DOWNLOAD Sandvik Mining PR200 Maintenance Manual C1847 PDF

PR200

Original Instructions

MAINTENANCE MANUAL C1847 Revision 0 992663-5720-B-G-MAN-0007 K3001-001-0037

PR200

MAINTENANCE MANUAL

1. Introduction

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 1 (16)

MAINTENANCE MANUAL

2 (16) | Chapter 1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4 1.1 1.2

Document history ...................................................................................................................................................4 Review information.................................................................................................................................................4

2 PRODUCT DOCUMENTATION .................................................................................................................................. 5 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8

Target group ...........................................................................................................................................................5 Supplementary instructions ..................................................................................................................................5 Location of the manuals on the product ..............................................................................................................5 How to identify the correct manual for the product.............................................................................................6 Objective of the product documentation ..............................................................................................................6 Replacement copies for the Maintenance Manual ...............................................................................................6 Warranty and liability .............................................................................................................................................7 Copyright notice .....................................................................................................................................................7

3 IDENTIFICATION OF THE PRODUCT .......................................................................................................................... 8 3.1 3.2 3.3

Identification plate of the product .........................................................................................................................8 Location of the Identification plate on the product .............................................................................................8 Name and address of the manufacturer ...............................................................................................................9

4 DEFINITIONS ....................................................................................................................................................... 10 5 TERMINOLOGY AND ABBREVIATIONS .................................................................................................................... 11

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 3(16)

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Michael Stock

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

4 (16) | Chapter 1

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200 2

MAINTENANCE MANUAL

PRODUCT DOCUMENTATION

This Maintenance Manual is part of the technical documentation for a Sandvik Mobile Machine.

It is intended as a supplement to the training provided, to supply the basic knowledge required for proper, safe and economical use of the machine supplied by Sandvik. Observing these instructions helps to avoid hazards and reduce repair and downtime costs, as well as increasing the reliability and useful life of the machine.

2.1

Target group

This Maintenance Manual is intended for users with knowledge of mechanical engineering and is for the exclusive use of the operator and his personnel. Personnel entrusted with work on the machine must have read and understood these operating instructions and comply with them.

This refers in particular to the following tasks:     

Operation ( starting and stopping) Troubleshooting Maintenance and upkeep Storage Maintenance and disposal of process materials, cleaning of machine and the area around the machine

In particular, the following must be considered:  

2.2

the chapter on ENVIRONMENT, HEALTH AND SAFETY the safety instructions contained in various other chapters

Supplementary instructions

The plant operator shall complete this manual by adding national regulations on occupational health and safety, and on environmental protection.

Instructions on any special operational conditions concerning work organization, sequence of work/operations and the personnel assigned to the job shall also be added. This includes instructions regarding obligatory supervision and notification requirements.

Drawings, plans and lists are referenced in all three types of manuals to the relevant original document in the latest revision.

2.3

Location of the manuals on the product

The machine is equipped with the Operator’s-, Maintenance- and OEM-Manual. The Operator’sand Maintenance Manual must be located on the machine.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 5 (16)

MAINTENANCE MANUAL 2.4

PR200

How to identify the correct manual for the product

The type of machine for which the manual is intended for is given on the cover of the Maintenance Manual and on the upper corner of each page.

2.5

Objective of the product documentation

The Maintenance Manual shall instruct an operator for a Sandvik Mining Systems Mobile Machine in the designated use of the machine and the safe operation of the machine.

Operating personnel has to be introduced to all functions and fault finding procedures, maintenance and inspection procedures which have to be done by the operators prior and subsequent to an operation.

Table 3: Content of the Maintenance Manual Chapter No.

Description of content

1

Introduction

2

Environment, health and safety instructions

3

Trouble shooting

4

Maintenance Instructions

5

Repair/Replacement Instructions

6

Accompanying documents

7

Feedback

A separate manual can be applicable, e.g. a Shipping Manual, a Long-term Storage Manual, an Erection Manual or a Commissioning Manual for Mobile Machines.

These instructions must be followed along with any instructions given in local laws and regulations, any orders given by local authorities and all protective measures specific for the site where the product is used.

Read and understand the complete Maintenance Manual and accompanying documents carefully and follow given instructions strictly. lf there is anything you do not understand, ask your employer or your local Sandvik representative.

All sections of this manual contain information which is vital for your safety. The manual must be replaced immediately if lost, damaged or unreadable. For replacement copies, please contact your local Sandvik representative.

2.6

Replacement copies for the Maintenance Manual

When ordering replacement copies you must provide your Sandvik representative with the following information of the product: 6 (16) | Chapter 1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200     

MAINTENANCE MANUAL

Machine type and Sandvik Reference Number or contract number Types of manuals Number of paper copies or electronic manuals Language version of the manuals Delivery address

The instructions set forth in the operator's and other manuals are to be used as a part of the training material during orientation. By following these instructions, safe practices will result, maintenance cost and downtime will be minimized and the reliability and lifetime of the machine will be optimized.

2.7

Warranty and liability

The Sandvik general terms of delivery and sale shall apply. Guarantee and liability claims towards Sandvik shall become void if personal injury or material damage is caused by one or several of the following:     

Use of the machine for any purpose other than its intended use.

Non-conformity of erection work, start-up and handling of the machine.

Non-observance of the safety instructions in the manual.

Non-authorized (structural) changes to the machine.

Non-observance of the maintenance and upkeep instructions.

In the event of a claim for repair under guarantee, Sandvik reserves the right to assess the damage to the machine.

2.8

Copyright notice

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG - © Sandvik Mining and Construction Materials Handling GmbH & Co KG. It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG prior written consent.

All Rights Reserved.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 7 (16)

MAINTENANCE MANUAL

3

PR200

IDENTIFICATION OF THE PRODUCT

The type and contract number of the machine are shown on the identification plate.

3.1

Identification plate of the product

Figure 1: Identification plate for PR200 - C1847

3.2

Location of the Identification plate on the product

The type and contract number of the product are shown on the identification plate which is located on or next to the e-house on the counterweight boom.

Figure 2: Location of the Identification plate

8 (16) | Chapter 1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200 3.3

MAINTENANCE MANUAL Name and address of the manufacturer

Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 8700 Leoben, AUSTRIA Phone: (+ 43) 3842 2077 – 0 Fax: (+ 43) 3842 2077 – 201 Email: info.mining@sandvik.com Internet: www.mining.sandvik.com

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 9 (16)

MAINTENANCE MANUAL

4

PR200

DEFINITIONS

The definitions are described in the Operator’s Manual. For detailed information refer to “Operator’s Manual / Chapter Introduction (pr200_C1847_OM01_en-v1”).

10 (16) | Chapter 1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200 5

MAINTENANCE MANUAL

TERMINOLOGY AND ABBREVIATIONS

The terminology and abbreviations are described in the Operator’s Manual of this machine. For detailed information refer to “Operator’s Manual / Chapter Introduction (pr200_C1847_OM01_en-v1”).

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 11 (16)

MAINTENANCE MANUAL

PR200

TABLE OF FIGURES

Figure 1: Identification plate for PR200 - C1847 ....................................................................................................... 8 Figure 2: Location of the Identification plate ............................................................................................................ 8

12 (16) | Chapter 1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

TABLE OF TABLES

Table 1: Document history.......................................................................................................................................... 4 Table 2: Review information ....................................................................................................................................... 4 Table 3: Content of the Maintenance Manual ............................................................................................................ 6

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 13 (16)

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10.2015 Created by: Michael Stock Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0

+43 3842 2077 – 201

info.mining@sandvik.com

www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM01_en-v1_Rev0.doc

Chapter 1 | 15(16)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

2. Environment, Health and Safety

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 1 (46)

MAINTENANCE MANUAL

2 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 5 1.1 1.2

Document history ...................................................................................................................................................5 Review information.................................................................................................................................................5

2 SAFETY LABELS, MESSAGES, SIGNALS .................................................................................................................. 6 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

General safety regulations .....................................................................................................................................6 Signal words ...........................................................................................................................................................6 Layout of safety signs ............................................................................................................................................7 Mandatory action symbols ....................................................................................................................................7 Prohibited action symbols .....................................................................................................................................8 General hazard symbol ..........................................................................................................................................9 Hazard symbols ......................................................................................................................................................9 Labels on the machine .........................................................................................................................................12 Visual and audible signals ...................................................................................................................................14

3 GUIDELINES AND USER OBLIGATIONS................................................................................................................... 15 3.1 3.2 3.3 3.4 3.5 3.6

Safety guidelines ..................................................................................................................................................15 User obligations ...................................................................................................................................................15 Managing work related hazards ..........................................................................................................................16 Scheduled safety inspections and preventive maintenance ............................................................................17 Personal safety guidelines ..................................................................................................................................17 Personal Protective Equipment ...........................................................................................................................18

4 M ACHINE SAFETY ............................................................................................................................................... 21 4.1 4.2 4.3 4.4 4.5

Intended use of the machine ...............................................................................................................................21 Modifications ........................................................................................................................................................21 Hazard zones ........................................................................................................................................................22 Confined space .....................................................................................................................................................23 Access to the machine .........................................................................................................................................23

5 SAFEGUARDING AND COMPLEMENTARY PROTECTIVE MEASURES........................................................................... 24 5.1 5.2 5.3 5.4

Safeguards ............................................................................................................................................................24 Protective devices ................................................................................................................................................24 Emergency stop buttons......................................................................................................................................25 Emergency stop pull wire switches ....................................................................................................................25

6 EMERGENCY EXIT ............................................................................................................................................... 26 7 LOCKING AND ENERGY DISSIPATION .................................................................................................................... 27 7.1

Storm tie-down procedure ...................................................................................................................................28

8 FIRE RISK CONTROL MEASURES........................................................................................................................... 30 8.1 8.2 8.3 8.4 8.5

Fire prevention ......................................................................................................................................................30 In case of fire accident .........................................................................................................................................31 Fire extinguishers (optional) ...............................................................................................................................31 Using a fire extinguisher (optional).....................................................................................................................31 After a fire accident ..............................................................................................................................................32

9 PROTECTION AGAINST HAZARDS ......................................................................................................................... 33 9.1 9.2 9.3 9.4

Noise hazard .........................................................................................................................................................33 Dust hazard ...........................................................................................................................................................33 High pressure hazard ...........................................................................................................................................34 Electric energy hazard .........................................................................................................................................34

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 3 (46)

MAINTENANCE MANUAL

PR200

10 EMERGENCY PROCEDURES ................................................................................................................................. 35 10.1 10.2 10.3 10.4 10.5

Emergency stop ................................................................................................................................................... 35 Emergency exit ..................................................................................................................................................... 35 Falling objects hazard.......................................................................................................................................... 35 Electric accidents ................................................................................................................................................. 35 After an accident or emergency situation .......................................................................................................... 36

11 SAFETY CONSIDERATIONS FOR MAINTENANCE ...................................................................................................... 37 11.1 11.2

Daily inspections and tasks for operators ......................................................................................................... 37 Definite technical skills and operator’s training ................................................................................................ 37

12 ENVIRONMENT .................................................................................................................................................... 38 12.1 12.2

Decommissioning ................................................................................................................................................ 38 Dismantling ........................................................................................................................................................... 38

12.2.1 12.2.2 12.3

Dismantling for transportation ........................................................................................................................ 38 Dismantling for disposal ................................................................................................................................. 38

Disposal ................................................................................................................................................................ 39

12.3.1 Disposal of the steel structure ........................................................................................................................ 39 12.3.2 Disposal of plastic .......................................................................................................................................... 39 12.3.3 Disposal of rubber parts ................................................................................................................................. 40 12.3.4 Disposal of glass ............................................................................................................................................ 40 12.3.5 Disposal of electrical and electronic waste .................................................................................................... 40 12.3.6 Disposal of lighting and lamps ....................................................................................................................... 40 12.3.7 Disposal of oils and fluids .............................................................................................................................. 40 12.3.8 Disposal of solid waste containing oil............................................................................................................. 40 12.3.9 Disposal of solvents and oil trap sludge ......................................................................................................... 40 12.3.10 Disposal of fuel oil .......................................................................................................................................... 41 12.4 12.5

Potential product related hazards identified by the user .................................................................................. 41 Incident reporting ................................................................................................................................................. 41

13 ORDERING SPARE PARTS .................................................................................................................................... 42

4 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Lan Wang

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

Reviewed

Function

11-2015

Marco Andrade

Mechanical lead engineer

11-2015

Walter Goncalves

Electrical lead engineer

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 5 (46)

PR200

MAINTENANCE MANUAL

2

SAFETY LABELS, MESSAGES, SIGNALS

2.1

General safety regulations

This section contains safety instructions which must be observed when the machine is operated.

Additional safety instructions for individual activities are provided. Warning signs are therefore used in the relevant sections of the manual.

Safety instructions for vendor parts are contained within the documentation provided by subsuppliers. These safety instructions supplement the Sandvik operating instructions. For detailed information refer to “OEM-Manual”.

The safety instructions supplement the Sandvik operating instructions.

All safety instructions must be observed. Non-observance of the safety instructions can lead to personal injury, damage to the environment and/ or material damage.

Sandvik requires the operating company to provide the following: 



2.2

The machine will be assembled under the supervision of qualified site supervisors in accordance with the local legislation. These site supervisors have the necessary training in mechanical engineering, design engineering, electrical engineering and other specialist areas.

The operating company must facilitate a comprehensive, general safety program.

Anyone working at or in the vicinity of the machine must have received training for working on the machine of this type and on the processes running there, including the hazards deriving from this machine.

Signal words

In the documentation for this machine the following symbols are used for very important information or instructions.

DANGER

DANGER indicates a hazard with a high level of risk which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazard with a medium level of risk which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE indicates a situation which, if not avoided, could result in damage to property.

6 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

The signal words “DANGER” or “WARNING” are selected based on the severity of a hazard, which is determined during the risk assessment for the machine.

2.3

Layout of safety signs PROHIBITION: A black graphical symbol inside a red circular band with a red diagonal bar defines a safety sign that indicates that an action shall not be taken or shall be stopped.

WARNING: A black graphical symbol inside a yellow triangle with a black triangular band defines a safety sign that indicates a hazard.

MANDATORY ACTION: A white graphical symbol inside a blue circle defines a safety sign that indicates that an action shall be taken to avoid a hazard.

2.4

Mandatory action symbols

Mandatory action symbols specify actions to be taken to avoid or reduce the impact of a hazard.

All personnel working on or near the machine must understand and comply with information given in all mandatory action symbols.

Wear approved safety helmet Wear approved eye protector

Wear approved hearing protectors

Wear approved respirator

Wear approved protective gloves

Wear approved safety footwear

Wear approved safety harness

Wear approved protective clothing

Wear approved high visibility clothing

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 7 (46)

PR200

MAINTENANCE MANUAL

Read manual

Keep safe distance

Apply indicator for pinhole leak test

Switch off and lock-out equipment

Disconnect equipment from power source

Signal horn

Wash hands

Use jack

Two persons for handling

Use walkway Figure 1: Mandatory action figures (ISO)

2.5

Prohibited action symbols

Prohibited action symbols indicate actions which are prohibited in order to avoid a hazard.

All personnel working on or near the machine must understand and comply with information given in all prohibited action symbols.

Access prohibited

Do not climb

Do not enter with pacemaker.

Do not touch

Do not test for leak with hands

Do not smoke

8 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

Access prohibited

Do not climb

Do not enter with pacemaker.

No open fire

Do not weld

Do not remove guard

Do not tamper Figure 2: Prohibited action symbols (ISO)

2.6

General hazard symbol

General hazard Figure 3: General hazard symbol The general hazard symbol as shown in Figure 3 identifies important safety messages in this manual. When you see this symbol, be alert; your safety is involved. Carefully read and understand the message that follows, and inform other users.

2.7

Hazard symbols

Hazard symbols are used to indicate the type of the hazard and the potential consequences.

Hazard symbols are indicated by a yellow triangle with black symbols and black frames. All personnel working on or near the machine must understand and comply with information given in all hazard symbols.

Falling load hazard

Falling objects hazard

High pressure hazard

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 9 (46)

PR200

MAINTENANCE MANUAL

Flying material hazard

Flying material to face hazard

Crushing hazard

Crushing hazard - feet

Crushing hazard - hands

Skin injection hazard

Entanglement hazard

Entanglement hazard

Slippery when frost hazard

Slipping hazard

Falling hazard

Tripping hazard

Forward/backward tipping hazard

Sideways tipping hazard

Figure 4: Mechanical hazard symbols (ISO)

Electrical shock / Electrocution hazard

Electrical hazard

Battery hazard

Strong magnetic field hazard Figure 5: Electrical hazard symbols (ISO)

10 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

Hot surface hazard

Hot coolant hazard

Figure 6: Thermal hazard symbols (ISO)

Noise hazard Figure 7: Noise hazard symbol (ISO)

Laser hazard

Bright light hazard

Radioactive hazard

Figure 8: Radiation hazard symbols (ISO)

Explosion hazard

Fire hazard

Toxic material hazard

Corrosive chemical hazard

Dust hazard

Harmful substance hazard

Figure 9: Material/ substance hazard symbols (ISO)

Heavy load hazard Figure 10: Heavy load hazard symbol (ISO)

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 11 (46)

MAINTENANCE MANUAL 2.8

PR200

Labels on the machine

The safety symbols found in this manual shall also be posted on the machine. All personnel who operate, repair, or service the machine must be familiar with and observe all safety symbols, labels and instructions..

The safely labels which are located on the machine and its components provide first-hand safety information for anyone close to the machine:    

The severity level of the risk The nature of the hazard (i.e., the type of hazard - cutting parts, high pressure, falling objects, dust, live parts, etc.)

The consequence of interaction with the hazard (i.e., cut, injection, crushing, explosion, electrocution etc.)

