................... 5.152 Fault log codes .............................................. 5.152 Real time codes............................................. 5.155

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

7. For your information For your information .............................................................. 7.3 Our service........................................................................... 7.3 Service address .............................................................. 7.3 Rebuild facility address ................................................... 7.4

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© DBT AMERICA 2007

Table of contents _________________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System

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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: DBT – FULL DIMENSION® Continuous Haulage System Serial No.: N/A and is only permitted to be used for equipment of this type.

© DBT AMERICA 2007

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 prepare the rise heading 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.

______________________________________________________________ A6474X251 VEVA / 01 1.3

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.

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 .

© DBT AMERICA 2007

service

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 1.4

________________________________________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.

© DBT AMERICA 2007

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.

■

Items in lists are marked with bullets.

–

Points in sub-lists are marked with a long dash at the start of the line.

Points in text marked in this way describe individual operations.

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

______________________________________________________________ A6474X251 VEVA / 01 1.5

© DBT AMERICA 2007

Before starting to work ________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 1.6

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2

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 by DBT America.

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

© DBT AMERICA 2007

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 Mines Inspectorate and

■

of the mining supervisory authorities

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

______________________________________________________________ A6474X251 VEVA / 01 2.3

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.

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 from DBT America or by specially qualified personnel of the mine.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.4

© DBT AMERICA 2007

Installation and repair

_________________________________________ 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

© DBT AMERICA 2007

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.

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

______________________________________________________________ A6474X251 VEVA / 01 2.5

© DBT AMERICA 2007

Operating conditions __________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.6

___________________________________________ 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:

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 2.7

Safety instructions ____________________________________________ moving parts

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

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.8

© DBT AMERICA 2007

Inform the persons involved about the intended transport route and the anticipated duration of the transport.

___________________________________________ 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

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 2.9

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 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 DBT America spare parts.

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.10

© DBT AMERICA 2007

problems and malfunctions

___________________________________________ 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.

© DBT AMERICA 2007

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

______________________________________________________________ A6474X251 VEVA / 01 2.11

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.

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.

Fig. 1: Example: 4SP hydraulic hose, designation

1 2 3

manufacturer hose type date of manufacture 1st quarter 2000

4 5

nominal diameter flame-resistant and antistatic

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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© DBT AMERICA 2007

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

___________________________________________ 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. 2).

Fig. 2: Laying hydraulic hoses, slack RIGHT

■

WRONG

are not twisted (Fig. 3).

Fig. 3: Laying hydraulic hoses, twisting © DBT AMERICA 2007

RIGHT

■

WRONG

are not bent directly behind the connections (Fig. 4). (distance min. 1.5 x nominal diameter).

Fig. 4: Laying hydraulic hoses, bending RIGHT

WRONG

______________________________________________________________ A6474X251 VEVA / 01 2.13

Safety instructions ____________________________________________ ■

cannot chafe (Fig. 5).

Fig. 5: Laying hydraulic hoses, crossing

■

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. 6).

Fig. 6: Laying hydraulic hoses, connections on moving parts RIGHT

WRONG

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© DBT AMERICA 2007

RIGHT

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

Chapter 3: Storage and transport IMPORTANT! Take care to ensure that new supplies are stored separately from existing stock and that removal takes place on the “first in, first out” principle.

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.

© DBT AMERICA 2007

Chapter 4: 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 from DBT America.

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 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: 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.

______________________________________________________________ A6474X251 VEVA / 01 2.15

Overview of safety instructions _________________________________ 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.

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.

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

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

Chapter 5: Operation DANGER! Incorrect operation endangers yourself and others!

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

Operate the 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.

IMPORTANT! For more detailed instructions on the display unit, refer to the Display Unit Troubleshooting guide.

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.

NOTICE: If any of the above occurs, all motors on all MBCs will stop. No motors will restart until all MBCs are reset.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.16

© DBT AMERICA 2007

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

________________________________ Overview of safety instructions IMPORTANT! The jog function is to be used only for one of two situations: ■ When something is stuck in the conveyor, and ■ When maintenance is required.

IMPORTANT! The automatic sequence control does not mean that the conveyors will start automatically. The conveyors must be started from each CST in each MBC. IMPORTANT! The individual control will still require that conveyors start from the outby to the inby. When a conveyor is switched to stop, that conveyor will stop as well as all inby conveyors.

IMPORTANT! Before trying to tram, ensure the following: All pump motors on all MBCs must be running.

© DBT AMERICA 2007

Both tram handles are in the centered position.

IMPORTANT! The tram function disables if not used for 20 seconds.

■ If the tram handles are not moved within twenty seconds of the tram enable button being pushed, the operator will need to re-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 twenty seconds, the operator will need to re-push the tram enable button in order to resume tramming.

NOTICE: The following toggle switches are spring returned to center when released: ■ ■ ■ ■ ■ ■ ■ ■ ■ ■

SYSTEM STOP JOG PIG #1 PIG #2 MBC MOTOR CANOPY CAB INBY OUTBY

NOTICE: Tram handles are spring returned to center when released.

WARNING! Do not attempt to tram a machine or operate any other functions from outside the operator’s compartment.

______________________________________________________________ A6474X251 VEVA / 01 2.17

Overview of safety instructions _________________________________ WARNING! Never operate any levers or pedals from outside the operator's compartment.

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.

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

Do not operate the continuous haulage system with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.

IMPORTANT! For specific part numbers, wiring diagrams, hydraulic circuits, etc., refer to the parts manual for the machine in question. All reference figures included herein are for general reference only.

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

IMPORTANT! The MBCs must be started in order, as follows: ■ The most outby operator must start their conveyors 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 operator may then start their conveyors.

■ This will continue until all conveyors in the system are running.

IMPORTANT! All operators in the system must have the switch set to automatic.

IMPORTANT! All operators in the system must have the switch set to forward.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.18

© DBT AMERICA 2007

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

________________________________ Overview of safety instructions 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.

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

© DBT AMERICA 2007

WARNING! Before performing maintenance on the unit, 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.

WARNING! Do not move any hydraulic 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.

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.

IMPORTANT! DBT America recommends the lubricants listed above. However, other brand names of equivalent quality and grade may be used.

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.

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.

______________________________________________________________ A6474X251 VEVA / 01 2.19

Overview of safety instructions _________________________________ 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.

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.

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.

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

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

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.

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.

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

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.20

© DBT AMERICA 2007

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.

________________________________ Overview of safety instructions 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.

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.

IMPORTANT! A hammer and short length of pipe or tubing may be used to press the retainer collar on connector pin.

IMPORTANT! Use a thin walled socket, universal and impact wrench to tighten locknut.

© DBT AMERICA 2007

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.

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

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.

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.

IMPORTANT! Heating connections with a torch may be required to ease the removal of spiral pins and connecting pins.

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.

______________________________________________________________ A6474X251 VEVA / 01 2.21

Overview of safety instructions _________________________________ 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.

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.

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.

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.

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.

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.22

© DBT AMERICA 2007

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.

________________________________ Overview of safety instructions IMPORTANT Most error codes are common between the fault log and real time codes.

Chapter 6: Technical data IMPORTANT The technical data listed in this chapter is for stock machines only. Customer specials may not be listed.

© DBT AMERICA 2007

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.

NOTICE! Use only lubrication fluids and greases approved by DBT America!

These fluids and greases have been tested at DBT America 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! DBT America expressly point out that 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 VEVA / 01 2.23

© DBT AMERICA 2007

Overview of safety instructions _________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 2.24

_______________________________________________________________

3

Storage and transport

________________________________________________________________

________________________________________________________________

_________________________________________________________________

________________________________________ 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.

© DBT AMERICA 2007

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, e.g. CV 50.

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.

______________________________________________________________ A6474X251 VEVA / 01 3.3

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.

On request, the inspection can be carried out by DBT America.

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 3.4

© DBT AMERICA 2007

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.

________________________________________ 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 (e.g. CV 50).

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.

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 3.5

© DBT AMERICA 2007

Storage and transport _________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 3.6

_______________________________________________________________

4

Installation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

__________________________________________________ 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.

© DBT AMERICA 2007

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 DBT America 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 i.e.: ■

hoists with adequate lifting capacity

■

means of attachment with adequate lifting capacity

■

impact wrenches, including accessories

■

jacks with adequate lifting capacity

______________________________________________________________ A6474X251 VEVA / 01 4.3

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 from DBT America. 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.

© DBT AMERICA 2007

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 4.4

__________________________________________________ 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.

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 4.5

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.

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

fire suppression

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 4.6

© DBT AMERICA 2007

Safety features include (Fig. 7):

__________________________________________________ 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.

© DBT AMERICA 2007

Fig. 7: 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

______________________________________________________________ A6474X251 VEVA / 01 4.7

Installation___________________________________________________ Overview of the continuous haulage system Fig. 8: Overview of a typical 5 unit continuous haulage system

Piggyback bridge

© DBT AMERICA 2007

Tail pulley support

Mobile bridge carrier

RFM intermediate

Piggyback bridge

Mobile bridge carrier (MBC)

Piggyback bridge conveyor (PBC) Tail dolly

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 4.8

__________________________________________________ Installation Fig. 9: Overview of the mobile bridge carrier (MBC) MBC dolly

Receiving boom

Conveyor chain

© DBT AMERICA 2007

Crawler drive (left)

Crawler drive (right)

Hydraulic oil tank

Adjustable canopy Discharge boom

Conveyor drive

Driveshaft

Operator’s compartment

Bolt-on yoke plate

______________________________________________________________ A6474X251 VEVA / 01 4.9

Installation___________________________________________________ Fig. 10: Overview of the piggyback bridge conveyor (PBC) Pin-on yoke plate

Conveyor chain

Conveyor drive

Drive shaft

Bolt-on yoke plate

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 4.10

© DBT AMERICA 2007

Tailshaft

__________________________________________________ Installation Fig. 11: Overview of the RFM intermediate section

© DBT AMERICA 2007

4” Diameter roll

Frame

Pin

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

Belt wiper

4” Diameter roll

Frame

Pin

______________________________________________________________ A6474X251 VEVA / 01 4.11

Installation___________________________________________________ Fig. 13: Overview of tail dolly Wheel

Belt trainer

Breaker mounting plate

Wheel (4)

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 4.12

© DBT AMERICA 2007

Bolt-on yoke plate

_______________________________________________________________

5

Operation

________________________________________________________________

________________________________________________________________

_________________________________________________________________

___________________________________________________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

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 5.3

Operation____________________________________________________ Controls and Indicators Operator’s compartment The primary controls for the system are located in the MBC operator’s compartment (Fig. 14).

I.S. Umbilical Station (CST)

The CST (Fig. 14) is located in the operator’s compartment of each MBC. The CST is a stainless steel enclosure that has the control switches, pushbuttons, and tram handles (Fig. 16) that are necessary to control the operation of one MBC and one outby PIG. Except for an attached system, where the most inby MBC’s CST will control one MBC and two PIGs, one inby and one outby.

Fig. 14: Operators compartment and CST location

© DBT AMERICA 2007

CST

display unit

The display unit (Fig. 15) is located in the MBC operator’s compartment of each MBC. The display unit provides the operator with machine status and fault/trip information of the control system (see Display unit troubleshooting guide in this chapter). The display is equipped with an infrared receiver to allow for changes to be made to the set up parameters and also to get to the fault log which will record the last 256 faults.

IMPORTANT! For more detailed instructions on the display unit, refer to the Display Unit Troubleshooting guide.

Fig. 15: Display unit Display unit

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.4

___________________________________________________Operation Fig. 16: Operator’s compartment, controls

3

2

4

6

5

7

8

9

11

10

1

© DBT AMERICA 2007

19

18

17

15

16 1 2 3 4 5 6 7 8 9 10

14

Motor start enable System stop stop/reset Jog Pig#1 start/stop Pig #2 start/stop Conveyor control Conveyor direction MBC start/stop Motor start/stop Canopy up/down

13

12 11 12 13 14 15 16 17 18 19

Cab up/down Light on/off Inby up/down Outby up/down Tram Enable Machine stop Horn Right forward/reverse Left forward/reverse

______________________________________________________________ A6474X251 VEVA / 01 5.5

man-in-position switch

There is a man-in-position switch (footswitch) in the MBC operators compartment (Fig. 17). If any operator takes his/her foot from the switch, it 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.

Emergency stop (panic strip)

The continuous haulage system is equipped with a panic strip (Fig. 17) 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. There will be a message displayed on all displays showing which panic strip on which MBC was actuated. All MBCs must be reset before any motors can restart.

Emergency stop (machine stop)

There is a machine stop pushbutton on the CST (Fig. 16). If this button is pressed it 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.

Motor start/stop

There is a (pump) motor start/stop toggle switch located on each CST (Fig. 16). If this toggle is switched to stop it 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.

System stop

There is a system stop toggle switch located on each CST (Fig. 16). If this toggle is switched to stop it will break the control circuit, stopping all motors. A system stop message will be displayed indicating which MBC was stopped. When moved to the “stop” position, this switch will stay in the stop position until manually switched.

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.

NOTICE: If any of the above occurs, all motors on all MBCs will stop. No motors will restart until all MBCs are reset.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.6

© DBT AMERICA 2007

Operation____________________________________________________

___________________________________________________Operation Fig. 17: Operator’s compartment; pressure gauges, panic strip, and man-in-position switch

Charge pressure

Right tram main pressure

Left tram main pressure

Valve bank pressure

Valve bank pilot pressure

Fire suppression actuator

Horn

© DBT AMERICA 2007

Emergency stop (panic strip)

Man-in-position switch

______________________________________________________________ A6474X251 VEVA / 01 5.7

Operation____________________________________________________ motor start enable jog start/stop

The motor start enable button is located on the CST (Fig. 16) and must be held down when starting the motors, requiring two handed start.

A jog start/stop toggle switch is located on the CST (Fig. 16). This switch allows for temporary use of the conveyors without running the other conveyors in the system. The switch will automatically return to center when released.

PIG #1 start/stop

A PIG #1 start/stop toggle switch is located on the CST (Fig. 16). This switch controls the outby PIG attached to that MBC. This switch is used only when the PIG needs to be run in individual mode. The switch will automatically return to center when released.

PIG #2 start/stop

A PIG #2 start/stop toggle switch is located on the CST (Fig. 16). This switch controls the inby PIG only on the most inby MBC and only when the system is an attached continuous haulage system. This switch is used only when the PIG attached to the miner needs to be run in individual mode. The switch will automatically return to center when released.

conveyor control auto/ind

A conveyor control (CONV CNTL) automatic/individual toggle switch is located on the CST (Fig. 16). This switch should be kept in the “automatic” position when not using individual mode. Individual mode allows each conveyor in the system to be started individually by the operator.

IMPORTANT! The automatic sequence control does not mean that the conveyors will start automatically. The conveyors must be started from each CST in each MBC. IMPORTANT! The individual control will still require that conveyors start from the outby to the inby. When a conveyor is switched to stop, that conveyor will stop as well as all inby conveyors.

conveyor direction fwd/rev

A conveyor direction (CONV DIR) forward/reverse (FWD/REV) toggle switch is located on the CST (Fig. 16). This switch should be kept in the “forward” position at all times, except when jogging the conveyor in reverse mode. Reverse may only be used when using the jog function in individual mode.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.8

© DBT AMERICA 2007

IMPORTANT! The jog function is to be used only for one of two situations: ■ When something is stuck in the conveyor, and ■ When maintenance is required.

© DBT AMERICA 2007

___________________________________________________Operation MBC start/stop

An MBC start/stop toggle switch is located on the CST (Fig. 16). This switch turns the MBC conveyor on and off. When conveyor control is set to automatic, the MBC toggle switch will turn on both the MBC conveyor and the outby PIG conveyor. Turning on the MBC requires holding down the “motor start enable” button while switching the MBC toggle switch on. The switch will automatically return to center when released.

motor start/stop

A motor start/stop toggle switch is located on the CST (Fig. 16). This switch turns the pump motor on and off. Turning on the pump motor requires holding down the “motor start enable” button while switching the MBC toggle switch on. The switch will automatically return to center when released.

canopy up/down

A canopy up/down toggle switch is located on the CST (Fig. 16). This switch is used to move the canopy above the operator’s compartment up and down. The switch will automatically return to center when released.

cab up/down

A cab up/down toggle switch is located on the CST (Fig. 16). This switch is used to move the operator’s compartment (cab) up and down.

The switch will automatically return to center when released.

light on/off

A light on/off toggle switch is located on the CST (Fig. 16). This switch turns lights (if equipped) on and off.

inby up/down

An inby up/down toggle switch is located on the CST (Fig. 16). This switch is used to move the inby boom up and down. The switch will automatically return to center when released.

outby up/down

An outby up/down toggle switch is located on the CST (Fig. 16). This switch is used to move the outby boom up and down. The switch will automatically return to center when released.

tram enable

The tram enable button is located above the machine stop on the CST (Fig. 16). Press the tram enable button to allow tramming using the tram handles.

IMPORTANT! Before trying to tram, ensure the following: All pump motors on all MBCs must be running.

Both tram handles are in the centered position.

IMPORTANT! The tram function disables if not used for 20 seconds.

■ If the tram handles are not moved within twenty seconds of the tram enable button being pushed, the operator will need to re-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 twenty seconds, the operator will need to re-push the tram enable button in order to resume tramming.