How to avoid the hazard

12 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

3

5 4

2 1

9 6 10 7 12 8 13

11

1

CA00016233, CA00016238

2

CA00016272

3

CA00016234

4

CA00016244

5

CA00016272

6

CA00016233

7

CA00016198, CA00016228, CA00016230, CA00016175, CA00016233, CA00016218, CA00016272, CA00016246, CA00016241

8

CA00016272

9

CA00016230

10

CA00016230

11

CA00016272

12

CA00016230

13

CA00016230

Figure 11: Position and type of safety signs on the machine, refer to drawing (ISO, typical) Keep the safety labels and all other labels (e.g. important information, solenoids, and panels) clean and visible at all times.

Check the condition of safety labels on a daily basis. Safety labels and instructions must be replaced before operating the machine if they:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 13 (46)

MAINTENANCE MANUAL      

PR200

Have faded Are damaged Are painted over Have come loose Do not meet the legibility requirements Are not fit for purpose

The spare part numbers of the safety labels are shown in the corresponding Spare Parts Catalogue for your machine. Contact your Sandvik representative for replacement of safety labels.  For detailed information refer to “Spare Parts Catalogue".

2.9

Visual and audible signals  

  

Operation alarm: The Operation alarm switches on when the machine is brought into operation. The alarm sound is a warning siren.

Warning and function signals: The warning and function signals give important information on the machine operating status, functions, warnings and alarms. Warning and function signals inform the operator, for example, of excessive oil pressures, slewing overload, etc.

Beacon (optional): The beacon is located close to ground level near the main machine access. The beacon flashes a yellow light when the machine is brought into operation.

Fire detection system signals: A warning sound is activated when the machine’ fire detection system detects a fire/ smoke.

Fire suppression system signals (with fire suppression system option): Visual alarm will be seen when the fire suppression system is activated.

14 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 3

MAINTENANCE MANUAL

GUIDELINES AND USER OBLIGATIONS

The following safety guidelines apply to each person operating the machine or working on it or in its operational area. Every single person is responsible for his or her own safety and for the safety of his or her colleagues. In case of violation of any safety instructions, guidelines or regulations, everyone has a duty to warn others and report near misses or any safety violation to the responsible supervisor.

3.1

Safety guidelines

It is advised that the product documentation is always available on a the machine.

Safety instructions and safety measures alone cannot prevent accidents. Every single person must be trained in and dedicated to:  

Individual accident control Safe operations scheduling

It is advised that any management, personnel or person who disrespects or ignores safety instrucitons or endangers others must be expelled from the machine or ist operational area..

3.2

User obligations

If you do not understand any information given in the Operator’s or Maintenance Manual, make sure that you get clarification from an authorized person who is well trained. If necessary, you or your representative must contact a Sandvik representative to seek clarification.

The safe use of a machine, among other things, depends on:   

A combination of the design and construction measures taken by the manufacturer The skills of the operators Protective measures taken by the operating company

The documentation and the instructions wihtin form an essential and integral part of the machinie and must be always available for its operators. It is important to pass on the information to any successive operator.

In context with the operation or maintenance of the machine Sandvik prohibits the consumption of:   

Drugs Alcohol Any other substance likely to impair judgment

Persons under the influence of substances which are likely to impair judgment must be kept away from the machine or its operational area.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 15 (46)

MAINTENANCE MANUAL

PR200

Safety information given within the documentation of this machine covers:    

Designated use Operation Inspection and maintenance Troubleshooting

Contact your local Sandvik representative if you require more detailed or additional instructions or information.

As part of ensuring the safe use of the machine, the operating company is responsible for:    

Personal Protective Equipment (PPE) for its personnel Scheduled testing and maintenance, not only but especially for safeguards and protective devices Provision and application of additional safeguards Regular training regarding site safety and safe working procedures

In addition, personnel must always be familiar with the following:   

Site organization and supervision Workplace safety, including safe working procedures Permit-to-work systems

All near-miss incidents and accidents where a Sandvik machine has been involved must be reported to your local Sandvik representative without delay.

Refer to “Customer relevant incident analysis - Chapter 13.1”.

3.3

Managing work related hazards

Always perform a local risk assessment before every new task, e.g. work phase or shift. This assessment, also known as a Real Time Hazard Analysis, ensures that personnel stops and thinks about what needs to be done before starting to work:  

Identify potential hazards that could impact you, your colleagues, the environment, your machine, plant and/ or work method while you are performing the task.

Assess the risks and implement the actions needed to eliminate or reduce the risks.

Only authorized and appropriately trained personnel may carry out operational and other tasks:  



All personnel must be trained, responsible and reliable people. Ensure that all personnel meet the legally stipulated minimum age and qualification requirements.

Supervisors in charge of any activity must be highly qualified. They must clearly define all operational, set-up, maintenance and repair tasks and assign tasks to personnel according to their level of competency.

Personnel are only authorized to interact with the machine with explicit permission from the supervisor!

16 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 



MAINTENANCE MANUAL

Personnel in training, including personnel receiving instructions and new operators, must be under the continuous supervision of an experienced and authorized specialist for the training.

Specially trained personnel under direct supervision of a skilled supervisor is the only personnel permitted to work on mechanical, electrical, electronic or hydraulic equipment, systems or components.

The operating company must:      

Provide theoretical and practical training Define clear roles and responsibilities for each personnel Validate training methods Verify competence and skills Monitor and evaluate personnel performance regularly Monitor and evaluate the safety related behavior of personnel regularly Different product lifecycle phases need personnel with different qualifications. It is in the responsibility of the operating company to make sure they have competent personnel for each product lifecycle phase.

3.4

Scheduled safety inspections and preventive maintenance

Before using a machine it is important to thoroughly inspect it and verify that it is safe to operate. Report any defects. Do not operate the machine if critical defects are present.  Refer to “Operation instructions - Chapter 10”.

Scheduled maintenance is an essential procedure to ensure and maintain safety and performance of the machine. Follow the instructions given for inspection and maintenance of the machine. Refer to “Maintenance Manual”.

3.5

Personal safety guidelines

You are responsible for your own safety and for the safety of your colleagues. In case of violation of any safety guidelines or regulations, warn the others and the responsible supervisor.

You have the duty to warn others who are not working according to the safety regulations. If this is not sufficient you have to inform the appropriate supervisor. Even if the supervisor is informed anonymously it can help to prevent future accidents.

Always work in accordance with the applicable safety guidelines. It is in your responsibility to do that with the appropriate attention and ability. This also is done by always wearing the appropriate PPE when being at the workplace.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 17 (46)

PR200

MAINTENANCE MANUAL You must not distract or to constrain another person at work.

Always regard hazard severity panels and safety signs with care and follow the instructions shown cautiously.

When removed from a workplace which holds obvious or unobvious hazards, it is very important that you instruct the supervisor who gave the order and the personnel who will continue in detail on these hazards.

When in doubt about the safe and correct execution of a task or working procedure, you must ask the appropriate supervisor.

Whenever a situation arises which seems to be dangerous, you have to inform the responsible supervisor about this situation.

Do not work with any tools or machinery that you have not been instructed on by an authorized person.

Do not work with defective machines or tools. If such equipment is found, you must inform the responsible supervisor that replacement is required prior to commencement of the works.

You must always keep the workplace clean. Cleaning with fuel as agent is prohibited. You must use appropriate cleaning agents only.

You must always adhere to the local safety standards, guidelines and regulations.

3.6

Personal Protective Equipment

DANGER DUST HAZARD Breathing dust will cause death or severe injury!

Always wear approved respirator.

WARNING ENTANGLEMENT HAZARD Loose clothing can become entangled and can cause death or severe injury!

Always wear approved protective clothing.

18 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

WARNING FALLING HAZARD Falling can cause death or severe injury!

Always use walkways and handrails.

Always wear approved safety harness when working in heights.

WARNING FALLING OBJECTS HAZARD Falling objects can cause death or severe injury!

Always wear approved safety helmet.

WARNING FLYING OBJECTS HAZARD Small flying objects can harm your eyes!

Always wear approved safety glasses.

WARNING HIGH PRESSURE HAZARD High pressure can cause death or severe injury!

Always check for leakage.

WARNING HOT SURFACE HAZARD Hot surface can cause severe injury!

Always wear approved safety gloves.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 19 (46)

PR200

MAINTENANCE MANUAL

WARNING NOISE HAZARD High noise levels can cause severe injury!

Always wear approved hearing protectors.

WARNING SLIPPING HAZARD Slipping can cause death or severe injury!

Always wear approved safety boots.

Operators and anyone in the vicinity of the machine must wear approved PPE, which includes but is not limited to:        

Safety helmet Eye-protector Hearing protectors Safety footwear Protective gloves Protective clothing Safety harness when working at heights High visibility clothing

Respirators or other PPE can be applicable and must be used if required.

Wear appropriate PPE which is in accordance with the local safety regulations at all times.

This applies to all personnel who:    

work on the machine work in the operating area of the machine work on the machine occasionally work in the operating area of the machine occasionally

This includes operators, supervisors, fitters, riggers, maintenance and transportation personnel.

PPE must not be modified or mended in any way. Corrupted or worn out PPE has to be exchanged immediately.

20 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

4

MACHINE SAFETY

4.1

Intended use of the machine

The machine with all its assembly groups, units, parts and devices, may only be used according to the purpose for which they are designed.

This purpose is specified in the appropriate original contract and must not be changed. The machine may only be used when it is in a sound state.

Using the machine for any other purpose than the one specified in the contract, is contradictory to the designated use. Sandvik assumes no liability for any consequences, damage or disadvantages. The risk of such activities is borne by the operating company.

At no time changes of the machine are allowed. Using the machine after such changes is contradictory to the designated use. Sandvik assumes no liability for any consequences, damage or disadvantages. The risk of such activities is borne by the operating company.

4.2

Modifications

All modifications and corrections not authorized in the design drawings or which may affect the maintenance, operation, safety, and availability of the product need to be approved in writing by the designer before implementation. Approval requires careful risk assessment taking into consideration any new risks that the modifications may bring.

Changes and modifications without proper risk assessment, elimination or reduction of risk and without appropriate safety measures may lead to death, serious personal injuries or damage to property or environment. Unauthorized modifications will also void the warranty.

If modifications and alterations that affect the maintenance, operation, safety and usability of the product are made without the written permission of the designer, Sandvik is not responsible for any incidents resulting in death, injury or property damage resulting from such modifications and alterations.

If a modification or alteration has been implemented without the deigner’s permission, its effect on warranty liability will be considered case-by-case. Thus, the warranty application may be rejected altogether.

Should you consider a modification or alteration as necessary, you must contact the designer of the machine. No modification is permitted unless you first obtain the written approval of the designer.

In order to plan and implement the modification you must deliver adequate documentation:     

Machine type and Sandvik reference number or contract number Description of the modification or correction Related blueprints Related photos Any other material deemed necessary Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 21 (46)

PR200

MAINTENANCE MANUAL 4.3

Hazard zones

When the machine is either operating or in a shutdown state, access to hazardous areas is prohibited unless the machine has been properly locked and isolated.

When the machine is either operating or in a shutdown state, numerous hazards abound to it, of which personnel and others have to be fully aware. Such hazards can result in persons being crushed, caught between, struck by, etc.

The machine may and will operate and relocate semi- or fully automatically and personnel working on or in the area of operation of the machine have to be fully aware of the likelihood of any such movements occurring.

Limbs, clothes, jewelry and personal adornments can be caught in an operating machine.

Personnel must be aware of this ever present hazard.

As dangerous areas are the machines itself, its vicinity and area of operation. Particular precaution, especially during operation, is required in respect to the following areas or components:

1

2

3

4

5

7

6

1

Inside the e-house

2

Material transfer area, i.e. center chute

3

Material transfer area, i.e. impact table

4

Bucket wheel boom conveyor

5

Bucket wheel area

6

Next to the bucket wheel drive

7

Underneath the bucket wheel boom

Figure 12: Hazard zones 22 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

During operation only the operator shall stay on the machine. If other personnel has to access the machine during operation, the operator must be informed prior to accessing the machine.

Only appropriately trained personnel is allowed to access the machine.

During operation no one is allowed to access the operational area of the machine.

During maintenance and/or repair works only appropriately trained personnel is allowed to stay in the vicinity of the machine when it is fully locked and isolated as per local safety regulations.

4.4

Confined space

Personnel assigned to duties or responsibilities related to entry into a confined space have to be instructed sufficiently and trained in the hazards of the space and the precautions identified in written procedures.

Before any personnel enter a confined space which is related to transport of any material, it has to be assured, that this space must be free of material.

Before any sufficiently and appropriately trained personnel enter a confined space, pre-entry inspection must be conducted by the appropriate supervisor to verify it is safe for a worker to enter.

4.5

Access to the machine

1

1

2

Access to the machine

2

Access to the machine

Figure 13: Access to the machine Access to the main machine is granted on either side of the yard conveyor via the main machine access (Figure 13, Item 1 and 2).

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 23 (46)

PR200

MAINTENANCE MANUAL

5

SAFEGUARDING AND COMPLEMENTARY PROTECTIVE MEASURES

5.1

Safeguards

WARNING MODIFICATION HAZARD! Removing or modifying safeguards can cause death or severe injury!

Do not remove or modify safeguards.

Safeguards which have been damaged, come loose or are missing must be replaced before the machine is put into operation.

Covers   

Must be present Not distorted so body parts cannot be placed behind them.

Corners must not be worn more than 10 mm.

Guards    

5.2

Must be present Must be properly secured Not damaged or bent Labeling must be present and legible

Protective devices

The machine is equipped with several protective devices which are designed to reduce risks to the users. Do not modify the protective devices; they must always be operable and in place.

Remember that regular preventive maintenance is required. Follow the instructions for scheduled maintenance provided in the Maintenance Manual. In addition to the Maintenance Manual the appropriate section within the Operator's Manual, as well as the EHS instructions give information on the protective devices.

The protective devices in the machine include but are not limited to the following:     

Emergency stop buttons Main circuit breaker release button Warning signs Pressure relief valves Preventative functions for machine movements

24 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200  

MAINTENANCE MANUAL

Fire extinguisher (optional) Fire suppression system (optional)

Some of the protective devices are delivered as optional equipment and must be ordered separately.

5.3

Emergency stop buttons

In case of dangerous situations immediately operate emergency stop buttons to stop the machine instantly.

Where dangerous situations may arise, the machine has to be stopped immediately by operating one of the emergency stop buttons.

These emergency stop buttons will trip the power supply to all drives and controls but will not isolate services such as lighting and power outlets.

An operated emergency stop button does not provide adequate protection against unauthorized starting of the machine equipment.

Ensure that the equipment is isolated according to the isolation and locking procedures.

5.4

Emergency stop pull wire switches

In case of dangerous situations in relation with the conveying system of the machine immediately operate emergency stop pull wire switches to stop the conveyor drives instantly.

The emergency stop pull wire switches will trip the power supply to all conveyor drives and controls but will not isolate services such as other drives or lighting and power outlets.

It can be necessary to additionally stop the machine immediately by operating one of the emergency stop buttons.

An operated emergency stop pull wire switch does not provide adequate protection against unauthorized starting of the machine equipment.

Ensure that the equipment is isolated according to the isolation and locking procedures.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 25 (46)

PR200

MAINTENANCE MANUAL

6

EMERGENCY EXIT

In an emergency situation use the safest escape way on both sides of the machine.

1

1

2

2

Emergency exit

Emergency exit

Figure 14: Emergency exit of the machine You must know the location of all emergency exits from your working area. In an emergency situation identify the closest emergency exit to your location and use it to get off the machine.

For example:   

If you are in the operator’s cabin, you descend to the bucket wheel boom walkway.

Head towards the center of the machine and decend to the slew deck walkway.

From the slew deck walkway decend to the portal and main access stairs to ground level ( refer to Figure 14).

26 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 7

MAINTENANCE MANUAL

LOCKING AND ENERGY DISSIPATION

The guidelines for isolation mean to protect personnel from uncollected starting of the machine.

Therefore it is of high importance that locks and signs apply to the appropriate regulations.

Many industrial accidents are caused by uncontrolled movements and starts. Unexpected movements of machines during maintenance or repair works can have severe consequences.

Therefore, when locking the machine, the various sources of danger have to be regarded.

Sandvik recommends the usage of top-quality locks and additional signs. The locks have the opportunity that they can only be removed with the appropriate key or significant effort and their significance is understood by everyone. Signs can be regarded as supporting warnings, but not as safety installation.

The locking material needs to be clearly identifiable and apply to a predefined format. The locks and signs may only be used for the purpose of locking the machine.

The locks need to be standardized by certain color, shape and size. All personnel and alien workers need to be acquainted to this standard, regard and implement them. It is also recommended to use locks with nameplates and/or photos. These need to be attached in a way that does not allow for easy exchange or loss. Then workers can be identified according to their lock, even when their workplace is not near the locking point. If an unidentifiable lock is spotted, the responsible supervisor is to be informed and identification has to be done.

Everyone is responsible and accountable for the own lock. Every single person has to apply the lock correctly and remove their lock only by themselves when finished. This assures that the lock is sustained until the last work has been finished.

Whenever a violation of the locking standards is detected, immediate action is required for observing who broke the guidelines and that the correct and safe locking condition is reestablished.

Signs have to be legible all the time. Signs which are illegible provide no additional safety.

As the machine is operated via computers or programmable logic controllers, it can be very difficult or even impossible to apply a complete locking of the machine. In such cases the signage needs to be very effective as to be an appropriate alternative for securing the machine.

Additionally the machine must be locked partly and especial care for the own safety is to be taken.

An operated emergency stop button does not provide adequate protection against unauthorized starting of the machine equipment.

Ensure that the equipment is locked according to the local locking procedures.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 27 (46)

PR200

MAINTENANCE MANUAL 7.1

Storm tie-down procedure

For wind speeds up to 20 m/s normal operation is granted.

If wind speeds go above 22 m/s, the operation must be stopped. Relocation operation must be continued to bring the machine into storm tie-down position.

Therefore:        

Slew the discharge boom away from the stockpile Luff the discharge boom up until the boom is clear of the work area The bucket wheel boom conveyor must be run empty Travel to the storm tie-down position Engage all long travel drive storm anchors Slew the discharge boom to 30 ° angle above the storm tie-down tower Luff the bucket wheel boom to – 9 ° into the storm tie-down tower Lock the bucket wheel boom against slewing The bucket wheel boom must not rest on the traverse of the storm tie-down tower.