______________________________________________________________ A6474X251 VEVA / 01 5.9

Operation____________________________________________________ horn

The horn button is located on the CST (Fig. 16) and manually sounds the horn.

right fwd/rev

The right fwd/rev handle (Fig. 16) controls the right tram. Tram handles are analog and will increase speed the further the handles are moved from center. The right and left trams are operated independently from each other to allow turning. The handle will automatically return to center when released.

left fwd/rev

The left fwd/rev handle (Fig. 16) controls the left tram. Tram handles are analog and will increase speed the further the handles are moved from center. The right and left trams are operated independently from each other to allow turning. The handle will automatically return to center when released.

■ ■ ■ ■ ■ ■ ■ ■ ■ ■

SYSTEM STOP JOG PIG #1 PIG #2 MBC MOTOR CANOPY CAB INBY OUTBY

NOTICE: Tram handles are spring returned to center when released.

WARNING! Do not attempt to tram a machine or operate any other functions from outside the operator’s compartment.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.10

© DBT AMERICA 2007

NOTICE: The following toggle switches are spring returned to center when released:

___________________________________________________Operation fire suppression actuators

The MBC is equipped with two fire suppression (remote) actuators (Figs. 18). The actuators are located as follows: ■ ■

To the operator’s left inside the 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.

© DBT AMERICA 2007

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

Fig. 18: Fire suppression actuators

Operator’s compartment Actuator

Crawler drive actuator

Plunger

Pin

CO2 cartridge (bomb) Typical actuator

______________________________________________________________ A6474X251 VEVA / 01 5.11

Operation____________________________________________________ Starting procedure After 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 all operators being required to practice operating the system in an open area where there is plenty of space before trying to operate in a production environment.

WARNING! Never operate any levers or pedals from outside the operator's compartment.

General 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.

Do not operate the continuous haulage system with any part of your body outside the operator's compartment to prevent having body parts caught between the unit and outside objects.

The panic strip may be pressed at any time to de-energize the conveyor and pump motors.

The machine stop button may be pressed at any time to deenergize the conveyor and pump motors.

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

IMPORTANT! For specific part numbers, wiring diagrams, hydraulic circuits, etc., refer to the parts manual for the system in question. All reference figures included herein are for general reference only.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.12

© DBT AMERICA 2007

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.

___________________________________________________Operation Check list inspection points

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 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.

© DBT AMERICA 2007

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.

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

______________________________________________________________ A6474X251 VEVA / 01 5.13

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

Before operating the system, inspect the following wear parts as to their degree of wear: the conveyor chain the conveyor chain flights the conveyor drive sprockets the conveyor tail shaft the conveyor wear plates the chain strippers

the crawler drive sprockets the crawler idler rollers

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.14

© DBT AMERICA 2007

the crawler pads

___________________________________________________Operation Operating Procedures Starting the pump motor The pump motor on each MBC can be started once the MCU’s at each MBC is in the normal state. The pump motor is started as follows: 1. Depress the footswitch. Footswitch must be held down continuously during operation.

2. Press and hold the MOTOR START ENABLE pushbutton, and 3. Move the PUMP toggle switch to start This action requires a two handed start. The MBC pump motors do not have to be started in any order.

4. When all pump motors are started the display will display a message “ALL PUMPS RUNNING”.

5. Before the pump motor starts a warning horn will sound for three(3) seconds

© DBT AMERICA 2007

Starting the conveyors (automatic mode) 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: ■ ■ ■ ■

The most outby operator must start their conveyors 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 operator may then start their conveyors.

This will continue until all conveyors in the system are running.

1. Ensure that the conveyor control (CONV CNTRL) toggle switch is set to automatic.

IMPORTANT! 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).

IMPORTANT! All operators in the system must have the switch set to forward.

3. Press and hold the MOTOR START ENABLE pushbutton

______________________________________________________________ A6474X251 VEVA / 01 5.15

Operation____________________________________________________ 4. Move the MBC toggle switch to start. This action requires a two handed start. After switching the MBC switch on, the following will occur in order: -

Warning horn will sound for 3 seconds.

Outby PIG conveyor will start.

MBC conveyors will start 2 seconds after the PIG conveyor.

5. To stop any of the conveyors, move the MBC toggle switch to the stop position. This can be done by any of the MBC operators and will stop that MBC’s conveyor, the outby PIG conveyor, and all conveyors inby to that conveyor. All conveyors outby of the stopped PIG conveyor will continue to run.

In this mode of operation each conveyor in the system may be started individually by the operator. The conveyors must still be started from the outby to the inby. As in the automatic mode, 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: ■ ■ ■ ■

The most outby operator must start their conveyors 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 operator may then start their conveyors.

This will continue until all conveyors in the system are running.

1. Ensure that the conveyor control (CONV CNTRL) toggle switch is set to individual.

IMPORTANT! 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).

IMPORTANT! All operators in the system must have the switch set to forward.

3. Press and hold the MOTOR START ENABLE pushbutton, and 4. Move the PIG #1 toggle switch to start. This action requires a two handed start.

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.16

© DBT AMERICA 2007

Starting the conveyors (individual)

___________________________________________________Operation 6. Press and hold the MOTOR START ENABLE pushbutton, and 7. Move the MBC toggle switch to start. This action requires a two handed start.

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

9. To stop a conveyor, move that conveyors (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.

Jogging the conveyors

© DBT AMERICA 2007

The jog function allows for temporary use of the conveyors without running the other conveyors in the system. To temporarily jog any of the conveyors, the conveyor control (CONV CNTRL) must be set to the individual position.

WARNING! The jog function is to be used only for one of two situations: ■ When something is stuck in the conveyor, and ■ When maintenance is required.

1. Ensure that conveyor control (CONV CNTRL) toggle switch is in the individual position.

2. Move the JOG toggle switch to the start position.

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

4. Press and hold the MOTOR START ENABLE pushbutton, and 5. Move the appropriate toggle switch, MBC or PIG, to start. This action requires a two handed start.

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

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

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 .

______________________________________________________________ A6474X251 VEVA / 01 5.17

Operation____________________________________________________ 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.

■

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

Stopping the pump To stop the pump motor, use one of the following mechanisms: ■

MOTOR start/stop toggle switch.

- Move the motor toggle switch to stop the system. This it 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.

■

SYSTEM STOP reset/stop toggle switch.

- Move the system stop toggle switch to stop the system. this will break the control circuit, stopping all motors. This switch will stay in the “stop” position until manually switched. A message will be displayed indicating which system was turned off.

All MBCs must be reset before any motors can restart.

■

Man-in-position switch (footswitch).

- Remove your foot from the footswitch to stop the system. This 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.18

© DBT AMERICA 2007

IMPORTANT! The tram function disables if not used for 20 seconds.

___________________________________________________Operation ■

MACHINE STOP (emergency stop) pushbutton.

- Press the machine stop pushbutton to stop the system. This 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.

■

Panic strip (emergency stop).

- Strike the panic strip to stop the system. This will break the control circuit, stopping all motors. There will be a message displayed on all displays showing which panic strip on which MBC was actuated. All MBCs must be reset before any motors can restart.

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.

© DBT AMERICA 2007

Pump motor reset If the pump motor has been stopped by any of the available aforementioned mechanisms; pump motor toggle switch, system stop toggle switch, footswitch, machine stop pushbutton, panic strip, or overload (See pages 5.17-5.18), the system must be reset before operation can continue. The following reset action is the same for all pump stop mechanisms and is as follows: 1. Move the system stop toggle switch to reset and release the switch allowing it to return to the centered position.

2. Once all MBCs have been reset, restart the pump motor as previously described (page 5.14).

Conveyor lift Outby and inby booms can be raised and lowered using the outby and inby up/down toggle switches. The switches will return to center when released.

Cab and canopy The Cab and the cab canopy can be raised and lowered using the cab and canopy up/down toggle switches. The switches will return to center when released.

Lights If the MBC is equipped with lights, lights may be turned on and off with the light on/off toggle switch.

______________________________________________________________ A6474X251 VEVA / 01 5.19

© DBT AMERICA 2007

Operation____________________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.20

________________________________________________ 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

© DBT AMERICA 2007

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 DBT 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 DBT America 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.

______________________________________________________________ A6474X251 VEVA / 01 5.21

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.

■

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.22

© DBT AMERICA 2007

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.

________________________________________________ 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.

© DBT AMERICA 2007

Table 1: Lubricant chart

Application

Lubricant

Spec. #

Electric motor bearings

Exxon Unirex-N-2

100-3

Bearings, pivot pins, wheels, and rollers

Exxon Lidok-EP-2

100-3

Gear boxes and wheel units

Century Powergear EP-680

100-2

Fluid Couplings (if equipped)

Dextron IIATF

None

Hydraulic fluid

AW 68 Renolin

100-1

IMPORTANT! DBT America recommends the lubricants listed above. However, other brand names of equivalent quality and grade may be used.

(See lubrication specifications in chapter 6 of this manual)

______________________________________________________________ A6474X251 VEVA / 01 5.23

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. 19) 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. 19: Central lubrication (mobile bridge carrier)

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)

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.24

© DBT AMERICA 2007

3

________________________________________________ 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 1

Exxon Lidok EP-2 Exxon Lidok EP-2

AW 68 Renolin

Spec. 100-3 Spec. 100-3 Spec. 100-1

Daily 6 10

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

1 2

Century Powergear EP-680 Century Powergear EP-680

Spec. 100-2 Spec. 100-2

Every week 1 4 2 1

Tail shaft

4 1

Exxon Lidok EP-2

Spec. 100-3 Spec. 100-3

Conveyor reducer

1

Exxon Lidok EP-2

Spec. 100-3

Tram reducer

1

Exxon Lidok EP-2

Spec. 100-3

2

Century Powergear EP-680

Spec. 100-2

Conveyor pivot pins

Exxon Lidok EP-2

First 50 hours of service © DBT AMERICA 2007

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

Exxon Lidok EP-2

Spec. 100-3

11

Cab tilt cylinder

2

Exxon Lidok EP-2

Spec. 100-3

18

Exxon Lidok EP-2

Spec. 100-3

Exxon Lidok EP-2

Spec. 100-3

Exxon Unirex N-2

Spec. 100-3 Spec. 100-3

Conveyor lift, inby (left and right)

4

19

Conveyor lift, outby (left and right)

4

12

Magnetic filter: Clean

1

Every 3 months 5 17

Electric Motors (tram) Electric Motors (conveyor drive)

1 1

Exxon Unirex N-2

Every 6 months 6

Conveyor reducer: Change oil

1

Century Powergear EP-680

Spec. 100-2

10

Tram reducer (left and right): Change oil

2

Century Powergear EP-680

Spec. 100-2

20

Control panel slide bracket

1

Exxon Lidok EP-2

Spec. 100-3

As required

______________________________________________________________ A6474X251 VEVA / 01 5.25

Maintenance _________________________________________________ Fig. 20: Lubrication chart, mobile bridge carrier (MBC)

4 8

Tail dolly

19

13

19

5 10

7

18 9 18

12

20

1 3

16

11

17

2 6

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.26

© DBT AMERICA 2007

13 15 21

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

Lubricate the drive shaft bearing with Spec. 100-3 through the grease fitting located on the central lubrication panel (Fig. 21) in front of the operator’s compartment. Pump grease into the fitting until new grease can be observed coming out of the bearing.

Fig. 21: Drive shaft bearing lubrication

© DBT AMERICA 2007

Central lubrication panel

pig (PBC) dolly

Drive shaft bearing

Lubricate the 4 grease fittings (2 per side) located on the pig (PBC) dolly with Spec. 100-3 (Fig. 22). Pump grease into the fitting (4) until new grease can be observed coming out from around the pin.

Fig. 22: Pig (PBC) dolly lubrication points Grease fitting

Grease fitting

Grease fitting

Grease fitting

______________________________________________________________ A6474X251 VEVA / 01 5.27

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. 23). The oil level should not be allowed to drop below the bottom sight glass. If the hydraulic oil level is low, add oil Spec. 100-1 through the fill cap located on top of the tank Fig. 23: Hydraulic oil check/add points

Oil filler cap

Thermometer and sight glass

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.28

© DBT AMERICA 2007

Sight glass

________________________________________________ Maintenance Daily: conveyor reducer

Check the breather and oil level in the conveyor drive reducer (Fig. 24): clean all dirt and debris from and around the breather. remove the dipstick and add Spec 100-3 oil as required per reading.

Fig. 24: Conveyor reducer oil level Oil fill

© DBT AMERICA 2007

Breather

Oil drain

tram reducer

Check the breather and oil level in both tram reducer drive gear boxes (Fig. 25): 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 Spec. 100-2 oil through the fill plug hole until it begins to flow out of the hole.

Do not overfill the reducer

Fig. 25: Tram reducer

Oil level/fill plug

Magnetic drain plug

______________________________________________________________ A6474X251 VEVA / 01 5.29

Maintenance _________________________________________________ Every week: Lubricate the conveyor pivot pins with Spec. 100-3 through the four grease fittings located on the central lubrication panel (Fig. 26) near the front of the operator’s compartment. Pump grease into the fittings until new grease can be observed coming out of the pin.

conveyor pivot pins

Fig. 26: Conveyor pivot pin lubrication

Central lubrication

tail shaft

Lubricate the tail shaft with Spec. 100-3 through the grease fitting located on the operator’s side of the machine (Fig. 27). 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. 27: Tail shaft lubrication

Grease fitting

Relief fitting

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.30

© DBT AMERICA 2007

Pivot pin location (both sides)

Pivot pin location (both sides)

________________________________________________ Maintenance conveyor reducer

Lubricate the two seal grease fittings on the conveyor reducer with Spec. 100-3 (Fig. 28). Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 28: Conveyor reducer lubrication To central lubrication panel fitting

Central lubrication panel fitting

© DBT AMERICA 2007

Grease fitting

tram reducer

Lubricate the seal grease fitting on the tram reducers with Spec. 100-3 (Fig. 29). Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 29: Tram reducer lubrication Grease fitting

______________________________________________________________ A6474X251 VEVA / 01 5.31

Maintenance _________________________________________________ After first 50 hours of service: tram reducer

Change the oil in both tram reducer drive gear boxes (Fig. 30): 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 with Spec. 100-2 oil until it begins to flow from the oil level/fill plug hole.

Do not overfill the reducer

Oil level/fill plug

Magnetic drain plug

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.32

© DBT AMERICA 2007

Fig. 30: Tram reducer oil change

________________________________________________ Maintenance Every 2 weeks: hydrostatic filter

Change the filter elements on both hydrostatic filters (Fig. 31): 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

© DBT AMERICA 2007

Fig. 31: Hydrostatic filter element replacement

______________________________________________________________ A6474X251 VEVA / 01 5.33

Maintenance _________________________________________________ pressure filter

Change the filter element in the pressure filter (Fig. 32): 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. 32): Remove the access cover from the machine.

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

Insert the new element into the bowl.

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

Use wrench to tighten securely.

Fig. 32: Pressure filter and return filter element replacement

Return Filter Pressure Filter

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.34

© DBT AMERICA 2007

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

________________________________________________ Maintenance charge filter

Change the filter elements on the three charge filters (Fig. 33): 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.

© DBT AMERICA 2007

Fig. 33: 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.

______________________________________________________________ A6474X251 VEVA / 01 5.35

Maintenance _________________________________________________ Every month: idler roller

Lubricate both right and left side idler rollers with Spec. 100-3 (Fig. 34): Clean dirt and debris from around fittings.

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

Fig. 34: Idler roller lubrication

cab tilt cylinder

Lubricate grease fittings on the rod and base end of the cab tilt cylinder with Spec. 100-3 (Fig. 35). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 35: Cab tilt cylinder lubrication Grease fitting

Grease fitting

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.36

© DBT AMERICA 2007

Grease fitting

________________________________________________ Maintenance conveyor lift cylinders, inby

Lubricate grease fittings on both of the rod and base ends of the conveyor lift (inby) cylinders with Spec. 100-3 (Fig. 36). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 36: Conveyor lift cylinder lubrication (inby)

Grease fitting Typical both sides Grease fitting

© DBT AMERICA 2007

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 with Spec. 100-3 (Fig. 37). Pump grease into the fittings until new grease can be observed coming out of the pins.

Fig. 37: Conveyor lift cylinder lubrication (outby)

Grease fitting

Typical both sides Grease fitting

Optional outby lift cylinder grease fitting block.

______________________________________________________________ A6474X251 VEVA / 01 5.37

Maintenance _________________________________________________ magnetic filter

Clean the magnetic filter located in the oil tank (Fig. 38).

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. 38: Magnetic filter cleaning

© DBT AMERICA 2007

Magnetic filter

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.38

________________________________________________ Maintenance Every 3 months: electric motor (tram)

Lubricate the two electric tram motors with Spec. 100-3 (Fig. 39): 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 with Spec. 100-3 (Fig. 39): Clean dirt and debris from around the two plugs, one is located on each end of motor.

Remove the plugs.

© DBT AMERICA 2007

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. 39: Electric motor lubrication

Conveyor motor

Tram motor

Tram motor

______________________________________________________________ A6474X251 VEVA / 01 5.39

Maintenance _________________________________________________ Every 6 months: conveyor reducer

Change the oil in the conveyor reducer while the reducer is at operating temperature (Fig. 40): 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 spec 100-3 oil as required per reading.