To engage the storm anchor for the long travel drive:   

1

1

Remove the lock pins which secure the position of the storm anchor pins Lower the storm anchor pins by using the levers Reinstall the levers which secure the position of the storm anchor pins

2

3

4

3

4

Storm anchor plate

2

Storm anchor pin

Lock pins

4

Levers for raising/ lowering of storm anchor pin

Figure 15: Storm anchor for long travel drive 28 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

To engage the locking spindles in the storm tie-down tower use the handweels on both sides of the tower.

1

1

2

3

2

Bucket wheel boom

3

3

Storm tower

Handwheel of spindle Figure 16: Bucket wheel boom in storm tower

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 29 (46)

PR200

MAINTENANCE MANUAL

8

FIRE RISK CONTROL MEASURES WARNING IGNITION HAZARD Ignited components can cause severe injury!

Open fire prohibited.

Smoking prohibited.

During operation and maintenance appropriate fire prevention and protection measures must be followed which include but are not limited:    

Personnel training Firefighting training Servicing fire extinguishing equipment a proactive approach

Smoking and open fire are prohibited on the machine and in its area of operation. Access to all fire-fighting equipment must be granted at all times, especially during operation and maintenance.

All fire-fighting equipment must be inspected and serviced regularly, according to local regulations.

Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.

Know the various types of fires and the appropriate fire-fighting methods. Be aware that various fires must not be extinguished with water. In most cases special extinguishing agents, dry powders or deoxygenating are required.

All personnel must be trained regularly in fire-fighting methods, in cooperation with local authorities and rescue organizations.

In case of fire, the fire alarm must be activated and all personnel must act according to the predetermined fire plan of the workplace.

8.1

Fire prevention

Fires in any environment are extremely dangerous and can quickly get out of control if not properly dealt with.

The following recommendations will help prevent the likelihood of a fire on the machine: 30 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 

  

8.2

MAINTENANCE MANUAL

Always keep the machine and its area of operation clean of flammable materials such as fluids and lubricants, dirt and debris, and any material that could cause or amplify fire.

Clean all fuel or oil spills as quickly as possible.

Immediately report all electrical wiring and component malfunctions to the appropriate supervisor Inspect the machine regularly for hydraulic and oil leaks.

Ensure that you are aware of, familiar with and trained on all firefighting equipment on the machine. Also ensure that all firefighting equipment is inspected regularly and kept in working order. If the machine does not have any firefighting equipment, ensure that required firefighting measures are available.

In case of fire accident

Always follow local guidelines and regulations regarding the firefighting procedures. Fight the fire as follows: 1. Stop the machine safely.

2. Press the emergency stop button.

3. Activate the fire suppression system (if fitted).

4. Escape from the cabin.

5. Use a hand held fire extinguisher

8.3

Fire extinguishers (optional)

A fire extinguisher is an active fire protection device which is used to extinguish or control small fires, often in emergency situations.

8.4

Using a fire extinguisher (optional)

All persons accessing the machine or its operational area must know how to operate a fire extinguisher. Fire extinguishers are different. Know how to use that specific extinguisher which is available in case of fire.

The instructions below are indicative. Familiarize yourself with the instructions printed on your extinguisher in advance.

1. Take the extinguisher from bracket.

2. Pull out the locking pin.

3. Take out the extinguishing gun from the holder and press down the release lever.

4. Extinguish the fire source from the bottom at a distance of 4 m.

5. Press the extinguishing gun, fan out the extinguishing agent.

6. Send the fire extinguisher immediately for refilling after use.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 31 (46)

MAINTENANCE MANUAL

PR200

Maintenance shall be performed according to local laws and regulations..

8.5

After a fire accident

Once the fire is out and the machine has cooled down, do not start the machine again until the cause of the fire has been established and the fault has been repaired.

Report all fires to the supervisor and to Sandvik. For detailed information refer to “Customer relevant incident analysis (pr200_C1847-OM13.1_en-v1.pdf)”.

32 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

9

PROTECTION AGAINST HAZARDS

9.1

Noise hazard

WARNING NOIZE HAZARD High noise levels can cause severe injury!

Always wear approved hearing protectors.

Noise levels for individual components are outlined in the contract.

9.2

Dust hazard

DANGER DUST HAZARD Breathing dust will cause death or severe injury!

Always wear approved respirator.

Breathing or inhaling dust particles will cause death or severe injury. Always work with a respirator approved by the respirator manufacturer for the job you are doing. It is essential that the respirator that you use protects you from the tiny dust particles which cause silicosis and which may cause other serious lung diseases. You should not use the machine until you are sure your respirator is working properly. This means the respirator must be checked to make sure that it is clean, that its filter has been changed and will protect you in the way it is meant to.

In any workplace where respirators are necessary to protect the health of the employee, the employer must establish and implement a written respiratory protection program with work site specific procedures and elements including but not limited to the selection of respirators, proper usage, maintenance and care, cleaning and disinfecting and training.

Regularly clean your working environment properly to minimize the dust level in the air. Always make sure dust has been cleaned off your boots and clothes when you leave your shift.

Respiratory silica dust is a hazard, which requires special attention. The smallest particles of dust are the most harmful. They may be so fine that you cannot see them. Remember, you must protect yourself from the danger of breathing or inhaling dust.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 33 (46)

PR200

MAINTENANCE MANUAL 9.3

High pressure hazard

WARNING HIGH PRESSURE HAZARD High pressure can cause death or severe injury!

Always check for leakage.

Improper handling of pressurized hydraulic lines and equipment can result in malfunction, personal injury and in worst case death. Read and understand maintenance procedures before working on or with pressurized parts and the hydraulic system of the machine.

9.4

Electric energy hazard

DANGER ELECTRIC HAZARD Electric shocks will cause death or severe injury!

Switch off, lock out and disconnect equipment from power source.

Work on the electrical system or equipment may only be carried out by authorized personnel.

The machine’s electrical system shall be checked regularly and any defects reported and remedied immediately.

In order to carry out operational, maintenance or repair work it is essential to lock the machine.

Installed components must be checked to ensure that they are not carrying current. Then they must be earthed and shorted out. The adjacent current-carrying components must be locked.

Should the machine become live due to cutting a power cable for instance the following regulations must be observed:    

Be aware of the potential gradient.

Do not leave or touch the machine.

Warn people in the vicinity against approaching and touching the machine.

Do not leave the machine before it is ascertained that the touched/damaged power cable is de-energized and that the machine is grounded.

De-energize the machine as soon as possible.

34 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 10

MAINTENANCE MANUAL

EMERGENCY PROCEDURES

It is the operating company’s responsibility to plan and prepare site specific instructions to be followed in case of an emergency or an accident. Sandvik can also give certain general guidelines which can be used as help in establishing the required procedures. Contact your local Sandvik representative for further information.

The following information should be considered when devising a site specific emergency plan.

This list is not meant to be comprehensive.

10.1

Emergency stop

If the machine has to be stopped immediately, use the emergency stop functions. Emergency stop functions stops all the ongoing functions excluding lighting and power outlets.

WARNING MODIFICATION HAZARD! Removing or modifying safeguards can cause death or severe injury!

Do not remove or modify safeguards.

10.2

Emergency exit

In an emergency situation, use the safest escape way or emergency exit. Rescue personnel can use these exits to reach an operator in the operator’s cabin.

10.3

Falling objects hazard

WARNING FALLING OBJECTS HAZARD Falling objects can cause death or severe injury!

Always wear approved safety helmet.

10.4

Electric accidents

If the machine touches an electric power line, the following instructions may prevent injuries or death:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 35 (46)

MAINTENANCE MANUAL    



PR200

If you are standing outside the machine, do not touch any part of the machine or try to get onto the machine. Keep everybody away from the machine.

If you are on the machine, do not try to get off it. If the machine is touching a power line, the machine can catch on fire.

Be aware of the potential gradient. The electric field in the ground can cause a dangerously high voltage between your legs.

If some component of the machine touches an electric power line, the whole machine becomes live. The machine needs to be isolated at least for 24 hours before taking any actions to the machine.

If you come to a place where an electric accident has taken place, do not risk your own life by acting incautiously to save others. Try to find out whether a high or a low voltage is involved. Where high voltage is involved, do not start any rescuing attempts until the power company has cut off the voltage. It can be dangerous even to approach a person in contact with the electric conductor, or with the machine that touches the conductor.

Remember that high voltage power lines have no fuses that blow; the conductors are always dangerous, until a qualified electrician has made them dead. For detailed information refer to “Customer relevant incident analysis (pr200_C1847-OM13.1_en-v1.pdf)”.

10.5

After an accident or emergency situation

Being on site where an incident of accident has occurred, do not take any actions with the equipment involved. Do not speculate or give opinions on the cause. Contact your Sandvik representative to get more information.

36 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200 11

MAINTENANCE MANUAL

SAFETY CONSIDERATIONS FOR MAINTENANCE

Before carrying out any maintenance read and understand the maintenance instructions. Make sure that you have all the required training, skills and authorization before starting any maintenance work.

The maintenance instructions support maintenance personnel performing preventive maintenance for the product. The maintenance instructions also provide information for maintenance and operating personnel on scheduled mechanical inspections of components and installed equipment.

Ensure all necessary machinery isolations have been carried out prior to commencing any maintenance work. Before carrying out any maintenance work, ensure that necessary original spare parts or materials are available, or can be ordered and supplied in time to meet the work schedule. You should only use parts recommended by Sandvik.

Failure to do so can cause death or injury or damage to equipment. Note all completed maintenance activities in a maintenance log or maintenance program.

11.1

Daily inspections and tasks for operators

Daily inspections and tasks that are allowed for the operators can be found in the chapter “Operation Instructions” Operators are required to perform the inspections and tasks. Note that in addition to the instructions given in the Maintenance Manual, the employer must provide operator training.

11.2

Definite technical skills and operator’s training

To avoid hazardous situations and severe consequences, leave all maintenance work to professionals. Tasks mentioned here below are examples of tasks which are allowed only for trained personnel. More details on the risks related to the tasks and instructions for carrying out these tasks safely can be found in the Maintenance Manual. Read the instructions.

Tasks that require definite technical skills and training include, but are not limited to:    

Lubrication system maintenance Mechanical components maintenance Electric system maintenance Structural and mechanical inspection tasks

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 37 (46)

MAINTENANCE MANUAL

12

PR200

ENVIRONMENT

This section provides general information on how to decommission, dismantle and dispose of the machine and how to handle harmful waste, hazardous substances and liquids without causing harm to people or the environment. These instructions give general knowledge of what needs to be considered when decommissioning and recycling the product. Always take into account that disassembly, disposal and recycling operations must be conducted in accordance with all applicable local, state and federal rules and regulations, in addition to complying with all local environmental, health and worker safety instructions.

12.1

Decommissioning

When the machine is decommissioned or put out of service for a longer period of time, it has to be prepared and stored properly. Correct preparations an d storage conditions are essential to maintain the machine in an operating condition and reach the expected lifetime. Appropriate decommissioning procedures also facilitate work when the machine is put back into service again.

Contact a Sandvik representative for instructions and further details when planning long term storage.

12.2

Dismantling

12.2.1

Dismantling for transportation

For transportation to the place of application the machine needs to be dismounted into shipping modules. When transporting the components, particular care is to be taken that they are in mating surfaces, are in no way damaged.

12.2.2

Dismantling for disposal

When the product has reached the end of its life-cycle, it has to be disposed of in a proper way.

The ultimate operating company or owner of the product is responsible for the product disposal.

If the ultimate operating company or owner does not have the ability or the resources to disassemble and dispose of the product, the work must be performed by someone who does possess the necessary knowledge and skills.

When dismantling the machine, the following must be considered: 

Contact a Sandvik representative to establish the contact to a special deconstruction engineer.  There are certain tasks which require special professional skills to ensure the work is done in a safe and proper manner. Follow the local regulations and guidelines set by your employer and the authorities.  Carry out the work in a safe area that will not be a traffic hazard for other machinery or personnel.

38 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200  

MAINTENANCE MANUAL

Use appropriate PPE. Prior to starting, ensure there are proper waste collection and recycling points for spare parts and materials, Fluids and chemicals shall be handled, separated and stored in compliance with all local, state and federal rules and regulations.

Clean the machine before dismantling.

Keep equipment for fire extinguishing, first aid and eye-washing closely available.

Before any dismantling operations, prevent accidental start-up of the machine and make sure that the machine will not move.

Note that there can be stored energy in various forms in the machine; follow the procedures for isolation and energy dissipation. Ensure that all energy sources are isolated and depressurized.

   

Before the actual disassembly of the machine, drainage must be completed. Drainage means the removal of chemicals, fluids and materials that are harmful to the environment. When carrying out the drainage operations, avoid spilling fluids and liquids on the ground. Use a sink or a container to avoid leakage. Any oil that is spilled onto the ground, including biodegradable oil, must be collected as quickly and as carefully as possible. For detailed information refer to “Lubrication schedule”.

Subsequent to drainage the recyclable parts can be separated from the machine.

12.3

Disposal

This section gives useful advice to identify which parts of the product are recoverable, with a view to recycling or reusing the materials or components for new applications. Correct handling of waste materials reduces costs and promotes the best use of the components and materials.

Local and national regulations must be observed when disposing of waste or other hazardous materials.

12.3.1

Disposal of the steel structure

All the steel constructions and the copper and aluminum in the electrical wiring are recyclable.

The metals can be melted and used as raw material for new products, except for parts that have been in contact with substances that are regarded as hazardous waste. The contaminated parts can usually be simply cleaned or rinsed, after which they can be recycled.

12.3.2

Disposal of plastic

Most plastic parts are recyclable, similarly to the metals. Each plastic part carries information on the material used and a manufacturing date, which can be used for determining whether the part can be recycled.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 39 (46)

MAINTENANCE MANUAL 12.3.3

PR200

Disposal of rubber parts

Rubber parts can be recycled, and used as recovered material. Worn-out parts can be returned to the dealer from whom they were originally bought. Rubber belts, tubes and hoses must be cleaned before they are disposed.

12.3.4

Disposal of glass

Glass can be recycled, as well as laminated glass such as windshields and windows. Various types of glasses shall be sorted according to local rules and regulations.

12.3.5

Disposal of electrical and electronic waste

Electrical and electronic components contain valuable and recyclable materials, and in addition a set of chemicals and heavy metals. Electrical components that are classified as hazardous waste (accumulators, batteries, circuit boards) and other hazardous waste must be delivered to a licensed waste treatment location or be disposed of according to local regulations. Never dump hazardous electrical or electronic waste.

12.3.6

Disposal of lighting and lamps

Gas discharge lamps contain mercury and are hazardous waste. They must not be dumped.

Lamps must be taken care of by an authorized hazardous waste disposal company.

12.3.7

Disposal of oils and fluids

Oil waste must not be disposed of by burning, and under no circumstances must oil be poured down the drain or into water systems. Waste oil shall be collected in appropriate containers. The best containers for collecting oil waste are the original containers for the oils. The original containers already have the necessary warning labels, are easy to close, and can be moved around fairly easily. Always strike out the product name on the label and clearly label the container "oil waste". Empty oil containers must not be dumped in landfills without having been cleaned. Cleaned plastic containers can be disposed of as regular waste. Most countries have arranged a recycling system for metal barrels. Greases, fuels, solvents, and other substances must not be mixed with oil waste.

12.3.8

Disposal of solid waste containing oil

Oil filters, oil rags, fuel filters, and oil absorbents must be collected in a separate container.

12.3.9

Disposal of solvents and oil trap sludge

Solvents and sludge that has collected on the surface of the oil traps can both be collected in a same container. The surface layer in the oil traps must be removed regularly, and the entire trap must be drained at least once a year, including the sludge at the bottom. Do not mix the oil trap sludge with oil waste.

40 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

12.3.10 Disposal of fuel oil Fuel oil is hazardous waste that must in all cases be processed by an authorized waste treatment plant.

12.4

Potential product related hazards identified by the user

Sandvik has taken all necessary precautions to design a safe machine. If, in spite of these efforts, you observe a hazard for which you believe there are insufficient safety measures, immediately inform your supervisor. If necessary, also inform the other employees working with the product. Report the hazard to your local Sandvik representative. Do not perform a task if you are unable to perform the task in a safe manner.

12.5

Incident reporting

Product safety issues to be reported are events where a machine designed by Sandvik Mining Systems has been involved in an accident or near-miss incident. Safety-related feedback, such as unauthorized modifications, missing manuals and safety labels, negligence of maintenance or misuse shall be reported to your local Sandvik representative as well.

Reporting is mandatory to ensure safe working conditions for employees, to provide information for the risk assessment process, and to initiate product improvements.

Contact your local Sandvik representative to report safety issues, such as those mentioned above.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 41 (46)

MAINTENANCE MANUAL

13 



PR200

ORDERING SPARE PARTS Spare parts for e.g. gear units, which are supplied by Sandvik, are specified in the relevant section of the OEM-Manual. The relevant drawings and spare part ID-codes are also included in these sections.

If spare parts have to be ordered refer to the corresponding Spare Parts Catalogue of your machine or contact your local Sandvik representative.  For detailed information refer to “Spare Parts Catalogue".