Fig. 40: Conveyor reducer oil change Breather

Oil drain

tram reducer

Change the oil in the tram reducer while the reducer is at operating temperature (Fig. 41): 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 with spec. 100-2 oil until it begins to flow from the oil level/fill plug hole.

Do not overfill the reducer

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.40

© DBT AMERICA 2007

Oil fill

________________________________________________ Maintenance Fig. 41: Tram reducer oil change

Oil level/fill plug

Magnetic drain plug

As required:

© DBT AMERICA 2007

control panel slide bracket

The control panel slide bracket (Fig. 42) 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 with Spec. 100-3.

Fig. 42: Control panel slide bracket lubrication

Grease fitting

______________________________________________________________ A6474X251 VEVA / 01 5.41

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

Exxon Spartan EP-460/680

1 2

Exxon Lidok EP-2 Exxon Lidok EP-2

Spec. 100-3 Spec. 100-3

2

Exxon Lidok EP-2

Spec. 100-3

4

Exxon Unirex N-2

2

Exxon Spartan EP-460/680

Every week 1 5

Tail shaft Conveyor reducer seal

Every 30 hours of operation 2

Drive shaft

Every 3 to 6 months 3

Electric motors

4

Conveyor reducer: Change oil

© DBT AMERICA 2007

Every 6 months

Fig. 43: Lubrication points, PIG

2

4

3

5

5 2

4

3

1

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.42

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

Check the conveyor drive gear box oil level by looking at the sight glass (Fig. 44). Oil must visible through the sight glass. If the oil level is low, add Exxon Spartan EP-460/680 oil through the plug located on top side of the gear case until oil fills to the centerline of the sight glass.

© DBT AMERICA 2007

Fig. 44: PIG, Conveyor reducer level check

Sight glass Sight glass

______________________________________________________________ A6474X251 VEVA / 01 5.43

Maintenance _________________________________________________ Every week: tail shaft

Lubricate the tail shaft with Spec. 100-3 through the grease fitting located on the operator’s side of the machine (Fig. 45). 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. 45: PIG, tail shaft lubrication

conveyor reducer

Lubricate the two seal grease fittings on each conveyor reducer with Spec. 100-3 (Fig. 46). Pump grease into the fittings until new grease can be observed coming out of the seal area.

Fig. 46: PIG, conveyor reducer seal lubrication

Grease fitting

Grease fitting

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.44

© DBT AMERICA 2007

Grease point

________________________________________________ Maintenance Every 30 hours of operation: drive shaft

Lubricate the drive shaft splines through the grease fittings located on each side of the conveyor with Spec. 100-3 (Fig. 47).

© DBT AMERICA 2007

Fig. 47: PIG, drive shaft lubrication

Grease fitting

______________________________________________________________ A6474X251 VEVA / 01 5.45

Maintenance _________________________________________________ Every 3 to 6 months: electric motors

Lubricate the two electric motors with Spec. 100-3 (Fig. 48): 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.

© DBT AMERICA 2007

Fig. 48: PIG, electric motor lubrication

Grease fitting Grease fitting

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.46

________________________________________________ Maintenance Every 6 months: conveyor reducer

Change the oil in the conveyor reducer while the reducer is at operating temperature (Fig. 49): 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 spec 100-2 Oil as required per reading.

© DBT AMERICA 2007

Fig. 49: PIG, conveyor reducer oil change

Oil fill

Breather

Oil drain

______________________________________________________________ A6474X251 VEVA / 01 5.47

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

© DBT AMERICA 2007

Fig. 50: Lubrication points, tail dolly

Belt trainer 6” or 9” wheels

Junction box mounting plate

Bolt-on yoke plate Cable tray

2

1

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.48

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

Lubricate the belt trainer roller with Spec. 100-3 through the grease fitting located on the inside of the belt trainer roller (Fig. 51). Pump grease into the fitting until new grease can be observed coming out of the rollers.

© DBT AMERICA 2007

Fig. 51: RFM belt trainer lubrication

Grease point

Every 24 hours of operation: dolly wheels

Lubricate the tail shaft with Spec. 100-3 through the grease fitting located on the operator’s side of the machine (Fig. 52). 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. 52: RFM tail dolly lubrication

Grease point

Grease point

______________________________________________________________ A6474X251 VEVA / 01 5.49

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. 53: Lubrication points, RFM pulley support section

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”

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.50

© DBT AMERICA 2007

Plow type belt wiper

________________________________________________ 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 with Spec. 100-3 (Fig. 54).

Fig. 54: RFM pulley support carrying roll lubrication

© DBT AMERICA 2007

Pulley bearing

Every 6 months: carrying rolls

Lubricate each side of the 3 carrying rolls located on RFM pulley support section with Spec. 100-3 (Fig. 55).

Fig. 55: RFM pulley support carrying roll lubrication Carrying roll grease points

Carrying roll grease points

______________________________________________________________ A6474X251 VEVA / 01 5.51

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. 56: Lubrication points, RFM intermediate section Carrying roll

Carrying roll

© DBT AMERICA 2007

Carrying roll

Dolly track

1

Skid foot varies from 3” to 10”

1

1

Skid foot varies from 3” to 10”

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.52

________________________________________________ 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 with Spec. 100-3 (Fig. 57).

© DBT AMERICA 2007

Fig. 57: RFM intermediate section carrying roll lubrication

Note: Figure shows multiple RFM sections in storage

Carrying roll grease points

______________________________________________________________ A6474X251 VEVA / 01 5.53

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 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.54

© DBT AMERICA 2007

Check oil level in the tram reducers.

________________________________________________ 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 wear parts as to their degree of wear.

Inspect: the conveyor chain the conveyor chain flights the conveyor drive sprockets the conveyor tail shaft the conveyor wear plates the chain strippers the crawler pads

© DBT AMERICA 2007

the crawler drive sprockets the 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. 58).

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.

______________________________________________________________ A6474X251 VEVA / 01 5.55

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

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

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.56

© DBT AMERICA 2007

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).

________________________________________________ Maintenance Recharge of fire suppression system on the mobile bridge carrier (MBC) To return your fire suppression system to service after use (Fig. 58).

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.

© DBT AMERICA 2007

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 VEVA / 01 5.57

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. 58).

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.58

© DBT AMERICA 2007

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

________________________________________________ Maintenance Fig. 58: Typical fire suppression system (MBC)

© DBT AMERICA 2007

Remote actuator

Extinguisher

Spray nozzle (Typical 7 places)

Extinguisher

Remote actuator

______________________________________________________________ A6474X251 VEVA / 01 5.59

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.

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. the conveyor chain the conveyor chain flights the conveyor drive sprockets the conveyor tail shaft the conveyor wear plates the chain strippers

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.60

© DBT AMERICA 2007

Check for proper conveyor chain tensioning.

________________________________________________ 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.

© DBT AMERICA 2007

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 VEVA / 01 5.61

© DBT AMERICA 2007

Maintenance _________________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.62

_______________________________________ 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. 59):

© DBT AMERICA 2007

Loosen bleeder fitting 2 – 3 turns.

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.

Close bleeder fitting.

Remove cover plate.

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.

______________________________________________________________ A6474X251 VEVA / 01 5.63

Adjustment procedures ________________________________________ 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.

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.

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

Fig. 59: Conveyor chain adjustment

Take-up cylinder

Lug

Tailshaft end

Rod end

Bleeder fitting

Grease fitting

Shim set

Cover

Bolts and lock washers

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.64

© DBT AMERICA 2007

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

_______________________________________ Adjustment procedures Crawler track The crawler track is a complete assembly and should be checked for wear and correct tension at regular intervals.

To adjust tension on the crawler track with the take-up cylinders proceed as follows (Fig. 60): 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.

Chain sag should be 2” to 2 ½” at the center of the crawler.

© DBT AMERICA 2007

To increase or decrease tension on the crawler track with the take-up cylinders proceed as follows (Fig. 60): 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.

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

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

Shutdown machine.

If necessary, re-adjust chain sag.

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

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.

Close bleeder fitting

______________________________________________________________ A6474X251 VEVA / 01 5.65

Adjustment procedures ________________________________________ Fig. 60: Crawler track adjustment

© DBT AMERICA 2007

Shim storage

2” to 2 ½” sag

Grease take-up with shim lock

Shims

Crawler track

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.66

_______________________________________ 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. 61):

© DBT AMERICA 2007

Loosen bleeder fitting 2 – 3 turns.

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.

Close bleeder fitting.

Remove cover plate.

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 VEVA / 01 5.67

Adjustment procedures ________________________________________ 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.

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

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

© DBT AMERICA 2007

Fig. 61: Conveyor chain adjustment

Take-up cylinder

Tailshaft end

Lug

Bleeder fitting

Rod end

Grease fitting

Shim set

Cover Bolts and lock washers

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.68

____________________________________ 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.

© DBT AMERICA 2007

The conveyor drive assembly (Fig. 62) consists of the following main components: ■ ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer drive shaft connecting tube

Fig. 62: Conveyor drive main components

Torque Limiter Connecting tube

Coupling

Reducer Drive motor

Drive shaft

______________________________________________________________ A6474X251 VEVA / 01 5.69

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. 63) consists of the following main components: ■ ■ ■ ■

drive shaft sprockets spacer tubes bearing

© DBT AMERICA 2007

Fig. 63: 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.70

____________________________________ 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. 64). 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. 64).

© DBT AMERICA 2007

Fig. 64: Remove chain stripper Reducer guard

Nuts, bolts, and washers

Chain stripper

______________________________________________________________ A6474X251 VEVA / 01 5.71

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. 65).

Fig. 65: Remove the retainer cap

Retainer cap

Remove the 3 bolts and lock washers that secure the bearing cover and remove cover (Fig. 66).

Fig. 66: Remove the bearing cover

Bearing cover

Three bolts and lock washers

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.72

© DBT AMERICA 2007

Locking wire, bolt, and lock washer

____________________________________ Replacement of wear parts Remove the 4 bolts and lock washers that secure the bearing adapter and remove adapter and bearing (Fig. 67).

© DBT AMERICA 2007

Fig. 67: 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 VEVA / 01 5.73

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. 68)

© DBT AMERICA 2007

Fig. 68: Installing drive shaft

Drive shaft assembly

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.74

____________________________________ 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. 69).

© DBT AMERICA 2007

Fig. 69: 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. 70).

Fig. 70: Install the bearing cover

Bearing cover

Three bolts and lock washers

______________________________________________________________ A6474X251 VEVA / 01 5.75

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

Torque the bolt to 280 ft-lb (Fig. 71). Install locking wire.

Fig. 71: Retainer cap installation

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. 72).

Fig. 72: Chain stripper installation

Twelve nuts, bolts, and washers

Chain stripper

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.76

© DBT AMERICA 2007

Locking wire, bolt, and lock washer

____________________________________ Replacement of wear parts Swing the reducer guard back to the correct position and secure with the two bolts and washers (Fig. 73). Install motor and reducer cover.

Fig. 73: Reducer guard Bolts and washers

© DBT AMERICA 2007

Reducer guard

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 VEVA / 01 5.77

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. 74) consists of the following main components: ■ ■ ■ ■

drive shaft sprockets spacer tubes bearing

© DBT AMERICA 2007

Fig. 74: 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.78

____________________________________ 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. 75): 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

© DBT AMERICA 2007

To install the drive shaft sprockets on the drive shaft assembly proceed as follows (Fig. 75): 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. 75: Drive shaft sprockets Sprocket Short spacer Key (2) Set screw 2 per sprocket

Long Spacer

Short spacer

______________________________________________________________ A6474X251 VEVA / 01 5.79

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.

Position both halves of sprocket over shaft, align keyway and tack weld. Use smallest tacks possible to hold sprocket during preheat (Fig. 76).

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.80

© DBT AMERICA 2007

Install new key.

____________________________________ 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).

© DBT AMERICA 2007

Fig. 76: Field replacement sprocket

Welding filler material Diameter Current -

E8018C3 1/8” DCEP (Reverse polarity)

______________________________________________________________ A6474X251 VEVA / 01 5.81

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. 77) consists of the following main components: ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer connecting tube

Torque limiter

© DBT AMERICA 2007

Fig. 77: Conveyor drive module components

Connecting tube Coupling

Reducer Drive motor

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.82

____________________________________ 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.

© DBT AMERICA 2007

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. 78).

Disconnect reducer bearing seal lubrication hoses, if applicable.

Remove the four bolts and lock washers that secure the reducer to the frame (Fig. 78). 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.

______________________________________________________________ A6474X251 VEVA / 01 5.83

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.84

© DBT AMERICA 2007

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.

____________________________________ Replacement of wear parts Fig. 78: Conveyor drive module removal and installation Retainer cap ,locking wire, bolt and lock

Bolts and lock washers (Typical 4 places)

© DBT AMERICA 2007

How to disassemble the conveyor drive module To disassemble the conveyor drive module proceed as follows (Fig. 79): 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.

______________________________________________________________ A6474X251 VEVA / 01 5.85

Replacement of wear parts _____________________________________ How to assemble the conveyor drive module To assemble the conveyor drive module proceed as follows (Fig. 79): 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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.86

© DBT AMERICA 2007

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.

____________________________________ 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. 79: Conveyor drive module disassembly and assembly

Bushing Torque limiter

© DBT AMERICA 2007

Connecting tube

Coupling

Motor Reducer

______________________________________________________________ A6474X251 VEVA / 01 5.87

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. 80) consists of the following main components: ■ ■ ■ ■ ■ ■ ■

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

© DBT AMERICA 2007

Fig. 80: 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.88

____________________________________ Replacement of wear parts How to remove the tail shaft To remove the tail shaft assembly from the receiving boom proceed as follows (Fig. 81): 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.

© DBT AMERICA 2007

How to install the tail shaft To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 81): 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.

______________________________________________________________ A6474X251 VEVA / 01 5.89

Replacement of wear parts _____________________________________ Fig. 81: Tail shaft removal and installation

MBC frame

Tail shaft

Guide plates

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.90

© DBT AMERICA 2007

Bumper

____________________________________ Replacement of wear parts How to disassemble the tail shaft To disassemble the tail shaft assembly proceed as follows (Fig. 83): 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.

© DBT AMERICA 2007

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

Inspect exposed caterpillar seal, item 3, for wear (Fig. 82).

- 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. 82) slightly, moving slowly inward until the inside diameter is reached.

Fig. 82: 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.

______________________________________________________________ A6474X251 VEVA / 01 5.91

Replacement of wear parts _____________________________________ How to assemble the tail shaft To assemble the tail shaft assembly proceed as follows (Fig. 83): 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 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.92

© DBT AMERICA 2007

Install retaining ring, Item 15.

____________________________________ Replacement of wear parts

© DBT AMERICA 2007

Fig. 83: 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. 84) consists of the following main components: ■ ■ ■ ■

chain chain connector flight nut (top lock)

______________________________________________________________ A6474X251 VEVA / 01 5.93

Replacement of wear parts _____________________________________ Fig. 84: Conveyor chain components

Nut (Top lock)

Chain Chain connector

How to assemble the conveyor chain sections To assemble the conveyor chain sections proceed as follows (Fig. 85): Lay conveyor chain sections on a clean flat surface.

Insert connector through retainer collar and through flight end.

IMPORTANT! A hammer and short length of pipe or tubing may be used to press the retainer collar on connector pin.

Install locknut on connector.

IMPORTANT! Use a thin walled socket, universal and impact wrench to tighten locknut.

Tack weld locknut to pin.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.94

© DBT AMERICA 2007

Flight

____________________________________ Replacement of wear parts 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.

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

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

© DBT AMERICA 2007

Fig. 85: Conveyor chain section assembly

Locknut Flight end

Retainer collar Connector

How to remove the conveyor chain assembly To remove the conveyor chain assembly 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).

Separate conveyor chain (Fig. 86).

______________________________________________________________ A6474X251 VEVA / 01 5.95

Replacement of wear parts _____________________________________ To separate the conveyor chain proceed as follows (Fig. 86): 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.

To install the conveyor chain assembly proceed as follows (Fig. 86): 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.96

© DBT AMERICA 2007

How to install the conveyor chain assembly

____________________________________ Replacement of wear parts 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).

© DBT AMERICA 2007

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

Fig. 86: Conveyor chain installation

Chain travel

Tail shaft Drive shaft

______________________________________________________________ A6474X251 VEVA / 01 5.97

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. 87) consists of the following main components: ■ ■ ■

Crawler pad spiral pin connector pin

© DBT AMERICA 2007

Fig. 87: Crawler track components

Forged pad

Spirol Pin Pin

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.98

____________________________________ Replacement of wear parts How to assemble the crawler track pads To assemble the crawler track pads proceed as follows (Fig. 87): Lay crawler track pads on a clean flat surface.

Each crawler pad connection requires one of the following connections per side (Fig. 87).

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.

© DBT AMERICA 2007

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. 87): 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. 87) 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.

______________________________________________________________ A6474X251 VEVA / 01 5.99

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

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).

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.100

© DBT AMERICA 2007

To install the crawler track pad assembly proceed as follows (Fig. 87):

____________________________________ 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. 88) consists of the following main components: ■ ■ ■

hydraulic drive motor tram drive gear case o-ring

© DBT AMERICA 2007

Fig. 88: 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. 88): 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.

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.

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Disconnect hydraulic hoses to drive motor and tag for reassembly.