42 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

TABLE OF FIGURES

Figure 1: Mandatory action figures (ISO) .................................................................................................................. 8 Figure 2: Prohibited action symbols (ISO) ................................................................................................................ 9 Figure 3: General hazard symbol ............................................................................................................................... 9 Figure 4: Mechanical hazard symbols (ISO)............................................................................................................ 10 Figure 5: Electrical hazard symbols (ISO) ............................................................................................................... 10 Figure 6: Thermal hazard symbols (ISO) ................................................................................................................. 11 Figure 7: Noise hazard symbol (ISO) ....................................................................................................................... 11 Figure 8: Radiation hazard symbols (ISO)............................................................................................................... 11 Figure 9: Material/ substance hazard symbols (ISO) .............................................................................................. 11 Figure 10: Heavy load hazard symbol (ISO) ............................................................................................................ 11 Figure 11: Position and type of safety signs on the machine, refer to drawing (ISO, typical) ............................ 13 Figure 12: Hazard zones ........................................................................................................................................... 22 Figure 13: Access to the machine ............................................................................................................................ 23 Figure 14: Emergency exit of the machine .............................................................................................................. 26 Figure 15: Storm anchor for long travel drive ......................................................................................................... 28 Figure 16: Bucket wheel boom in storm tower ....................................................................................................... 29

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 43 (46)

MAINTENANCE MANUAL

PR200

TABLE OF TABLES

Table 1: Document history ......................................................................................................................................... 5 Table 2: Review information....................................................................................................................................... 5

44 (46) | Chapter 2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10-2015 Created by: Lan Wang Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0

+43 3842 2077 – 201

info.mining@sandvik.com

www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM02_en-v2_Rev0.doc

Chapter 2 | 45 (46)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

3. Troubleshooting for maintenance

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

Chapter 3 | 1 (10)

MAINTENANCE MANUAL

2 (10) | Chapter 3

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4 1.1 1.2

Document history ...................................................................................................................................................4 Review information.................................................................................................................................................4

2 TROUBLESHOOTING TABLE ................................................................................................................................... 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

Chapter 3 | 3 (10)

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Michael Stock

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

4 (10) | Chapter 3

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

PR200 2

MAINTENANCE MANUAL

TROUBLESHOOTING TABLE

Table 3: Troubleshooting No. Problem

Malfunction

Action

Faults with the belt or its splices.

Faults with material loading.

  

Wander due to faults with splices or the belt.

Wander due to component problems.

 

Align and/or adjust conveyor components.

One or more idlers not rectangular to the longitudinal axis of the belt.

Sticking idlers.



Adjust idlers.



Clean idlers and belt, install belt cleaning.



Level the structure.



Conveyor frame or structure not level or crooked.

Guiding not sufficient.



Tilt idlers and/or install belt guiding.



Belt splicing not straight.



Re-splice the belt.



Bowed belt





Loading being placed on the belt off-center.





Guiding not sufficient.



A new belt should straighten out after operated under full load tension, use self-aligning idlers on the return strand ahead of the tail pulley if necessary.

Adjust chute and loading conditions to place load in the center of the belt.

Tilt idlers and/or install bet guiding.



One or more idlers not rectangular to the longitudinal axis of the belt.

Sticking idlers.



Adjust idlers.



Clean idlers and belt, install belt cleaning.



Sticking or blocking guide idler set.



Maintain the guider idler set movable or replace it.



Rubber cushions discs worn out or loose.



Exchange rubber cushion discs.

1

Causes of mistracking.



2

Causes of mistracking.



3

Causes of mistracking.



4

Causes of mistracking.



5

Conveyor running to one side at a given point on structure.



 

6

7

Particular section of the belt runs to one side at all points.

Conveyor belt runs to one side at all points.





Check belt splice.

Check belt surfaces.

Center material stream on receiving belt.

Provide homogenous material stream.

Check belt splice.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

Chapter 3 | 5 (10)

PR200

MAINTENANCE MANUAL

No. Problem

Malfunction 

Conveyor frame or structure not level or crooked.

Side loading.



Level the structure.





Missing steering devices on return stand.





Material trapped between belt and tail pulley.

Not parallel installed scraper on return strand.



Loading in direction of belt travel, in center of conveyor.

Install steering devices, e.g. troughed roof idlers in angle of 10-15° on the return stand.

Install v-scrapers, install decking or guards.

Rubber sealing of the chute is not correct installed or not symmetric.

Loading being placed on the belt off-center.





Material builds up at the pulley.





Belt too stiff to train.





Belt to flexible in cross direction.





One or more idlers not rectangular to the longitudinal axis of the belt.

Sticking idlers.



Correction of idlers.



Lubricate or exchange idlers, improve maintenance.



8

Conveyor belt runs to one side for a longer distance.

 



9

Belt running to one side at or close to the pulley.



6 (10) | Chapter 3

Action





Check the position of the scraper, change worn scraper blades.

Install sealings perpendicular to the belt surface, change worn sealings.

Adjust chute and loading conditions to place load in center of the belt.

Remove accumulation; install scrapers, install decking or guards, improve loading.

Reduce the troughing angel; tilt troughing idlers forward but not more than 2°.

Use belt with higher rating or thicker carcass.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

TABLE OF FIGURES

No table of figures entries found.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

Chapter 3 | 7 (10)

MAINTENANCE MANUAL

PR200

TABLE OF TABLES

Table 1: Document history ......................................................................................................................................... 4 Table 2: Review information....................................................................................................................................... 4 Table 3: Troubleshooting ........................................................................................................................................... 5

8 (10) | Chapter 3

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10.2015 Created by: Michael Stock Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0

+43 3842 2077 – 201

info.mining@sandvik.com

www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM03_en-v1_Rev0.doc

Chapter 3 | 9 (10)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

4. Maintenance instructions

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 1 (88)

MAINTENANCE MANUAL

2 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 5 1.1 1.2

Document history ...................................................................................................................................................5 Review information.................................................................................................................................................5

2 GENERAL INFORMATION ........................................................................................................................................ 6 2.1

Safety instructions .................................................................................................................................................6 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6

General safety instructions ...............................................................................................................................6 Qualification of personnel assigned .................................................................................................................6 Tools ................................................................................................................................................................6 Power supply....................................................................................................................................................7 Lighting.............................................................................................................................................................7 Original Spare parts .........................................................................................................................................7

3 CLEANING ............................................................................................................................................................ 8 3.1 3.2 3.3

Safety during cleaning and maintenance .............................................................................................................8 Cleaning intervals ...................................................................................................................................................8 Cleaning methods...................................................................................................................................................8

4 SAFETY INSPECTIONS ......................................................................................................................................... 10 4.1 4.2

Safety inspection protocol ...................................................................................................................................10 Structural Integrity................................................................................................................................................12 4.2.1 4.2.2 4.2.3 4.2.4 4.2.5 4.2.6 4.2.7 4.2.8

4.3

Frequency of inspection .................................................................................................................................12 Structural Components...................................................................................................................................12 Portal ..............................................................................................................................................................14 Slew deck structural inspection ......................................................................................................................16 Rocker & Counterweight boom structural inspection ......................................................................................18 Bucket wheel boom structural inspection .......................................................................................................19 Bucket wheel structural inspection .................................................................................................................22 Long travel arrangement structural inspection ...............................................................................................24

Mechanical inspection .........................................................................................................................................26 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 4.3.6

Frequency of inspection .................................................................................................................................26 Long travel drive arrangement .......................................................................................................................26 Rocker & Counterweight boom ......................................................................................................................39 Bucket wheel boom ........................................................................................................................................44 Bucket wheel boom conveyor system ............................................................................................................48 Bucket wheel ..................................................................................................................................................51

5 PERIODIC MAINTENANCE ..................................................................................................................................... 54 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13

Maintenance of surface treatment.......................................................................................................................54 Description of maintenance symbols .................................................................................................................54 Maintenance of safety switch ..............................................................................................................................55 Maintenance of pull cord emergency switch .....................................................................................................55 Maintenance of start pre-warning device ...........................................................................................................55 Setting up a maintenance schedule ....................................................................................................................55 Maintenance schedule - Daily ..............................................................................................................................57 Maintenance schedule - Weekly ..........................................................................................................................59 Maintenance schedule – Monthly ........................................................................................................................62 Maintenance schedule - Every 3 month..............................................................................................................66 Maintenance schedule - Every 6 month..............................................................................................................68 Maintenance schedule – Every year ...................................................................................................................71 Maintenance schedule - Every 2 years ...............................................................................................................75

6 FASTENERS ........................................................................................................................................................ 78 6.1

Coefficients of friction and lubrication ...............................................................................................................80

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 3(88)

MAINTENANCE MANUAL

PR200

7 LUBRICANT REQUIREMENTS ................................................................................................................................ 81 7.1

General information ............................................................................................................................................. 81 7.1.1

7.2 7.3 7.4

Safety during lubrication ................................................................................................................................ 81

Methods for taking oil samples ........................................................................................................................... 81 Oil lubrication schedule ....................................................................................................................................... 82 Grease lubrication schedule ............................................................................................................................... 82

4 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Michael Stock

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 5 (88)

MAINTENANCE MANUAL

2

PR200

GENERAL INFORMATION

This chapter describes the activities required for maintenance the machine. Possible malfunctions and troubleshooting methods are also presented.

The Sandvik service department is at your disposal for troubleshooting, as well as for extensive maintenance and repair work. For detailed information refer to “Chapter - Troubleshooting”.

Maintenance work on the machine components must be carried out at the manufacturer's works. Workers trained and authorized by Sandvik may carry out repairs on site after obtaining permission to do so from Sandvik.

2.1

Safety instructions

2.1.1

General safety instructions

All applicable accident prevention regulations must be observed. Maintenance and service work is not permitted while the machine is in operation.

Do not exceed permissible crane loads and weights on lifting gear and ropes/shackles. Secure loads to prevent them from falling.

Do not step or walk below suspended loads! Standing below suspended loads can have fatal consequences and thus is strictly forbidden!

The machine must be thoroughly cleaned before carrying out any maintenance work.

Depressurize the systems before starting maintenance work on hydraulics.

Before carrying out any maintenance, read and ensure that you understand the maintenance instructions. Make sure that you have all the necessary training, skills and authorization before starting any maintenance work. The maintenance instructions support the maintenance personnel in performing preventative maintenance on the product. The maintenance instructions also provide information for the maintenance and operating personnel on scheduled mechanical inspections of components and installed equipment.

2.1.2

Qualification of personnel assigned

The machine may only be operated by qualified personnel. Operating personnel must be instructed in the function and possible failure of machine monitoring equipment and in carrying out maintenance and inspection work (shift log book, maintenance inspection records). The defined PPE must be worn carrying out work 2.1.3

Tools

Only use tools of a reputable brand and in good condition for any work performed on the machine.

6 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200 2.1.4

MAINTENANCE MANUAL Power supply

DANGER ELECTRIC HAZARD Electric shocks will cause death or severe injury!

Switch off, lock out and disconnect equipment from power source.

Before beginning any maintenance or repair work the operator must disconnect the power supply to all drives securely. This can be achieved with a service switch, lockable racks in the MCC, or with other suitable measures that comply with the safety regulations.

2.1.5

Lighting

The maintenance operator must ensure that adequate lighting is provided (with low-voltage bulbs) during service and repair work.

2.1.6

Original Spare parts

Before carrying out any maintenance work, ensure that necessary original spare parts or materials are available, or can be ordered and supplied in time to meet the work schedule. You must only use parts recommended by Sandvik. Failure to do so can cause death or injury or damage to equipment. Keep a note of all completed maintenance activities in a maintenance log or maintenance program.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 7 (88)

PR200

MAINTENANCE MANUAL

3

CLEANING

The machine with its equipment has to be cleaned regularly. In addition, the covering constructions and structures, as well as the walkways of the conveyors have to be cleaned from material and dust regularly.

3.1

Safety during cleaning and maintenance 





If it is necessary to go near the equipment, mechanism during the maintenance, cleaning etc., or if it is necessary to remove guards or open doors, the equipment has to be stopped and the start has to be prevented by a safety switch.

The safety switch has to be always locked in the position "0" with a separate lock, and the key has to be kept by the person who is carrying out the above measures or by the person in charge.

Removed guards have to be always put back in place.

By being extra careful some cleaning work, such as floor cleaning, can be done when the equipment is operating. In that case the entire cleaning personnel must know the possible threats with the equipment.

3.2

Cleaning intervals

It is difficult to define any exact general cleaning intervals, because the cleaning interval depends on the material, the dust-proofness of the equipment and the dust removal and ventilation systems. The cleaning intervals have to be planned separately for each place on the basis of experience and the intervals has to be planned so that the dust in equipment and surroundings does not harm the equipment or general safety (note the fire safety).

Maintenance personnel must prepare cleaning instructions with timetables which must be followed.

Cleaning is needed daily in some very difficult places and places with very dusty materials. On the other hand, with not so dusty places and non-flammable materials a general cleaning once a year can be enough.

3.3

Cleaning methods

The cleaning method depends on the place, material to be handled and the available cleaning systems and equipment.

In most cases traditional sweeping with a brush or shoveling (if needed) is a sufficient cleaning method.

8 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

If vacuum cleaning system is available, cleaning will be, of course, considerably better and faster. Compressed air might be in some cases good, but cleaning only with compressed air is usually not a sufficient cleaning method, because dust and dirt only moves from one place to another.

Generally material handling systems supplied by Sandvik are planned so that they can be cleaned also with low-pressure water jet. Before using a washer jet it has to be made sure that it is allowed to clean the equipment with water jet, and that the accumulation of washer waste has been arranged in a proper way.

Water jet must not ever be pointed to non-hardy parts of the equipment, such as electric appliances, bearings and their sealing.

When using water in cold circumstances, the possibility of freezing has to be taken into consideration.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 9 (88)

PR200

MAINTENANCE MANUAL

4

SAFETY INSPECTIONS

Safety inspection has to be performed at least once a year. The person who carries out the inspection has to know well enough the construction, safety devices and dangerous objects of the machine. The safety inspections can be also performed at the same time as the periodic inspections and maintenance, but it is necessary to mark the register and draw up a separate record.

4.1

Safety inspection protocol

Company

Name of machine:

Plant

Machine number

Safety and control equipment

OK To be repaired/remarks

emergency stop safety switch start warning control push-buttons etc. indicator lights To be inspected: function, condition, signs etc.

Shielding of dangerous places

OK To be repaired/remarks

drive end, drive mechanism tail end counterweight take-up device carrying rollers return rollers transferable equipment inspection doors To be inspected: safety guards, gap guards, safety rails etc.

Walkways, ambient conditions

OK To be repaired/remarks

service bridges,maintenance walkways stairs, ladders lightning

10 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Walkways, ambient conditions

OK To be repaired/remarks

noise, dust signs, maintenance manuals To be inspected: condition, tidiness and signs. Safety inspection shall be carried out at least once a year. The person carrying out this inspection must have adequate knowledge of the machine, structure, safety equipment and dangerous places.

Date:

Inspector:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 11 (88)

PR200

MAINTENANCE MANUAL

4.2

Structural Integrity

4.2.1

Frequency of inspection

At a minimum, Sandvik recommends that these inspections have to be carried out every 6 months.

4.2.2

Structural Components

Inspection procedures (IP):      

Sub-Consultant Visual Non-Destructive Testing Dimension Check Motion Check Observation

SC V NDT D MC O

Procedures that are bracketed in the specific inspection instructions are conducted at the discretion of the engineers responsible for the inspection.

Inspect the mechanical components listed on the following pages, noting any:       

Missing components or bolts Cracking Components with insufficient grease or lubrication Areas with insufficient paint or surface finish protection Any encrustation, such as accumulation of spillage or material that sticks to the mechanical components that hasn’t been cleaned off in the preparation wash down Loss of cross sectional area due to wear or corrosion Deformation or buckling or Excessive vibration

Examples for distinctive features on machines are shown below.

Figure 1: Cracking in a structural member

12 (88) | Chapter 4

Figure 2: Corroded and heavily pitted longitudinal beam

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 3: Web plate of boom girder deformed

Figure 4: Damaged edge of cross beam

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 13 (88)

PR200

MAINTENANCE MANUAL

4.2.3

Portal

Table 3: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0042 Portal general arrangement 1847PR1-50-010

Portal assembly

1847PR1-50-011

Portal main steel structure

1847PR1-50-015

Equalizer girder

1847PR1-50-020

Portal main bearing

1847PR1-50-030

Portal walkways complete

1847PR1-50-060

Cable chain general arrangement

Inspect the portal for any defects in the primary structure.

To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

OK

Not OK

Remarks

2 Areas with insufficient paint protection. V, (NDT) 3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

7 Any missing spillage shedders, rubber V, (NDT) flaps, cable trays, brackets etc.

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figures below and give a brief description.

14 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 5: Portal general arrangement

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 15 (88)

PR200

MAINTENANCE MANUAL

4.2.4

Slew deck structural inspection

Table 4: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0043-1

Slew deck with pylon general arrangement 1/2

992663-5720-B-M-DWG-0043-2

Slew deck with pylon general arrangement 2/2

1847PR1-60-010

Slew deck with pylon assembly

1847PR1-60-011

Slew deck steel structure

1847PR1-60-013

Pylon part-1

1847PR1-60-015

Pylon part-2

1847PR1-60-020

Slew deck walkway complete

Inspect the slew deck with pylon for any defects in the primary structure.

To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

2 Areas with insufficient paint protection.

V, (NDT)

3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

7 Any missing spillage shedders, rubber flaps, cable trays, brackets etc.

V, (NDT)

OK

Not OK

Remarks

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figures below and give a brief description.

16 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 6: Slew deck general arrangement

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 17 (88)

PR200

MAINTENANCE MANUAL

4.2.5

Rocker & Counterweight boom structural inspection

Table 5: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0044 Rocker & Counterweight boom general arrangement 1847PR1-61-010

Connection rod

1847PR1-61-020

Rocker

1847PR1-61-030

Main part counterweight boom

1847PR1-61-040

Suspension rod

1847PR1-61-050

Pivot rocker (point D)

1847PR1-61-060

Pivot suspension rod (point E)

1847PR1-61-070

Pivot counterweight boom (point F)

1847PR1-61-080

Pivot connection rod (point G)

1847PR1-61-100

Counterweight system

1847PR1-61-101

Counterweight plate

1847PR1-61-102

Counterweight concrete

Inspect the rocker and counterweight boom for any defects in the primary structure and note any: To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

2 Areas with insufficient paint protection.

V, (NDT)

3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

7 Any missing spillage shedders, rubber flaps, cable trays, brackets etc.

V, (NDT)

OK

Not OK

Remarks

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figure below and give a brief description.

18 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 7: Rocker & Counterweight boom 4.2.6

Bucket wheel boom structural inspection

Table 6: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0045-1

Bucket wheel boom steel structure general arrangement 1/2

992663-5720-B-M-DWG-0045-2

Bucket wheel boom steel structure general arrangement 2/2

1847PR1-70-010

Head part

1847PR1-70-012

Middle part

1847PR1-70-014

Pivot part

1847PR1-70-020

Mast

1847PR1-70-030

Pivot bucket wheel boom (point A)

1847PR1-70-045

Pivot mast (point C)

1847PR1-70-050

Walkway pivot part

1847PR1-70-051

Walkway middle part

1847PR1-70-052

Walkway head part Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 19 (88)

PR200

MAINTENANCE MANUAL

Drawing no.

Denomination

1847PR1-70-055

Cabin platform arrangement

1847PR1-70-080

Pivot mast (point B)

Inspect the bucket wheel boom for any defects in the primary structure and note any: To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

2 Areas with insufficient paint protection.

V, (NDT)

3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

7 Any missing spillage shedders, rubber flaps, cable trays, brackets etc.

V, (NDT)

OK

Not OK

Remarks

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figure below and give a brief description.

20 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 8: Bucket wheel boom steel structure

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 21 (88)

PR200

MAINTENANCE MANUAL

4.2.7

Bucket wheel structural inspection

Table 7: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0040-1

Bucket wheel general arrangement 1/3

992663-5720-B-M-DWG-0040-2

Bucket wheel general arrangement 2/3

992663-5720-B-M-DWG-0040-3

Bucket wheel general arrangement 3/3

1847PR1-03-010

Bucket wheel steel structure

1847PR1-03-020

Bucket complete

1847PR1-03-030

Bucket steel structure

1847PR1-03-040

Ring chute

1847PR1-03-041

Bracket for ring chute support

1847PR1-03-050

Shaft and bearings

1847PR1-03-051

Bucket wheel shaft

1847PR1-03-065

Shaft connection

1847PR1-03-070

Torque support

Inspect the bucket wheel steel structure for any defects in the primary structure and note any: To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

2 Areas with insufficient paint protection.

V, (NDT)

3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

7 Any missing spillage shedders, rubber flaps, cable trays, brackets etc.

V, (NDT)

OK

Not OK

Remarks

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figure below and give a brief description.

22 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Figure 9: Bucket wheel general arrangement

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 23 (88)

PR200

MAINTENANCE MANUAL

4.2.8

Long travel arrangement structural inspection

Table 8: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0038 Long travel general arrangement 1847PR1-01-020

Two wheel bogie steel structure

1847PR1-01-022

Two wheel bogie single driven assembly

1847PR1-01-024

Two wheel bogie with encoder assembly

1847PR1-01-028

Two wheel bogie single driven assembly

1847PR1-01-029

Support for rail clamp

1847PR1-01-040

Four wheel bogie steel structure

1847PR1-01-060

Six wheel bogie steel structure

1847PR1-01-120

Twelve wheel bogie steel structure

1847PR1-01-300

Storm anchor

1847PR1-01-400

Wheel set non driven

1847PR1-01-410

Wheel set driven

1847PR1-01-420

Wheel set with encoder

1847PR1-01-700

Rail cleaner

1847PR1-01-720

Rail cleaner with plough

1847PR1-01-970

Torque support

Inspect the equalizer bogies for any defects in the primary structure and note any: To be checked

IP

1 Any encrustation, such as accumulation of spillage or material that sticks to the structure that hasn’t been cleaned off in the preparation wash down.

V

2 Areas with insufficient paint protection.

V, (NDT)

3 Loss of cross sectional area due to wear or corrosion.

V, (NDT)

4 Deformation and buckling.

V, (NDT)

5 Missing members or bolts.

V, (NDT)

6 Cracking in welds or members.

V, (NDT)

24 (88) | Chapter 4

OK

Not OK

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Remarks

PR200

MAINTENANCE MANUAL

To be checked

IP

7 Any missing spillage shedders, rubber flaps, cable trays, brackets etc.

OK

Not OK

Remarks

V, (NDT)

Pay particular attention to the members like welding, drilling, struts, ties or notches. Note any signs of modification to these members that may induce fatigue cracking. Indicate the location of any defects on the figure below and give a brief description.

Figure 10: Equalizer bogie

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 25 (88)

PR200

MAINTENANCE MANUAL

4.3

Mechanical inspection

4.3.1

Frequency of inspection

Procedures that are bracketed in the specific inspection instructions are conducted at the discretion of the engineers responsible for the inspection. For example, (NDT) indicates that NDT may be conducted but is not mandatory.

However, if findings result from mechanical inspection, a NDT must be carried out for further definition of the irregularity.

Inspect the mechanical components listed on the following pages, noting any:          4.3.2

Missing components or bolts Cracking Components with insufficient grease or lubrication Areas with insufficient paint or surface finish protection Any encrustation, such as accumulation of spillage or material that sticks to the mechanical components that hasn’t been cleaned off in the preparation wash down Loss of cross sectional area due to wear or corrosion Deformation or buckling Excessive vibration Wear Long travel drive arrangement

Table 9: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0038 Long travel general arrangement 1847PR1-01-020

Two wheel bogie steel structure

1847PR1-01-022

Two wheel bogie single driven assembly left

1847PR1-01-024

Two wheel bogie with encoder assembly

1847PR1-01-028

Two wheel bogie single driven assembly right

1847PR1-01-029

Support for rail clamp

1847PR1-01-040

Four wheel bogie steel structure

1847PR1-01-060

Six wheel bogie steel structure

1847PR1-01-120

Twelve wheel bogie steel structure

1847PR1-01-300

Storm anchor

1847PR1-01-400

Wheel set non driven

26 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Drawing no.

Denomination

1847PR1-01-410

Wheel set driven

1847PR1-01-420

Wheel set with encoder

1847PR1-01-700

Rail cleaner

1847PR1-01-720

Rail cleaner with plough

1847PR1-01-970

Torque support

1, 2

3, 4

19,20

5, 6

21,22

23,24

7, 8

9,10

11,12

13,14

15,16

17,18

25,26

27,28

29,30

31,32

33,34

35,36

Figure 11: Main machine running wheels 4.3.2.1 Permissible wheel flange dimensional variation Following dimensional deviations are permissible for every single wheel flange:     

Max. permissible reduction for measurement C: Max. permissible reduction for measurement A & B: All measurements taken from point C have to be in the range o: Nominal dimension for measurement C: Nominal dimension for measurement A & B:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

- 5 mm - 3 mm ± 3 mm 25 mm 25 mm

Chapter 4 | 27 (88)

PR200

MAINTENANCE MANUAL

Figure 12: Wheel flange diagram

Bogie No.

Machine wheel 1

Machine wheel 2

Machine wheel 3

Machine wheel 4

Machine wheel 5

Machine wheel 6

Machine wheel 7

Machine wheel 8 28 (88) | Chapter 4

Position

Measurement

Position

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Measurement

PR200 Bogie No.

Machine wheel 9

Machine wheel 10

Machine wheel 11

Machine wheel 12

Machine wheel 13

Machine wheel 14

Machine wheel 15

Machine wheel 16

Machine wheel 17

Machine wheel 18

MAINTENANCE MANUAL

Position

Measurement

Position

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Measurement

Chapter 4 | 29 (88)

PR200

MAINTENANCE MANUAL

Bogie No.

Machine wheel 19

Machine wheel 20

Machine wheel 21

Machine wheel 22

Machine wheel 23

Machine wheel 24

Machine wheel 25

Machine wheel 26

Machine wheel 27

Machine wheel 28 Machine wheel 30 (88) | Chapter 4

Position

Measurement

Position

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Measurement

PR200

MAINTENANCE MANUAL

Bogie No.

Position

29

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

A

A

B

B

C

C

Machine wheel 30

Machine wheel 31

Machine wheel 32

Machine wheel 33

Machine wheel 34

Machine wheel 35

Machine wheel 36

Measurement

Position

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Measurement

Chapter 4 | 31 (88)

PR200

MAINTENANCE MANUAL

4.3.2.2 2-wheel bogie single driven left 6,7

5

3 2 8 4

1

Figure 13: 2-wheel bogie single driven left For mechanical inspection of the drive unit use the OEM-Manual of the manufacturer. For detailed information refer to “PR200-OEM”.

Inspect all thirteen 2-wheel bogies single driven left according to the following table: To be checked

IP

1 Running Wheel

V, O, D

26

2 Wheel axle

V, O

26

3 Drive shaft

V, O

13

4 Wheel bearings

V, O

52

5 Bogie pin

V, O

13

6 Drive unit

V, O

13

7 Drive unit brakes

V, O

13

8 Torque arm

V, O

13

9 Mounting bolts

V

all

10 Rail cleaner/plough (if fitted)

V

all

32 (88) | Chapter 4

OK

Not OK QTY

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Remarks

PR200

MAINTENANCE MANUAL

4.3.2.3 2-wheel bogie single driven right 6,7 8 5 4

1

2

3

Figure 14: 2-wheel bogie single driven right For mechanical inspection of the drive unit use the OEM-Manual of the manufacturer. For detailed information refer to “PR200-OEM”.

Inspect all three 2-wheel bogies single driven right according to the following table: To be checked

IP

OK

Not OK QTY

1 Running Wheel

V, O, D

6

2 Wheel axle

V, O

6

3 Drive shaft

V, O

3

4 Wheel bearings

V, O

12

5 Bogie pin

V, O

3

6 Drive unit

V, O

3

7 Drive unit brakes

V, O

3

8 Torque arm

V, O

3

9 Mounting bolts

V

all

10 Rail cleaner/plough (if fitted)

V

all

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Remarks

Chapter 4 | 33 (88)

PR200

MAINTENANCE MANUAL

4.3.2.4 2-wheel bogie with encoder 4

3

1

2

Figure 15: 2-wheel bogie with encoder Inspect both 2-wheel bogies with encoder according to the following table: To be checked

IP

1 Running Wheel

V, O, D

4

2 Wheel axle

V, O

4

3 Wheel bearings

V, O

16

4 Bogie pin

V, O

2

5 Encoder

V, O

2

5 Mounting bolts

V

all

6 Rail cleaner/plough (if fitted)

V

all

34 (88) | Chapter 4

OK

Not OK QTY

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Remarks

PR200

MAINTENANCE MANUAL

4.3.2.5 Four wheel bogie

1

Figure 16: Four wheel bogie Inspect all six four wheel bogies according to the following table: To be checked

IP

OK

Not OK QTY

1 Bogie pin

V, O

12

2 Mounting bolts

V, O

all

Remarks

4.3.2.6 Six wheel bogie

1

Figure 17: Six wheel bogie

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 35 (88)

PR200

MAINTENANCE MANUAL Inspect all six six wheel bogies according to the following table: To be checked

IP

OK

Not OK QTY

1 Bogie pin

V, O

6

2 Mounting bolts

V, O

all

Remarks

4.3.2.7 Twelve wheel bogie

1

Figure 18: Six wheel bogie Inspect both twelve wheel bogies according to the following table: To be checked

IP

1 Bogie pin

V, O

4

2 Mounting bolts

V, O

all

36 (88) | Chapter 4

OK

Not OK QTY

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Remarks

PR200

MAINTENANCE MANUAL

4.3.2.8 Slewing system Table 10: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0039 Slewing system 1847PR1-02-002

Planetary gearbox

1847PR1-02-010

Thread stud M30 x 315

1847PR1-02-011

Thread stud M30 x 255

1

2

3 4

Figure 19: Slewing system For mechanical inspection of the slew drive unit use the OEM-Manual of the manufacturer. For detailed information refer to “PR200-OEM”.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 37 (88)

PR200

MAINTENANCE MANUAL Inspect the slewing assembly according following table: To be checked

IP

1

Slew drive unit

V, O

3

2

Slew bearing

V, O

1

3

Slew drive pinion

V

1

4

Slew bearing mounting bolts/studs

V

72/72

5

Slew drive mounting bolts

V

all

6

Mounting bolts

V

all

38 (88) | Chapter 4

OK

Not OK QTY

Remarks

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

4.3.3

MAINTENANCE MANUAL

Rocker & Counterweight boom

Table 11: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0044 Rocker & Counterweight boom general arrangement 1847PR1-61-050

Pivot rocker (point D)

1847PR1-61-060

Pivot suspension rod (point E)

1847PR1-61-070

Pivot counterweight boom (point F)

1847PR1-61-080

Pivot connection rod (point G)

1

2

3

4

Figure 20: Rocker & Counterweight boom general arrangement To be checked 1

Pivot suspension rod (point- E)

2

Pivot connection rod (point- G)

3

Pivot rocker (point-D)

4

Pivot counterweight boom (point-F)

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 39 (88)

PR200

MAINTENANCE MANUAL

4.3.3.1 Pivot suspension rod (point-E) 2 5

1

3

6

7

Figure 21: Pivot suspension rod (point-E) Inspect the pivot suspension rod (point-E) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Pivot pin

V, O

1

2

Distance ring

V, O

1

3

Cover

V, O

2

4

Mounting bolts

V, O

1

Pivot floating side 5

Distance ring

V, O

1

6

Pivot pin

V, O

1

7

Cover

V, O

2

8

Mounting bolts

V, O

all

40 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

4.3.3.2 Pivot connection rod (point-G)

2

1

10

3 9

11

12 4 7

6

13 15

5

14

Figure 22: Pivot connection rod (point-G) Inspect the pivot connection rod (point-G) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Pivot bearing

V, O

2

2

Pivot pin

V, O

2

3

Distance ring 2

V, O

2

4

Cover 2

V, O

2

5

V-seal V-250A

V, O

4

6

Distance ring 1

V, O

2

7

Cover 1

V, O

2

8

Mounting bolts

V, O

all

Pivot pin

V, O

2

10 Distance ring 2

V, O

2

11 Cover 1

V, O

2

12 Distance ring 1

V, O

2

13 Pivot bearing

V, O

2

14 V-seal V-250A

V, O

4

Pivot flaoting side 9

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 41 (88)

PR200

MAINTENANCE MANUAL

To be checked

IP

OK

Not OK

QTY

15 Cover 2

V, O

2

16 Mounting bolts

V, O

all

Remarks

4.3.3.3 Pivot rocker (point-D)

1

3

2

11

12

4

13

10

8

7

6

5

16

14

Figure 23: Pivot rocker (point-D) Inspect the pivot rocker (point-D) assembly according to the following table: To be checked

IP

15

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Cover 1

V, O

1

2

Pivot bearing

V, O

1

3

Distance ring 2

V, O

1

4

Cover 2

V, O

1

5

Pivot pin

V, O

1

6

V-seal V-340A

V, O

1

7

Distance ring 1

V, O

1

8

V-seal V-300A

V, O

1

9

Mounting bolts

V, O

all

10 Pivot pin

V, O

1

11 Cover 2

V, O

1

12 Pivot bearing

V, O

1

42 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Pivot flaoting side

PR200

MAINTENANCE MANUAL

To be checked

IP

OK

Not OK

QTY

13 Cover 1

V, O

1

14 Distance ring 3

V, O

1

15 V-seal V-300A

V, O

1

16 V-seal V-340A

V, O

1

17 Mounting bolts

V, O

all

Remarks

4.3.3.4 Pivot counterweight boom (point-F)

1

6

2 5

3

Figure 24: Pivot counterweight boom (point-F) Inspect the pivot counterweight boom (point-F) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Pivot pin 1

V, O

1

2

Distance ring

V, O

1

3

Cover

V, O

2

4

Mounting bolts

V, O

1

Pivot floating side 5

Cover

V, O

1

6

Pivot pin 2

V, O

1

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 43 (88)

PR200

MAINTENANCE MANUAL

To be checked

IP

8

V, O

Mounting bolts

4.3.4

OK

Not OK

QTY

Remarks

all

Bucket wheel boom

Table 12: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0045-1

Bucket wheel boom steel structure general arrangement 1/2

992663-5720-B-M-DWG-0045-2

Bucket wheel boom steel structure general arrangement 2/2

1847PR1-70-030

Pivot bucket wheel boom (point A)

1847PR1-70-045

Pivot mast (point C)

1847PR1-70-080

Pivot mast (point B)

3

2

1

Figure 25: Bucket wheel boom steel structure To be checked 1

Pivot bucket wheel boom (point-A)

2

Pivot mast (point- C)

3

Pivot mast (point-B)

44 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

4.3.4.1 Pivot bucket wheel boom (point-A) 3

2

11

1

4

8

7

12

10

5

5

14

13

6

Figure 26: Pivot bucket wheel boom (point-A) Inspect the pivot bucket wheel boom (point-A) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Cover 1

V, O

1

2

Distance ring 1

V, O

1

3

Distance ring 2

V, O

1

4

Cover 2

V, O

1

5

Pivot pin

V, O

1

6

V-seal V-304A

V, O

1

7

Pivot bearing

V, O

1

8

V-seal V-276A

V, O

1

9

Mounting bolts

V, O

all

10 V-seal V-304A

V, O

1

11 Pivot bearing

V, O

1

12 V-seal V-276A

V, O

1

13 Cover 1

V, O

1

14 Pivot pin

V, O

1

15 Cover 2

V, O

1

Pivot flaoting side

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 45 (88)

PR200

MAINTENANCE MANUAL

To be checked

IP

16 Mounting bolts

V, O

OK

Not OK

QTY

Remarks

all

4.3.4.2 Pivot mast (point-C) 2

6

1 5

3

Figure 27: Pivot mast (point-C) Inspect the pivot mast (point-C) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

Remarks

Pivot fixed side 1

Pivot pin 1

V, O

1

2

Distance ring

V, O

1

3

Cover

V, O

2

4

Mounting bolts

V, O

all

Pivot floating side 5

Cover

V, O

2

6

Pivot pin 2

V, O

1

8

Mounting bolts

V, O

all

46 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

4.3.4.3 Pivot mast (point-B)

1

Figure 28: Pivot mast (point-B) Inspect the pivot mast (point-B) assembly according to the following table: To be checked

IP

OK

Not OK

QTY

2

Distance ring

V, O

8

4

Mounting bolts

V, O

all

Remarks

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 47 (88)

PR200

MAINTENANCE MANUAL

4.3.5

Bucket wheel boom conveyor system

Table 13: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0041-1

Bucket wheel boom conveyor system general arrangement 1/2

992663-5720-B-M-DWG-0041-2

Bucket wheel boom conveyor system general arrangement 1/2

1847PR1-04-011

Center chute – impact plate

1847PR1-04-012

Center chute portal

1847PR1-04-013

Center chute - middle part

1847PR1-04-014

Center chute – slew deck

1847PR1-04-015

Center chute – top part

1847PR1-04-019

Platform – impact table

1847PR1-04-020

Bucket wheel chute

1847PR1-04-022

Bucket wheel chute liners

1847PR1-04-030

Take-up station

1847PR1-04-951

Roll transition idler dia. 152

1847PR1-04-953-3

Roll transition idler II dia. 152

1847PR1-04-953-5

Carrying idler for weight scale dia. 152

1847PR1-04-953-6

Carrying idler self aligning dia.152

1847PR1-04-953-7

Impact idler I dia.152

1847PR1-04-953-8

Impact idler II dia. 152

1847PR1-04-953-9

Two-roll “vee” return idler dia. 152

1847PR1-04-954

Carrying idler for belt scale

1847PR1-04-955

Scale w eight idler dia. 152

48 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL 2 1

9

8

7

3, 4

5, 6 11

10

10

Figure 29: Bucket wheel boom conveyor system For mechanical inspection of the conveyor drive unit use the OEM-Manual of the manufacturer. For detailed information refer to “PR200-OEM”.