____________________________________ Replacement of wear parts How to assemble the crawler drive module To assemble the crawler drive module proceed as follows (Fig. 88): 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.

© DBT AMERICA 2007

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. 89) consists of the following main components: ■ ■ ■

idler assembly shims grease take-up cylinder

© DBT AMERICA 2007

Fig. 89: 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. 89): 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.

© DBT AMERICA 2007

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. 89): 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.

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

Do not replace relief fitting with standard type grease fitting.

____________________________________ 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.

© DBT AMERICA 2007

The conveyor drive assembly (Fig. 90) consists of the following main components: ■ ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer drive shaft connecting tube

Fig. 90: 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. 91) consists of the following main components: ■ ■ ■

drive shaft sprockets spacer tubes

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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Fig. 91: Drive shaft main components

____________________________________ 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. 92).

Remove the bolts, nuts, and washers that secure the chain stripper and remove chain stripper (Fig. 92).

© DBT AMERICA 2007

Fig. 92: 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. 93).

Fig. 93: Remove the retainer cap

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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Locking wire, bolt, and lock washer

____________________________________ 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. 94)

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Fig. 94: 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. 95). Install locking wire.

Fig. 95: Retainer cap installation

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. 96).

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Locking wire, bolt, and lock washer

____________________________________ Replacement of wear parts Fig. 96: Chain stripper installation Chain stripper

Nuts, bolts, and washers

© DBT AMERICA 2007

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. 97).

Fig. 97: 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. 98) consists of the following main components: ■ ■ ■

drive shaft sprockets spacer tubes

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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Fig. 98: Drive shaft main components

____________________________________ 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. 99): 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

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To install the drive shaft sprockets on the drive shaft assembly proceed as follows (Fig. 99): 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. 99: 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.

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. 100).

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. 100). 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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Remove old key.

____________________________________ Replacement of wear parts Fig. 100: 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. © DBT AMERICA 2007

The conveyor drive module (Fig 101) consists of the following main components: ■ ■ ■ ■ ■

Drive motor coupling torque limiter reducer connecting tube

Fig. 101: 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. 102).

Remove drive module guard (Fig. 102) 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.

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. ??).

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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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.

____________________________________ 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.

© DBT AMERICA 2007

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. 102).

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. 102).

Install the motor and reducer cover (Fig. 102).

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Replacement of wear parts _____________________________________ Fig. 102: Conveyor drive module removal and installation

© DBT AMERICA 2007

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. 103): 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.

© DBT AMERICA 2007

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. 103): 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.

© DBT AMERICA 2007

Fig. 103: 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. 104) consists of the following main components: ■ ■ ■ ■ ■ ■

shaft roller assembly face seal o-ring retaining ring bushing

© DBT AMERICA 2007

Fig. 104: 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. 105): 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.

To install the tail shaft assembly into the receiving boom proceed as follows (Fig. 105): 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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How to install the tail shaft

____________________________________ Replacement of wear parts Fig. 105: Tail shaft removal and installation

bumper plate

© DBT AMERICA 2007

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. 107): 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. 106).

-

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. 106) slightly, moving slowly inward until the inside diameter is reached.

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Replacement of wear parts _____________________________________ Fig. 106: 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.

To assemble the tail shaft assembly proceed as follows (item numbers refer to Fig. 107): 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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How to assemble the tail shaft

____________________________________ 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.

© DBT AMERICA 2007

Fig. 107: 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 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.

Each conveyor chain section (Fig. 108) consists of the following main components: ■ ■ ■ ■

chain chain connector flight nut (top lock)

© DBT AMERICA 2007

Fig. 108: Conveyor chain components

Nut (Top lock)

Flight

Chain Chain connector

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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. 109): Lay conveyor chain sections on a clean flat surface.

Insert connector through chain, retainer collar, and flight end.

IMPORTANT! A hammer and short length of pipe or tubing may be used to press the retainer collar on connector pin.

Install locknut on connector.

IMPORTANT! Use a thin walled socket, universal and impact wrench to tighten locknut.

© DBT AMERICA 2007

Tack weld locknut to pin.

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.

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

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

Fig. 109: Conveyor chain section assembly

Locknut Flight end

Connector

Retainer collar

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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. 110): 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).

-

Tension must be released (see previous instructions).

-

Align chain connector with access holes (Fig. 110) 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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Separate conveyor chain. To separate the conveyor chain proceed as follows (Fig. 110):

____________________________________ Replacement of wear parts How to install the conveyor chain assembly To install the conveyor chain assembly proceed as follows (Fig. 110): 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.

© DBT AMERICA 2007

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. 110: Conveyor chain installation

Chain travel

Tail shaft

Access hole

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Drive shaft

__________________________ 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.

© DBT AMERICA 2007

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)

______________________________________________________________ A6474X251 VEVA / 01 5.133

Replacement of hydraulic components ___________________________ Fig. 111: Hydraulic component locator (MBC)

9

3 4 5

4 © DBT AMERICA 2007

1 7 18 2 16 12

13

12

17

2 16

11

8

6

14

8

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.134

__________________________ 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. 112) consists of the following main components: ■ ■ ■ ■

hydrostatic pump electric motor connecting tube coupling

© DBT AMERICA 2007

Fig. 112: Tram hydrostatic pump drive main components

Hydrostatic pump

Electric motor Hydrostatic pump

Electric motor Connecting tube

Connecting tube Coupling

Coupling

______________________________________________________________ A6474X251 VEVA / 01 5.135

Replacement of hydraulic components ___________________________ How to disassemble the hydrostatic pump drive To disassemble the hydrostatic pump drive proceed as follows (Fig. 112): 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 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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.136

© DBT AMERICA 2007

Remove the bolts and lock washers that secure the connecting tube cover and remove cover.

__________________________ Replacement of hydraulic components How to assemble the hydrostatic pump drive To assemble the hydrostatic pump drive proceed as follows (Fig. 112): 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.

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 5.137

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. 113): 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.

How to install the tram motor To install the tram motor proceed as follows (Fig. 113): 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. 113: Tram motor removal and installation

Tram motor

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.138

© DBT AMERICA 2007

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

__________________________ 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.

© DBT AMERICA 2007

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.

______________________________________________________________ A6474X251 VEVA / 01 5.139

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.

Purge hydraulic system of air.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.140

© DBT AMERICA 2007

Connect hydraulic hoses as previously tagged.

__________________________ 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. 114): Lower cylinder until it is completely retracted and no load is resting on the cylinder.

Disconnect hydraulic hoses to cylinder and tag for reassembly.

© DBT AMERICA 2007

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. 114): 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.

______________________________________________________________ A6474X251 VEVA / 01 5.141

Replacement of hydraulic components ___________________________ Fig. 114: Canopy cylinder removal and installation

Bolt and elastic

Cylinder cap

Canopy cylinder

Cylinder cover

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.142

© DBT AMERICA 2007

Mounting bolts and lock washers

_____________________________________________ 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:

© DBT AMERICA 2007

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.

_____________________________________________________________ A6474X251 VEVA / 01 5.143

Troubleshooting ______________________________________________ Hydraulic system (general) Table 7: Hydraulic system (general) troubleshooting

Dirty oil

Foaming oil

Moisture in oil

Probable cause

Test, check and/or remedy

Components not properly cleaned after servicing.

Disassemble components 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.

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.

Soluble oil solution splashing into poorly gasketed tanks or fill holes left open.

Drain out and refill with clean oil. Check fill pipes to see if they are properly closed.

Moisture in cans or used replacement oil.

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 too low.

Reset the relief valve to specifications.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.144

© DBT AMERICA 2007

Trouble, symptom, or cause

_____________________________________________ Troubleshooting Table 7 (continued): Hydraulic system (general) troubleshooting Trouble, symptom, or cause

Test, check and/or remedy

Sealing compound (pipe dope, Teflon tape).

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.

© DBT AMERICA 2007

foreign matter sources in the circuit

Probable cause

_____________________________________________________________ A6474X251 VEVA / 01 5.145

Troubleshooting ______________________________________________ Hydraulic cylinders Table 8: Hydraulic cylinder troubleshooting Trouble, symptom or cause Cylinder drifts

Probable cause

Test, check and/or remedy

Piston seal leak.

Repair seals or replace cylinder.

Control cartridge by-passing.

Replace cartridge or cylinder as required.

Correct leaks.

Cylinder fails to move the load when actuated

Pressure too Iow.

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.

Excessive friction due to misalignment and/or side loading.

Correct cylinder to load alignment.

Air in circuit.

Cycle cylinder to full stop positions to purge air.

Excessive system pressure due to over adjustment.

Correct pressure adjustment to rated limits.

Excessive friction due to misalignment and/or side loading.

Correct cylinder to load alignment.

Excessive pressure.

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.

Dirt has scored the piston or the rod.

Replace piston or rod.