Inspect the discharge boom conveyor system according to the following table: To be checked

IP

OK

Not OK

QTY

1

Center chute

V, O

1

2

Drive/Take-up pulley

V

1

3

Take-up station

V, O

1

4

Take-up equipment

V, O

all

5

Primary scraper

V

1

6

Secondary scraper

V

1

7

Idlers/Garlands

V

50

8

Conveyor belt

V

1

9

Bucket wheel chute

V, O

1

10 Tail pulley

V

1

11 Snub pulley

V

3

11 Conveyor drive/brake incl.

V, O

2

Remarks

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 49 (88)

PR200

MAINTENANCE MANUAL

To be checked

IP

OK

Not OK

QTY

Remarks

torque arm 12 Plough scraper

V

1

13 Mounting brackets of the components

V

all

14 Mounting supports of the components

V

all

15 Mounting pins and bolts

V

all

50 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200 4.3.6

MAINTENANCE MANUAL

Bucket wheel

Table 14: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037

General Arrangement PR200

992663-5720-B-M-DWG-0040-1

Bucket wheel general arrangement 1/3

992663-5720-B-M-DWG-0040-2

Bucket wheel general arrangement 2/3

992663-5720-B-M-DWG-0040-3

Bucket wheel general arrangement 3/3

1847PR1-03-010

Bucket wheel steel structure

1847PR1-03-020

Bucket complete

1847PR1-03-030

Bucket steel structure

1847PR1-03-040

Ring chute

1847PR1-03-041

Bracket for ring chute support

1847PR1-03-050

Shaft and bearings

1847PR1-03-051

Bucket wheel shaft

1847PR1-03-065

Shaft connection

1847PR1-03-070

Torque support

1

Figure 30: Bucket wheel arrangement 1/2

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 51 (88)

PR200

MAINTENANCE MANUAL

2

6

Figure 31: Bucket wheel arrangement 2/2

6

7 8

Figure 32: Buckets

52 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

1

PR200

MAINTENANCE MANUAL

Inspect the bucket wheel according to the following table: To be checked

IP

OK

Not OK

QTY

1

Bucket wheel

V

1

2

Bucket wheel drive

V, O

1

3

Mounting bolts

V

all

4

BW shaft

V

1

5

BW bearings

V, O

2

6

Bucket wedges

V

all

7

Buckets

V

9

8

Bucket pins

V

9

Remarks

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 53 (88)

PR200

MAINTENANCE MANUAL

5

PERIODIC MAINTENANCE

If a device or component of the equipment has separate maintenance and inspection instructions given by the manufacturer, observe primarily the maintenance schedules and oil change intervals given there in.

5.1

Maintenance of surface treatment

Damages in the surface treatment noticed at maintenance and inspections must be repaired in an appropriate way without delay.

After modification or repair work of steel constructions the surface treatment must be carried out immediately.

At repair painting the compatibility of paints with each other must be taken into consideration and the operation and painting instruction of the paint manufacturer are to be followed.

5.2

Description of maintenance symbols

The following symbols are used in the maintenance schedules for a better visualization of the described maintenance tasks: Table 15: Maintenance symbols Symbol

54 (88) | Chapter 4

Description

Symbol

Description

Adjust

Drain

Change/Replace

Lubricate

Check

Measure

Clean

Service

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200 5.3

MAINTENANCE MANUAL Maintenance of safety switch

The safety switch stop system does not require any special maintenance, but regular cleaning and periodic inspections are necessary.

In periodic inspections it has to be checked that the switch and its cables are fixed properly.

Check that the switch device and locking are working. All covers must be fixed and name tags at their places.

When performing a function inspection check that the switch functions properly when turned into 0-position, and check that the control system performs the necessary stops and alarm indications when the switch is turned.

5.4

Maintenance of pull cord emergency switch

The pull cord emergency stop system does not require any special maintenance, but cleaning and regular periodic inspections are necessary.

In periodic inspections it has to be checked that the switch and its cables are fixed properly.

Check that the cord, its locks and fixtures are OK. Check that the cord is tensioned to the right tightness, and that it can move freely.

In the functioning inspection it has to be checked that the switch functions well also when one pulls at the farthest point of the cord. Check that the locking of the switch in the open position and its resetting function flawlessly. Check that the control system affects the necessary stops and alarm indications when the cord is pulled.

5.5

Maintenance of start pre-warning device

Start pre-warning devices do not require any special maintenance, but regular cleaning and inspections are necessary.

In periodic inspections the warning device and cable connections must be checked.

In operation inspection check that every warning device functions properly and the warning signal is heard by every person in the zone, and also check that the machines cannot be started without the start warning signal.

Do not ever cover the start pre-warning device or reduce its loudness or functioning.

5.6

Setting up a maintenance schedule

In addition to periodic inspections and maintenance the machine operating personnel must daily check that all protective and safety devices of the equipment are in place and in working order.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 55 (88)

PR200

MAINTENANCE MANUAL

The maintenance intervals given in the maintenance schedule are maximum guiding values. If the experience from the operation and maintenance show it necessary, the maintenance and inspection intervals should be shortened.

In some objects it is also possible to lengthen the intervals, e.g. for cleaning, if the experience has shown that it is not necessary to clean so often.

The measures to be performed in periodic inspections and maintenance are described in the instructions of the device or component.

The performed inspection and maintenance measures and repairs must be marked in the equipment maintenance book.

WARNING TAMPERING HAZARD Bypassing protective measure can cause death or severe injury!

Do not bypass protective measure.

In the course of general machine checks, all additional units should also be checked to guarantee that the entire plant functions satisfactorily. For these checks, the attached maintenance and upkeep instructions provided by the manufacturer must be observed. For detailed information refer to “OEM-Manual”.

56 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200 5.7

MAINTENANCE MANUAL

Maintenance schedule - Daily

During the maintenance periods the machine should be shut down, thoroughly cleaned, and checked for wear and tear. Conditions affect the time interval of maintenance schedule.

Operation – Daily  Notes

Maintenance Procedure

References

Gearbox – Long travel drive unit Visual check of the Surface.



Remove deposits on casing and components



Check for unsual noise, vibrations and changes



Gearbox - Slew drive unit

PR200-OEM

Check oil temperature



Check for unsual noise



Remove deposits on casing and components



Motor – Bucket wheel boom conveyor drive unit

PR200-OEM

Visual check of the Surface.



Remove deposits on casing and components



Gearbox – Bucket wheel boom conveyor drive unit Check oil temperature



Check for unsual noise



Remove deposits on casing and components



Conveyor belt

PR200-OEM

Check for unsual noise and vibration



Check misalignment of belt



Pulleys Check for damage

PR200-OEM 

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 57 (88)

PR200

MAINTENANCE MANUAL

Operation – Daily Maintenance Procedure

 Notes

Check for freely rotation



Clear any material around the pulleys



Check for unsual noise



Check for damage and wear



Idlers/Garlands

PR200-OEM

Remove material build up



Visually check rollers for wear and damage



Check for unsual noise and vibration



Check full seat of the rollers in brackets



Hydraulic system for luffing

PR200-OEM

Remove deposits on casing and components



Check reservoir fluid level and replenish if required.



Check oil temperature < 40°C (e.g. via control system).



Check the filter clogging indicators at oil temperatures > 25°C and < 40°C.



Check the filters.



Check bearing vibration and temperature of the motors.



Check winding temperature of the motors.



When completed: Date:

Operation:

Approved:

58 (88) | Chapter 4

References

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

5.8

MAINTENANCE MANUAL

Maintenance schedule - Weekly

During the maintenance periods the machine should be shut down, thoroughly cleaned, and checked for wear and tear. Conditions affect the time interval of maintenance schedule.

Operation – Weekly  Notes

Maintenance Procedure Motor – Long travel drive unit

References PR200-OEM

Remove deposits on casing and in air ducts.



Check starting and stop frequency



Check for abraded parts



Check position of the motor



Gearbox – Long travel drive unit Check that fastening bolts on gearboxes and add-on elements are securely tightened



Long Travel Wheels Check for unsual noise, vibration, wear



Rail Cleaner Check for cleaning up the rail top



Motor – Discharge boom conveyor drive unit

PR200-OEM

Remove deposits on casing and in air ducts



Check starting and stop frequency



Check for abraded parts



Check position of the motor



Disc brake – Discharge boom conveyor drive unit Check of optional features (limit switripper carhes, manual release, etripper car.)



Check of hydraulic unit oil level



Check condition of bolts and screw connections



Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 59 (88)

PR200

MAINTENANCE MANUAL

Operation – Weekly  Notes

Maintenance Procedure Conveyor belt

PR200-OEM 

Check for damage Belt Scraper

PR200-OEM

Check for wear and damage



Adjust as per OEM documentation and specification if necessary



Clean any residues off the scraper blades if required



Check whether freedom of movement corresponds to specs



Check tightness of all bolts screws etc.



Lubrication

PR200-OEM

Check oil level



Check for leakage



Check lubricant pump for pressure built up at pressure gauge



Check lubricant filter in the pumps and filling lines for contamination and purification



Check solenoid valves and change-over valves for tightness and function (perfe Check pumping station for unusual noises



Check oil filter for for contamination switch-over filter to clean it, when visual/electr. has occurred.



Check lubricant distributor motion indicator for proper function (retract and extend it up to limit switching)



Main Steel Structure Check steel structure visually for wear and damage.



Walkways and platforms

60 (88) | Chapter 4

References

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Weekly

Maintenance Procedure

 Notes

Check gratings and handrails security of the grating.



Check gratings and handrails for damage and deformation.



Remove material built-up (on gratings).



References

Control Systems – Electrical Equipment Safety devices for proper function (e.g pullcords, stop buttons etc.).



Normal and over-travel limits for proper function.



Switchroom – Electrical Equipment Clean Switchroom, remove rubbish and check for water and dust leaks.



When completed: Date:

Operation:

Approved:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 61 (88)

PR200

MAINTENANCE MANUAL

5.9

Maintenance schedule – Monthly Operation – Monthly  Notes

Maintenance Procedure Motor – Long travel drive unit

References PR200-OEM



Cleaning the surface.

Gearbox – Long travel drive unit Check housing temperature



Check oil level



Check the oil level sensor



Check for leakage



Replace bearings if necessary



Rail clamps

PR200-OEM

Check that guide rollers are the only part of the mechanism in contact with the rail when clamp is released



Check the serrations on the shoes are sharp



Check that shoes fully contact rail when clamp is applied



Check hydraulic fluid level



Check all hydraulic lines and fittings for leaks



Lubricate spring assembly guide rods EP2 grease



Lubricate float feature plates using the grease nipples supplied. Also lubricate vertical guide bar using a small brush to ensure complete coverage with grease



Check hydraulic pressure gauge



Check that the springs are clean, as dirt may peel the paint when spring coils



62 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Monthly  Notes

Maintenance Procedure

References

contact each other. Lubricate springs with EP2 Grease.

Motor - Slew drive unit

PR200-OEM

Check for unusual noises and changes



Check the housing temperature (max.

90°C)



Visible inspection of seals for leakage



Visible inspection of oil level gauge in the agitator flange



Remove deposits on casing and components



Gearbox – Slew drive unit Check housing temperature



Check oil level



Check the oil level sensor



Check for leakage



Replace bearings if necessary



Brake – Slew drive unit Check function of the brake/brake system (after 450 operating hours)



Check brake shoe lift-off (after 450 operating hours)



Check lining wear/lining thickness (after 450 operating hours)



Check general state of the brake (after 450 operating hours)



Check thruster reserve stroke (after 450 operating hours)



Check brake spring tension (torque) (after 450 operating hours)



Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 63 (88)

PR200

MAINTENANCE MANUAL

Operation – Monthly Maintenance Procedure

 Notes

Check adjustment of proximity switches, hand release devices and other optional equipment (after 450 operating hours)



Check easy mobility of the brake linkage (after 450 operating hours)



Check state of the automatic wear compensator (after 450 operating hours)



Check condition of the brake disc (after 450 operating hours)



Slew bearing

References

PR200-OEM

Re-lubrication of bearing



Check the bolts



Motor –Discharge boom conveyor drive unit Remove deposits on casing and in air ducts.

PR200-OEM 

Gearbox – Discharge boom conveyor drive unit Check oil level



Check gearbox for leakage



Hydraulic system for luffing

PR200-OEM

Check all components for secutity of attachment and signs of (potential) leakage.



Inspect pipewok for damage and inspect pipe connections for (potential) leakage.



Check pipework for abrasion especially where pipes run close to other equipment.



Check hoses for damage or leakage.



Lubrication

PR200-OEM

Check screw joints at the aggregate, lubrication points and pipelines for tightness



Check hose pipes and hose fittings for



64 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Monthly  Notes

Maintenance Procedure

References

tightness Walkways and Platforms – Structural Equipment Remove deposits on casing and in air ducts.



VVVF Converters, Rectifiers and Breaking Resistors – Electrical Equipment Inspect air filters



Cleaning the surface



UPS (if fitted) – Electrical Equipment 

Cleaning Lighting – Electrical Equipment Check lights are clean and dry



Check tightness of all fastenings



Lighting – Electrical Equipment Inspect filter



Replace throwaway type filters when they become clogged with dust and lint



clean cleanable type filters



When completed: Date:

Operation:

Approved:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 65 (88)

PR200

MAINTENANCE MANUAL

5.10

Maintenance schedule - Every 3 month Operation – Every 3 month  Notes

Maintenance Procedure Gearbox – Long travel drive unit

References PR200-OEM



Check the coupling Rail clamps

PR200-OEM

Inspect eccentric pins, lubricate as required



Check that clamp is operating within prescribed range on indicating label



Rail clamp - Power unit Check hydraulic fluid level



Check pressure developed – Pressure gauge



Check hydraulic lines and fittings for leakage



Motor - Slew drive unit

PR200-OEM

Clean the exterior of the vent plug



Gearbox – Slew drive unit Clean coarse filter



Clean the air filter



Coupling – Slew drive unit Check for damage



Check for alignment



Check the connection bolts



Check the backlash



Check the flexible spider/ elements



Slew bearing Check the backlash

66 (88) | Chapter 4

PR200-OEM 

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Every 3 month

Maintenance Procedure

 Notes

Check meshing gearing with pinion of slew drive unit



Check the gearing for unusual wear



Gearbox – Discharge boom conveyor drive unit

References

PR200-OEM

Clean coarse filter



Clean the air filter



Disk brake - Discharge boom conveyor drive unit Complete check of entire brake system



Check of hydraulic or pneumatic piping



Check of power/electrical supply wiring/cabeling



Check of brake clamping force (if necessary)



Check of brake shoes, brake linings and brake drum/disk



Hydraulic system for luffing

PR200-OEM

Draw fluid samples and sent in for analysis of contaminants, water content and viscosity.



Change the fluid (as required or on reccomendation of the oil supplier).



UPS (if fitted) – Electrical Equipment Check that connections, seals and mounting are tight and secure.



Check the function.



When completed: Date:

Operation:

Approved:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 67 (88)

PR200

MAINTENANCE MANUAL

5.11

Maintenance schedule - Every 6 month Operation – 6 month  Notes

Maintenance Procedure Motor – Long travel drive unit

References PR200-OEM

Maintain the electrical parameters (500 hours)



Comply with the permissible bearing temperatures



Check for unusual noise



The motor foundation must have no indentations or cracks



Brake – Long travel drive unit Operational brake (after 4,000 operating hours)



Gearbox – Long travel drive unit Check the oil quality



Clean the gearbox ventilation or replace if necessary



Remove deposits on casing and components



Check rubber buffers on torque arms



Rail clamp - Power unit

PR200-OEM

Check all settings and reset if necessary



Motor – Slew drive unit

PR200-OEM

Check rubber buffer set



Check the fixing bolts



Gearbox – Slew drive unit Refill grease for Tacolab seals (3,000 operating hours)



Refill the Taconite seals with grease (3,000 operating hours)



68 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – 6 month

Maintenance Procedure

 Notes

Comparison of vibration values for



References

bearing monitoring with initial values (reference values) on starting up (every 3,000 operating hours) Slew bearing

PR200-OEM 

Check the sealing system Gearbox – Discharge boom conveyor drive unit

PR200-OEM

Refill grease for Tacolab seals (3,000 operating hours)



Refill the Taconite seals with grease (3,000 operating hours)



Comparison of vibration values for



bearing monitoring with initial values (reference values) on starting up (every 3,000 operating hours) Hydraulic system for luffing Check all settings and reset if necessary (1000 cycles).

PR200-OEM 

Cable reel – Roller chains

PR200-OEM

Clean and grease roller chains (Every 2,000 to 2,500 operating hours)



Check chain tensioner for proper function, re-tense if required (Every 2,000 to 2,500 operating hours)



Cable reel – drive gear box (Every 3,000 operating hours) Check oil and oil level



Check running nois for possible bearing demage



Check for leakage



Check and replace the rubber buffers (for gear units with torque arm)



Distribution Boards – Electrical Equipment Inspection inside DB’s ensure all surfaces



Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 69 (88)

PR200

MAINTENANCE MANUAL

Operation – 6 month  Notes

Maintenance Procedure and components are clean and dry, and that all mechanical and electrical connections are sound.



Test protection devices.

Switchrooms – Electrical Equipment Test Stacker earthing system.



PLC – Electrical Equipment Inspect inside PLC cubicles. Ensure all surfaces and components are clean and dry and that all mechanical and electrical connections are sound. Check PLC cards are not loose.



VVVF Converters, Rectifiers and Braking Resistors (if fitted) – Electrical Equipment Inspect inside VVVF converter and braking resistor cubicles. Ensure all surfaces and components are clean and dry and that all mechanical and electrical connections are sound.



When completed: Date:

Operation:

Approved:

70 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

References

PR200

5.12

MAINTENANCE MANUAL

Maintenance schedule – Every year Operation – Every year  Notes

Maintenance Procedure Gearbox – Long travel drive unit

References PR200-OEM

Check the friction clutch and adjust if necessary



Carry out a complete inspection of the geared motor



Rail clamps

PR200-OEM

Change filler breather



Adjust wedge



Drain hydraulic tank and replace fluid



Change or clean suction strainer



Spring force back pressure check



Rail clamp – Power unit Check hand pump operation



Check for correct setting time (adjust flow control if necessary)



Motor - Slew drive unit

PR200-OEM

Grease the bearing in the agitator flange



Check the air gap



Clean the fan wheel of the motor (depending on outside influences)



Gearbox – Slew drive unit Test the water content of the oil (after approx. 400 hours)



Check hose lines

 Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 71 (88)

PR200

MAINTENANCE MANUAL

Operation – Every year Maintenance Procedure

 Notes

Check friction linings of torque-limiting backstop



Slew bearing

PR200-OEM

Check the raceway system



Gearbox – Discharge boom conveyor drive unit

PR200-OEM

Test the water content of the oil (after approx. 400 hours)



Check hose lines



Check shrink disk



Check friction linings of torque-limiting backstop



Hydraulic system for luffing

PR200-OEM

Check system thoroughly for security of attachment of all components and for any sign of leakage.



Test all interlocks physically from the instrument right through and the control system.



Lubrication

PR200-OEM

Check foundation screws of pumping station for tight fit



Cable reel – Slip ring assembly

PR200-OEM

Clean casing, slip rings, current collectors and insulators (Every 4,500 to 5,000 operating hours)



Check slip rings, graphite brushes and insulators for damages (Every 4,500 to 5,000 operating hours)



Check slip rings and graphite brushes for wear and exchange if needed (Every 4,500 to 5,000 operating hours)



Check all screws and other connections (Every 4,500 to 5,000 operating hours)



Cable reel – Guide facility 72 (88) | Chapter 4

References

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Every year

Maintenance Procedure

 Notes

Check for wear of contact guide roller (Every 4,500 to 5,000 operating hours)



References

Cable reel – Guide facility/ direction change over roles Check for wear of idler (Every 4,500 to 5,000 operating hours)



Cable reel – all sprocket wheels Check for wear (Every 4,500 to 5,000 operating hours)



Cable reel – Angular gear (guide tube) Check oil level (Every 4,500 to 5,000 operating hours)



Cable reel – Gear of the drive motor Check oil level (Every 4,500 to 5,000 operating hours)



Cable reel – Brake Check for wear of brake lining (Every 4,500 to 5,000 operating hours)



Cable reel – Bearings of the real Re-grease if required (Every 4,500 to 5,000 operating hours)



Structural Equipment – Main Steel Structure 

Inspect and NDT test

Structural Equipment – Steel Structure and stress points Inspect for stress signs and deformations



Structural Equipment – Bearings Check all bearings on the main structure for damage and wear



Distribution Boards – Electrical Equipment Conduct thermographical survey of busbars and connections



VVVF Converters, Rectifiers and Braking Resistors (if fitted) – Electrical Equipment

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 73 (88)

PR200

MAINTENANCE MANUAL

Operation – Every year Maintenance Procedure

 Notes

Conduct thermographical survey of busbars and connections



Air condition (if fitted) – Electrical Equipment Inspect indoor coin, drain pan and condensate drain. Clean when necessary



Inspect indoor fan motor and wheel for cleanliness and alignment. Clean lubricat and aling the motor assenbly where applicable. Replace worn belts where applicable



Inspect outdoor coil. Clean when necessary



Inspect outdoor fans and motors. Ensure that fan blades are clean and adequately balanced



Inspect the unit cabinet and insulation for demage and corrosion. Repair where necessary. Check for vibration and excessive noise. Correct where necessary



Inspect refrigerant tubing for oil accumulations. If oil is detected, leak test refrigerant tubing using an electronic leak detector or liquid soap solution



Check refrigerant charge by measurment of superheat and subcooling. Where necessary, adjust the charge to achieve optimum performance



When completed: Date:

Operation:

Approved:

74 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

References

PR200

5.13

MAINTENANCE MANUAL

Maintenance schedule - Every 2 years

During the maintenance periods the machine should be shut down, thoroughly cleaned, and checked for wear and tear. Conditions affect the time interval of maintenance schedule.

Operation – Every 2 years  Notes

Maintenance Procedure Gearbox – Long travel drive unit

References PR200-OEM03

Check the oil level sensor (regularly and after oil changes)



Change the roller bearing grease (regularly and after oil changes)



Brake – Long travel drive unit Holding brake with emergency stop (after 10 million cycles)



Rail clamps

PR200-OEM04

Inspect guide wheel assembly and repack with grease if necessary



Rail clamp – Power unit Change filler breather



Drain hydraulic tank and replace fluid



Replace filter



Gearbox – Slew drive unit

PR200-OEM05

Clean fan and gear unit



Check cooling coil



Check tightness of fastening bolts



Check air-oil cooler as to condition



Check water-oil cooler as to condition



Inspection of the gear unit



Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 75 (88)

PR200

MAINTENANCE MANUAL

Operation – Every 2 years Maintenance Procedure

 Notes

Change the hose lines



Gearbox – Discharge boom conveyor drive unit

PR200-OEM08

Clean fan and gear unit



Check cooling coil



Check tightness of fastening bolts



Check air-oil cooler as to condition



Check water-oil cooler as to condition



Inspection of the gear unit



Change the hose lines



Cable reel

PR200-OEM23

Check all screws and other connections (Every 8,000 to 10,000 operating hours)



Cable reel – Drive motor Re-grease the bearings (Every 8,000 to 10,000 operating hours)



Cable reel – Gears of the drive motor Check and clean the slip rings and brushes (Every 8,000 to 10,000 operating hours)



Cable reel – drive gear box Replace rolling bearing grease



Replace oil seal (do not install in the same track)



Touch up or renew the surface/anticorrosion coating



PLC – Electrical Equipment

76 (88) | Chapter 4

References

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL Operation – Every 2 years

Maintenance Procedure

 Notes

Replace CPU battery.



References

When completed: Date:

Operation:

Approved:

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 77 (88)

PR200

MAINTENANCE MANUAL

6

FASTENERS

Bolts and screws are manufactured in several classes of material. The heads of these screws and bolts are marked to show the strength class. Damaged or lost fasteners should only be replaced with fasteners of the same material.

The installation data apply to standard screwed/bolted connections at the machine and should only be used if no special installation data are stated in the assembly drawings.

The information in the following table applies to the commercially available assembly preload FM Tab and tightening torque MA with v=0.9 for shank bolts with metric standard thread according to DIN ISO 262.

Table 16: Assembly preload and tightening torque Assembly preloaded FM Tab in kN vor μG

Strenght Size Grade

Tightening torque MA in Nm für μK = μG

0.08 0.10 0.12

0.14

0.16

0.20

0.24

0.08

0.10

0.12

0.14

0.16

0.20

0.24

M4

8.8 10.9 12.9

4.6 6.8 8.0

4.4 6.5 7.6

4.3 6.3 7.4

4.2 6.1 7.1

3.9 5.7 6.7

3.7 5.4 6.3

2.3 3.3 3.9

2.6 3.9 4.5

3.0 4.6 5.1

3.3 4.8 5.6

3.6 5.3 6.2

4.1 6.0 7.0

4.5 6.6 7.8

M5

8.8 10.9 12.9

7.6 7.4 7.2 11.1 10.8 10.6 13.0 12.7 12.4

7.0 10.3 12.0

6.8 10.0 11.7

6.4 9.4 11.0

6.0 8.8 10.3

4.4 6.5 7.6

5.2 7.6 8.9

5.9 8.6 10.0

6.5 9.5 11.2

7.1 10.4 12.2

8.1 11.9 14.0

9.0 13.2 15.5

M6

8.8 10.9 12.9

10.7 10.4 10.2 15.7 15.3 14.9 18.4 17.9 17.5

9.9 14.5 17.0

9.6 14.1 16.5

9.0 13.2 15.5

8.4 12.4 14.5

7.7 11.3 13.2

9.0 13.2 15.4

10.1 14.9 17.4

11.3 16.5 19.3

12.3 18.0 21.1

14.1 20.7 24.2

15.6 22.9 26.8

M7

8.8 10.9 12.9

15.5 15.1 14.8 22.7 22.5 21.7 26.6 26.0 25.4

14.4 21.1 24.7

14.0 20.5 24.0

13.1 19.3 22.6

12.3 18.1 21.2

12.6 18.5 21.6

14.8 21.7 25.4

16.8 24.7 28.9

18.7 27.5 32.2

20.5 30.1 35.2

23.6 34.7 40.6

26.2 38.5 45.1

M8

8.8 10.9 12.9

19.5 19.1 18.6 28.7 28.0 27.3 33.6 32.8 32.0

18.1 26.6 31.1

17.6 25.8 30.2

16.5 24.3 28.4

15.5 22.7 26.6

18.5 27.2 31.8

21.6 31.8 37.2

24.6 36.1 42.2

27.3 40.1 46.9

29.8 43.8 51.2

34.3 50.3 58.9

38.0 55.8 65.3

M10

8.8 10.9 12.9

31.0 30.3 29.6 45.6 44.5 43.4 53.3 52.1 50.8

28.8 42.2 49.4

27.9 41.0 48.0

26.3 38.6 45.2

24.7 36.2 42.4

36 53 62

43 63 73

48 71 83

54 79 93

59 87 101

68 100 116

75 110 129

M12

8.8 10.9 12.9

45.2 44.1 43.0 66.3 64.8 63.2 77.6 75.9 74.0

41.9 61.5 72.0

40.7 59.8 70.0

38.3 56.3 65.8

35.9 52.8 61.8

63 92 108

73 108 126

84 123 144

93 137 160

102 149 175

117 172 201

130 191 223

M14

8.8 10.9 12.9

62.0 60.6 59.1 57.5 91.0 88.9 86.7 84.4 106.5 104.1 101.5 98.8

55.9 82.1 96.0

52.6 77.2 90.4

49.3 72.5 84.8

100 146 171

117 172 201

133 195 229

148 218 255

162 238 279

187 274 321

207 304 356

78 (88) | Chapter 4

4.5 6.7 7.8

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Assembly preloaded FM Tab in kN vor μG

Strenght Size Grade

0.08 0.10 0.12

0.14

0.16

Tightening torque MA in Nm für μK = μG

0.20

0.24

0.08

0.10

0.12

0.14

0.16

0.20

0.24

M16

8.8 10.9 12.9

84.7 82.9 80.9 78.8 76.6 72.2 67.8 153 124.4 121.7 118.8 115.7 112.6 106.1 99.6 224 145.5 142.4 139.0 135.4 131.7 124.1 116.6 262

180 264 309

206 302 354

230 338 395

252 370 433

291 428 501

325 477 558

M18

8.8 10.9 12.9

107 152 178

104 149 174

102 145 170

99 141 165

96 137 160

91 129 151

85 121 142

220 314 367

259 369 432

295 421 492

329 469 549

360 513 601

415 592 692

462 657 769

M20

8.8 10.9 12.9

136 194 227

134 190 223

130 186 217

127 181 212

123 176 206

116 166 194

109 156 182

308 438 513

363 517 605

415 592 692

464 661 773

509 725 848

588 838 980

655 933 1092

M22

8.8 10.9 12.9

170 242 283

166 237 277

162 231 271

158 225 264

154 219 257

145 207 242

137 194 228

417 595 696

495 704 824

567 807 945

634 697 808 901 904 993 1151 1284 1057 1162 1347 1502

M24

8.8 10.9 12.9

196 280 327

192 274 320

188 267 313

183 260 305

178 253 296

168 239 279

157 224 262

529 754 882

625 714 798 875 1011 1126 890 1017 1136 1246 1440 1604 1041 1190 1329 1458 1685 1877

M27

8.8 10.9 12.9

257 367 429

252 359 420

246 351 410

240 342 400

234 333 389

220 314 367

207 295 345

772 915 1050 1176 1292 1498 1672 1100 1304 1496 1674 1840 2134 2381 1287 1526 1750 1959 2153 2497 2787

M30

8.8 10.9 12.9

313 446 522

307 437 511

300 427 499

292 416 487

284 405 474

268 382 447

252 359 420

1053 1246 1428 1597 1754 2931 2265 1500 1775 2033 2274 2498 2893 3226 1755 2077 2380 2662 2923 3386 3775

M33

8.8 10.9 12.9

389 554 649

381 543 635

373 531 621

363 517 605

354 504 589

334 475 556

314 447 523

1415 1679 1928 2161 2377 2759 3081 2015 2392 2747 3078 3385 3930 4388 2358 2799 3214 3601 3961 4598 5135

M36

8.8 10.9 12.9

458 652 763

448 638 747

438 623 729

427 608 711

415 591 692

392 558 653

368 524 614

1825 2164 2482 2778 3054 3541 3951 2600 3082 3535 3957 4349 5043 5627 3042 3607 4136 4631 5089 5902 6585

M39

8.8 10.9 12.9

548 781 914

537 765 895

525 748 875

512 729 853

498 710 831

470 670 784

443 630 738

2348 2791 3208 3597 3958 4598 5137 3345 3975 4569 5123 5637 6549 7317 3914 4652 5346 5994 6596 7664 8562

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 79 (88)

PR200

MAINTENANCE MANUAL

6.1

Coefficients of friction and lubrication

The coefficient of friction depending on the lubrication can be found in the following table.

Table 17: Recommended lubrication and friction coefficients Lubrication

μ 5.6 / 8.8 / C3-80

A4-50 / A4-70 / A4-80

0.1

MoS2

Chlorinated paraffin or MoS2

0.125

Dry or oiled

0.14

Anti-Seize compounds

If the special lubricants mentioned here are not used, following the respective manufacturer's instructions.

The manufacturer's instructions must be observed for sub-supplies pertaining to the machine.

Wrong torque tightening may cause machine damage and hazards leading to personal injury.

Apply the tightening torques as shown in the drawings and table (Table 16: Assembly preload and tightening torque).

80 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200 7

MAINTENANCE MANUAL

LUBRICANT REQUIREMENTS

If a device or component of the equipment has separate maintenance and inspection instructions given by the manufacturer, observe primarily the maintenance schedules and oil change intervals given there in.

The Machine has been provided with heavy-duty gears. Premature lubrication will be required in case of undue contamination of lubrication and filters or of lubrication deficiencies. Oil must be filled very carefully into the gear boxes to prevent any contamination. The area around the filling hole must be cleaned before filling and a suitable funnel with screen must be used. Overfilling can cause damage to the gear due to temperature and/or pressure rise. The prescribed oil quantities are to be seen as approximate values only. An oil level check is always necessary to determine the actual amount of oil needed.

7.1

General information

Always use lubricants recommended by the manufacturer of the device or component. Read the instructions provided by device or component manufacturer. For detailed information refer to “OEM-Manual”.

This instruction contains general instructions for choosing and handling of lubricants for the material handling equipment delivered by Sandvik.

General information on lubricants and choosing of them is available also from the suppliers of lubricants.

7.1.1

Safety during lubrication

When handling industrial oils and lubricants long-term and repeated contact with oil and lubricants must be avoided, wear protective clothing and appropriate tools.

Normally the used lubricant is classified as a problem waste, take care of appropriate handling, storing and destroying of the lubricants.

7.2

Methods for taking oil samples

Before taking samples refer to the Sandvik Safety Policy and the Section 1 of the Equipment Manual.

Most preferred is to take the sample from the return line upstream of the return line filter. Use a suitable ball valve as sampling fitting.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 81 (88)

MAINTENANCE MANUAL 

 

PR200

Make sure the system has been operating for at least a ½ of an hour before taking the sample, and that the system has not been shut-down for more than 15 minutes or ½ of an hour. Otherwise settling occurs.

Fully open the ball valve and flush from 200 ml to 600 ml of fluid to clean the line.

Remove the lid from the bottle being careful not polluting it, then insert the bottle in the flow stream. When the bottle is 2/3rd to 3/4th full remove the bottle. Do not open and close the valve while filling the bottle as debris from the ball valve may contaminate the sample. Immediately replace the cap on the bottle.

Taking the sample from the center of the reservoir: 

    

Make sure the system has been operating for at least a ½ of an hour before taking the sample, and that the system has not been shut-down for more than 15 minutes or ½ of an hour. Otherwise settling occurs.

Use a suitable suction pump to draw a sample from the center of the reservoir.

The most common place to enter the reservoir is by removing the filler breather and screen. Be careful not to get debris in the oil during drawing.