Piston freezes to the tube

Scoring in the piston.

Replace.

Packing and gasket leaks develop

Excessive heat.

Replace packing and gasket.

Erratic or chatter in operation

Excessive or rapid piston seal wear

Cylinder body seal leak

Piston is leaking

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.146

© DBT AMERICA 2007

Other circuit leaks.

_____________________________________________ Troubleshooting Hydraulic pump Table 9: Hydraulic pump troubleshooting Trouble, symptom or cause

© DBT AMERICA 2007

Pump makes excessive noise

Seal leak

Probable cause

Test, check and/or remedy

Vacuum leaks in suction line.

Check for leaks in fittings or damaged suction lines.

Vacuum leaks in the pump shaft seal.

Check pump.

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 squeeze due to flat spots or wear on O.D. or I. D.).

Replace seal .

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.

_____________________________________________________________ A6474X251 VEVA / 01 5.147

Troubleshooting ______________________________________________

Trouble, symptom or cause Seal leak (continued)

Pump failure to deliver oil

Oil leakage around pump

Probable cause

Test, check and/or remedy

Oil viscosity too high or operating temperature too low.

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 in through inlet pipe opening.

Check oil level.

Air bubbles in intake oil.

Check oil level and tighten any loose fittings.

Pump housing bolts loose or not properly torqued.

Tighten the housing bolts and re-torque bolts.

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 .

Shaft seal worn.

Replace seals.

Head of oil on suction hose connection leaking.

Tighten bolts. Tighten or replace connections.

Pump housing bolts loose or improperly torqued.

Tighten bolts.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.148

© DBT AMERICA 2007

Table 9 (continued): Hydraulic pump troubleshooting

_____________________________________________ Troubleshooting Table 9 (continued): Hydraulic pump troubleshooting Trouble, symptom or cause Excessive pump wear

Probable cause Abrasive dirt in hydraulic oil being circulated through the system.

Test, check and/or remedy Replace oil with clean hydraulic oil.

OiI viscosity too Iow. System pressure exceeding pump rating.

Replace with recommended oil.

Relief valve out of adjustment.

Pump misalignment.

Realign pump.

© DBT AMERICA 2007

Pump parts inside the housing are broken

Seizure due to lack of oil.

Check oiI level.

Excessive system pressure above maximum pump rating.

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.

_____________________________________________________________ A6474X251 VEVA / 01 5.149

Troubleshooting ______________________________________________ Valves Table 10: Valve troubleshooting Probable cause

Test, check and/or remedy

Valve spring broken.

Replace the spring.

Open valve in the system.

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 blocked or pressure fluctuates

Dirt in the system.

Remove the valve and clean it thoroughly; flush the system as necessary.

Pressure fluctuates and there is extreme noise in the valve

Air in the system.

Check for leaks.

Pressure or volume too high.

Adjust the pressure or volume.

Valve piston and body worn.

Replace the valve.

Valve excessively hot.

Remove the valve and clean it thoroughly; flush the system.

Dirt in the system.

Replace oil.

Operating pressure cannot be changed

Valve leaks internally Excessive leakage or sticking pistons occurs

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.150

© DBT AMERICA 2007

Trouble, symptom or cause

_____________________________________________ 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.

© DBT AMERICA 2007

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.

_____________________________________________________________ A6474X251 VEVA / 01 5.151

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 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.152

© DBT AMERICA 2007

Fault log No.

_____________________________________________ Troubleshooting Table 12 (continued): Fault log codes (assumes an 8 unit system)

© DBT AMERICA 2007

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

_____________________________________________________________ A6474X251 VEVA / 01 5.153

Troubleshooting ______________________________________________ Table 12 (continued): Fault log codes (assumes an 8 unit system) 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.154

© DBT AMERICA 2007

Fault log No.

_____________________________________________ Troubleshooting Table 13: Real time codes (assumes an 8 unit system)

© DBT AMERICA 2007

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 VEVA / 01 5.155

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.

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.

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 5.156

© DBT AMERICA 2007

Conveyor control switch was changed from “auto” to CONV CNTRL SW CHANGE “individual” or from “individual” to “auto” while the conveyor was running

_______________________________________________________________

6

Technical data

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_______________________________________________ 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)

© DBT AMERICA 2007

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” Capacity (based on product at 65 lb/ft3): approx. 15 TPM 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 VEVA / 01 6.3

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

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.4

© DBT AMERICA 2007

Piggyback bridge Conveyor (PBC)

_______________________________________________ Technical data Piggyback bridge Conveyor (PBC - liquid cooled)

© DBT AMERICA 2007

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” Capacity (continuous/peak at 65 lb/ft3): approx. 15 TPM 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”

______________________________________________________________ A6474X251 VEVA / 01 6.5

© DBT AMERICA 2007

Technical data ________________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.6

___________________________________________ 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

© DBT AMERICA 2007

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 VEVA / 01 6.7

Tightening torques ____________________________________________

Nominal diameter

Recommended torque setting

1/4” 5/16” 3/8” 7/16” 1/2” 9/16” 5/8” 3/4” 7/8” 1” 1 1/8” 1 1/4” 1 3/8” 1 1/2” 1 3/4” 2” 2 1/4” 2 1/2” 2 3/4” 3”

9 ft-lbs 18 ft-lbs 31 ft-lbs 50 ft-lbs 75 ft-lbs 110 ft-lbs 150 ft-lbs 250 ft-lbs 378 ft-lbs 583 ft-lbs 782 ft-lbs 1,097 ft-lbs 1,461 ft-lbs 1,748 ft-lbs 3,114 ft-lbs 4,504 ft-lbs 6,497 ft-lbs 7,144 ft-lbs 12,092 ft-lbs 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.8

© DBT AMERICA 2007

Table 16: FSR hex bolts (SAE 5 and 325 steel)

___________________________________________ 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)

© DBT AMERICA 2007

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 VEVA / 01 6.9

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) 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.10

© DBT AMERICA 2007

Property class

___________________________________________ 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

© DBT AMERICA 2007

Table 25: Electrically zinc plated (Coarse thread, continued) Property class 5.6 8.8 10.9 12.9

Torque Ma

Recommended Nominal diameter torque setting M12 M14 M16 M18 M20 M22

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

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 Nominal diameter torque setting M24 M27 M30

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 VEVA / 01 6.11

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)

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.12

© DBT AMERICA 2007

Property class

___________________________________________ Permissible media Permissible media Lubrication fluids and greases

© DBT AMERICA 2007

NOTICE! Use only lubrication fluids and greases approved by DBT America! These fluids and greases have been tested at DBT America 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! DBT America expressly point out that 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 VEVA / 01 6.13

Permissible media ____________________________________________ Approved suppliers:

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.14

© DBT AMERICA 2007

Table 30: Anti-wear hydraulic oil (Spec 100-1)

___________________________________________ Permissible media

© DBT AMERICA 2007

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 VEVA / 01 6.15

Permissible media ____________________________________________

1

Supplier 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

Brand name 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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.16

© DBT AMERICA 2007

Table 32: Extreme pressure motor bearing grease (Spec. 100-3)

___________________________________________ 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.

© DBT AMERICA 2007

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 VEVA / 01 6.17

Permissible media ____________________________________________

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.18

© DBT AMERICA 2007

Table 35: Extreme pressure gear oil, SAE 90 (Spec. 100-6)

___________________________________________ Permissible media

© DBT AMERICA 2007

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 VEVA / 01 6.19

Permissible media ____________________________________________

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.20

© DBT AMERICA 2007

Table 37: Hydraulic and general purpose oil heavy/R&O inhibited (Spec. 100-8) Supplier Brand name

___________________________________________ Permissible media

© DBT AMERICA 2007

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 5 6 7

Supplier Exxon / Mobil Century / Fuchs Shell Chevron BP Lubricants Quaker State Conoco

Brand name Mobilfluid 424 Multitran Donax TD Tractor Hydraulic Fluid Tractran UTH Quaker State FCI HD Powertran Fluid

______________________________________________________________ A6474X251 VEVA / 01 6.21

© DBT AMERICA 2007

Permissible media ____________________________________________

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 6.22

_______________________________________________________________

7

For your information

________________________________________________________________

________________________________________________________________

_________________________________________________________________

_________________________________________________ Our service

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

© DBT AMERICA 2007

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

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

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

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

Marion, IL 3206 west DeYoung Street Marion, IL 62959 Phone:(618) 997-4335 Fax:(618) 993-5618

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

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

Price, UT 1814 North 1500 West P.O. Box 1016 Price, UT 84501 Phone: (435) 637-3930 Fax: (435) 637-9754

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

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

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

______________________________________________________________ A6474X251 VEVA / 01 7.3

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

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

© DBT AMERICA 2007

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

_________________________________________________________________ DBT – FULL DIMENSION® Continuous Haulage System 7.4