Draw the sample from as near the center of the reservoir as possible.

Fill the bottle 2/3rd – 3/4th full.

Immediately replace the cap on the bottle.

Never take a sample by unscrewing a fitting or hose and filling the bottle. Great quantities of contamination are generated during this process.

The quality and accuracy of your sample will be in proportion to how carefully these procedures are followed.

7.3

Oil lubrication schedule

During the maintenance periods the machine should be shut down, thoroughly cleaned, and checked for wear and tear. Conditions affect the time interval of maintenance schedule. For detailed information refer to “OEM-Manual”. For detailed information refer to the external Document “Oil and Grease Lubrication Schedules (pr200_C1847-LS_en-v1.pdf)”.

7.4

Grease lubrication schedule

During the maintenance periods the machine should be shut down, thoroughly cleaned, and checked for wear and tear. Conditions affect the time interval of maintenance schedule.

It is important to use the OEM-Manual for correct lubrication procedures.

82 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

For detailed information refer to “OEM-Manual”. For detailed information refer to the external Document “Oil and Grease Lubrication Schedules (pr200_C1847-LS_en-v1.pdf)”.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 83 (88)

MAINTENANCE MANUAL

PR200

TABLE OF FIGURES

Figure 1: Cracking in a structural member ............................................................................................................. 12 Figure 2: Corroded and heavily pitted longitudinal beam ..................................................................................... 12 Figure 3: Web plate of boom girder deformed ........................................................................................................ 13 Figure 4: Damaged edge of cross beam ................................................................................................................. 13 Figure 5: Portal general arrangement...................................................................................................................... 15 Figure 6: Slew deck general arrangement .............................................................................................................. 17 Figure 7: Rocker & Counterweight boom ................................................................................................................ 19 Figure 8: Bucket wheel boom steel structure ......................................................................................................... 21 Figure 9: Bucket wheel general arrangement ......................................................................................................... 23 Figure 10: Equalizer bogie........................................................................................................................................ 25 Figure 11: Main machine running wheels ............................................................................................................... 27 Figure 12: Wheel flange diagram ............................................................................................................................. 28 Figure 13: 2-wheel bogie single driven left ............................................................................................................. 32 Figure 14: 2-wheel bogie single driven right .......................................................................................................... 33 Figure 15: 2-wheel bogie with encoder ................................................................................................................... 34 Figure 16: Four wheel bogie..................................................................................................................................... 35 Figure 17: Six wheel bogie ....................................................................................................................................... 35 Figure 18: Six wheel bogie ....................................................................................................................................... 36 Figure 19: Slewing system ....................................................................................................................................... 37 Figure 20: Rocker & Counterweight boom general arrangement ......................................................................... 39 Figure 21: Pivot suspension rod (point-E) .............................................................................................................. 40 Figure 22: Pivot connection rod (point-G) .............................................................................................................. 41 Figure 23: Pivot rocker (point-D) ............................................................................................................................. 42 Figure 24: Pivot counterweight boom (point-F) ...................................................................................................... 43 Figure 25: Bucket wheel boom steel structure ....................................................................................................... 44 Figure 26: Pivot bucket wheel boom (point-A) ....................................................................................................... 45 Figure 27: Pivot mast (point-C) ................................................................................................................................ 46 Figure 28: Pivot mast (point-B) ................................................................................................................................ 47 Figure 29: Bucket wheel boom conveyor system .................................................................................................. 49 Figure 30: Bucket wheel arrangement 1/2............................................................................................................... 51 Figure 31: Bucket wheel arrangement 2/2............................................................................................................... 52 Figure 32: Buckets .................................................................................................................................................... 52

84 (88) | Chapter 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

TABLE OF TABLES

Table 1: Document history.......................................................................................................................................... 5 Table 2: Review information ....................................................................................................................................... 5 Table 3: Drawing reference ....................................................................................................................................... 14 Table 4: Drawing reference ....................................................................................................................................... 16 Table 5: Drawing reference ....................................................................................................................................... 18 Table 6: Drawing reference ....................................................................................................................................... 19 Table 7: Drawing reference ....................................................................................................................................... 22 Table 8: Drawing reference ....................................................................................................................................... 24 Table 9: Drawing reference ....................................................................................................................................... 26 Table 10: Drawing reference ..................................................................................................................................... 37 Table 11: Drawing reference ..................................................................................................................................... 39 Table 12: Drawing reference ..................................................................................................................................... 44 Table 13: Drawing reference ..................................................................................................................................... 48 Table 14: Drawing reference ..................................................................................................................................... 51 Table 15: Maintenance symbols ............................................................................................................................... 54 Table 16: Assembly preload and tightening torque ............................................................................................... 78 Table 17: Recommended lubrication and friction coefficients .............................................................................. 80

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 85 (88)

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10.2015 Created by: Michael Stock Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0

+43 3842 2077 – 201

info.mining@sandvik.com

www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM04_en-v1_Rev0.doc

Chapter 4 | 87(88)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

5. Repair/Replacement Instructions

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 1 (20)

MAINTENANCE MANUAL

2 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4 1.1 1.2

Document history ...................................................................................................................................................4 Review information.................................................................................................................................................4

2 SLEW ASSEMBLY .................................................................................................................................................. 5 2.1

Slew bearing ...........................................................................................................................................................5 2.1.1 2.1.2 2.1.3 2.1.4 2.1.5 2.1.6 2.1.7 2.1.8

Personnel .........................................................................................................................................................5 Equipment ........................................................................................................................................................5 Masses of equipment .......................................................................................................................................6 Time schedule ..................................................................................................................................................6 Additional safety instructions ............................................................................................................................6 Preparation for replacement .............................................................................................................................6 Repair/ Replacement location ..........................................................................................................................7 Repair/ Replacement procedure ......................................................................................................................8

3 APPENDIX .......................................................................................................................................................... 14 3.1 Standard torque table...........................................................................................................................................14 Table of Figures ...............................................................................................................................................................16

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 3 (20)

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

30.10.2015

Description

Modified by

First issue

Daniel Hammer

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

4 (20) | Chapter 5

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

2

SLEW ASSEMBLY

2.1

Slew bearing

The following instruction describes the replacement of a slew bearing. Also the necessary tools, manpower, duration and environmental conditions are given to complete the job in a structured way.

2.1.1

Personnel

During the procedure the following persons and/or operators are needed:      2.1.2

6 x Mechanical tradesperson 2 x Electrical tradesperson 1 x Rigger 1 x Crane operator 1 x EWP Equipment

During the procedure the following equipment, tools and lifting devices are needed:            

Mobile crane, capacity appropriate for task EWP 3 x hydraulic lock nut cylinders, stroke-controlled, capacity appropriate for task Synchronous lifting system including pressure monitoring for each cylinder 2 x come-along appropriate for task Slew bearing lifting cross beam Slew bearing lifting eye bolts Appropriate rigging gear – requirements to be assessed by fully qualified rigger Supporting beams with support structure to slide the bearing out/in Hand tools Torque wrench, hydraulic bolt tensioner, torque multiplier or equivalent Stabbing guides

Table 3: Drawing reference Drawing no.

Denomination

992663-5720-B-M-DWG-0037 General Arrangement PR200 992663-5720-B-M-DWG-0039 Slewing assembly general arrangement 1847PR1-50-010

Portal assembly

1847PR1-60-010

Slew deck with pylon assembly

For detailed information refer to “OEM-Manual”.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 5 (20)

MAINTENANCE MANUAL 2.1.3

PR200

Masses of equipment

Table 4: Masses of equipment Slew bearing 2.1.4

approx.5,952 kg

Time schedule

The time required is approximately 14 days.

2.1.5

Additional safety instructions

All personnel working on this task must read this replacement instruction to familiarize them with the work process. It is very important to stick to the following safety instructions:   

Fence-off the working area and provide warning signs to alert bystanders of the potential hazards and the work being carried out.

Crane and rigging operations must be carried out according to site specific safety regulations.

When manually lifting components, use assistance where required and employ correct manual handling techniques. Be aware of working with heavy parts. For further safety information refer to “Chapter - PR200_C1847-MM02_en-v1”.

2.1.6

Preparation for replacement

During preparation of the replacement of the slew bearing the following steps need to be completed:          

Inspect all lifting equipment and confirm it is in good operational condition and the rated capacity is suitable for the task.

Inspect the supporting beams for cracks or damage.

Inspect the bearing cross brace for cracks or damage.

Inspect the area where the crane will be located during the bearing change-out and level as required.

Inspect the area where the EWP will be operating and remove any equipment, spillage, etc.

Confirm the ground is suitable for the task to proceed and there are no underground services.

Leave the replacement bearing in its transporting container until just before it is required.

Assemble all replacement parts and equipment that is possible near the change-out location.

Measure cylinder pressures on rod and piston side and forward them to Sandvik for verification of the balancing of the machine.

Verify that the jacking points and their reinforcement are in a sound state.

6 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200 2.1.7

MAINTENANCE MANUAL

Repair/ Replacement location

Figure 1: Slew bearing – Repair/ Replacement location on machine

1

1

Slew bearing

Figure 2: Slew bearing – Repair/ Replacement location detailed view

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 7 (20)

MAINTENANCE MANUAL

2.1.8

PR200

Repair/ Replacement procedure

1. Drive the machine to the maintenance position.

2. While continuously taking the readings of the cylinder pressures (rod- and piston side) for both cylinders, luff to the maximum extent possible: o the boom down (take care not to ground the BW) o the boom up o the boom down into the maintenance position.

3. Shut down the machine.

4. Wait for 2 hours.

5. Take the cylinder pressures (rod- and piston side) for both cylinders again.

6. Inspect the machine and note all additional all changed equipment on the machine.

7. Inspect the jacking points on the inside and outside for the Slew deck and the Portal.

8. Inspect the machine and note all modifications to the original design of the machine.

9. For the previous steps provide a photo report with detailed information and weights.

10. Forward all readings and the photo report to Sandvik Center of Excellence Mobile Machines.

8 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

11. Slew the bucket wheel boom until the 3 jacking points are correctly aligned.

1

2

4

3

1

Jacking point #1

2

Jacking point #2

3

Jacking point #3

4

Bucket wheel boom direction

Figure 3: Jacking points Information given in Figure 3 is preliminary and MUST NOT be used for the execution. Final information will be available subsequent to the evaluation of the cylinder pressures.

12. Isolate as per task requirements.

13. Label, disconnect and seal against dirt ingress each of the slew bearing’s lubrication lines.

14. Disconnect and pull back all electrical, control cables and other lines or equipment passing through the slew bearing.

15. Install stabbing guides between the portal and slew deck, next to the jacking points.

16. Remove all limit switches, brackets and electrical cables in the bearing change-out path.

17. Remove all walkways, hand rails, guards and gratings which might be in conflict with the procedure.

18. Remove all slew bearing covers if fitted.

19. It is recommended to remove all slew drive units and send them to the workshop to allow pinion replacement and maintenance.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 9 (20)

MAINTENANCE MANUAL

PR200

Good work practices dictate that all slew drive units are removed and all slew pinions are replaced.

This presents new and known good work surfaces which are impacting on the life of the slew gears.

20. Remove all slew drive units.

21. Remove all parts of the center chute which might be in conflict with the procedure.

22. Remove the parts of the cable chain which might be in conflict with the procedure.

23. Install the temporary slide out table. Ensure that the slide out table supporting structure has a solid foundation.

24. Check that the surfaces of the slide-out table are positioned at the same height and exactly at the same level as the bottom side of the slew bearing.

25. Ensure that the slide-out table is secured against any movement by connecting the beams to the structure of the portal.

26. A fully qualified rigger must install an appropriate lifting arrangement to elevate the lock nut cylinders into position on the jacking points.

27. Extend the three hydraulic lock nut cylinders, extend the jacks to just contact the slew deck steel structure but do not take any weight at the moment.

28. Take up 25 % of the slewing structure weight, by applying pressure on each lock nut cylinder and lock off each by using the lock nut. Use the values indicated on the pressure gauges to indicate the load.

29. Loosen off the nuts from the upper ring of the slew bearing. At this time, the structure shall not lift. Particular caution must be taken on the boom side bolts as the machine is counterweight heavy.

30. Take up 100 % weight of the upper structure on the lock nut cylinders.

31. Remove the nuts and studs completely from the upper slew bearing ring.

32. Lift the upper structure so there is sufficient room to attach the slide out rails to the portal structure and to slide out the slew bearing.

33. Lock the lock nut cylinders in place.

34. Lock the stabbing guides in position.

35. Use slings or wire rope around the slew bearing circumference and attached to two chain blocks to pull the slew bearing (approx. 300 mm) out from beneath the slew deck structure.

36. The chain blocks are attached to the outer end of the sliding table structure. A fully qualified rigger must to asses and confirm this arrangement. Ensure the bearing does not catch on anything.

37. Pull the slew bearing for about 300 mm and connect a sling around the front end of the slew bearing.

10 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

38. Using the sling, pull the slew bearing out until the first bore holes outside the supporting beams allow threaded rods to be bolted through the slew bearing. The function of the threaded rods is to guide the slew bearing centrally along the supporting beams during the removal process.

Check before and during any movement of the slew bearing that the slew bearing is positioned exactly in the center line of the supporting structure.

39. Move the slew bearing out until it is clear and can be lifted by the crane.

40. Install the lifting cross on the old bearing.

41. Install bearing lifting eyes and rig the old bearing to the crane. Lift the old bearing off the sliding table and lower it to the ground.

42. Clean up the portal and slew deck mounting faces and check for burrs or damage created during the old bearing removal. Repair as required.

43. Install the lifting cross onto the new bearing.

44. Install bearing lifting eyes and rig the new bearing to the crane.

45. Lift the new bearing onto the sliding table.

46. When lowering the new bearing onto the sliding table, ensure that the bearing upper and lower “soft spot” are positioned in the same place as for the removed bearing.

47. Check that the bearing is positioned exactly in the center of the supporting beams.

48. Install threaded rods in the same manner as for removal to guide the bearing along the support beams.

49. A fully qualified rigger must assess and arrange the rigging requirements to pull the slew bearing along the support beams and into position. Take care the bearing does not catch on anything as it is moved into position. (To assist in maneuvering the bearing, the sliding table may be lightly greased.)

50. Remove the threaded rods before they contact the machine.

51. Rotate the slew bearing upper ring to align the mounting holes in the upper slew bearing ring with slew deck mounting holes.

52. Ensure that the upper soft spot is correctly aligned.

53. Insert at 120 ° spacing, through the slew deck bearing surface, three of the upper ring slew bearing studs into the bearing.

54. Evenly tighten these three studs to lift the bearing off of the lower mounting surface.

55. Rotate the slew bearing lower ring to align the mounting holes in lower slew bearing ring with the portal structure mounting holes.

56. Ensure that the lower soft spot is correctly aligned.

57. Install the lower ring studs of the slew bearing.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 11 (20)

MAINTENANCE MANUAL

PR200

58. Slowly and evenly release the three upper ring studs to lower the bearing onto the lower mounting surface.

59. Measure the roundness of one of the rings by measuring the diameter at each of six different positions the ring (60 ° apart).

60. If the difference in two or more measurements is greater than 1 mm then the bearing requires adjustment.

61. Torque lower studs to 50 % in the correct sequence. For detailed information refer to “OEM-Manual”.

62. Install upper slew bearing upper ring studs.

63. Release the stabbing guides.

64. Lower the slewing structure ensuring jack heights do not vary.

65. Lower the structure until 25 % weight remains on the hydraulic jacks.

66. Torque upper studs to 50 %. Lower the hydraulic jacks completely and remove.

67. Torque both upper and lower studs to 100% in the correct sequence. For detailed information refer to “OEM-Manual”.

68. Re-install the slew drives complete with new pinions and adjust the backlash. The backlash can be adjusted by rotating the slew drive unit. For detailed information refer to “OEM-Manual”.

69. Manually and thoroughly lubricate the slew gear and reinstall the covers.

70. Re-connect all the cables and hoses passing through the slew chamber.

71. Re-connect the slew bearing lube lines.

72. Re-connect the limit switches and brackets.

73. Re-install in reverse order as in previous steps.

74. Re-install the removed section of handrail, handrail support and gratings.

75. Manually operate the slew bearing grease pump and confirm the lubrication system is operating correctly.

76. Remove the horizontal anchors for the slew bearing.

Remove the horizontal anchors for the slew bearing replacement before taking the machine into operation.

Nonobservance will result in severe damage to the machine.

77. Flange surface to be ground subsequent to removal of the horizontal anchors.

78. Remove isolations and test run the slew.

79. Verify all limits are operational and set correctly, adjust or re-commission as required.

12 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

80. When correct operation is confirmed hand back to operations.

81. Remove all tools, equipment and rubbish from the work area.

82. Operate the machine at 50% capacity for four hours and monitor operations.

83. Operate the machine at normal capacity and monitor for 24 hours.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 13 (20)

PR200

MAINTENANCE MANUAL

3

APPENDIX

3.1

Standard torque table

Bolts and screws are manufactured in several classes of material. The heads of these screws and bolts are marked to show the strength class. Fasteners shall be used only once. When replacing fasteners always use such of the same standard as the original have been.

The installation data apply to standard screwed/bolted connections at the machine and should only be used if no special installation data are stated in the assembly drawings.

The information in the following table applies to the commercially available assembly preload FM Tab and tightening torque MA with v=0.9 for shank bolts with metric standard thread according to DIN ISO 262.

Assembly preloaded FM Tab in kN vor μG

Strength Size Grade

Tightening torque MA in Nm für μK = μG

0.08 0.10 0.12

0.14

0.16

0.20

0.24

0.08

0.10

0.12

0.14

0.16

0.20

0.24

M4

8.8 10.9 12.9

4.6 6.8 8.0

4.4 6.5 7.6

4.3 6.3 7.4

4.2 6.1 7.1

3.9 5.7 6.7

3.7 5.4 6.3

2.3 3.3 3.9

2.6 3.9 4.5

3.0 4.6 5.1

3.3 4.8 5.6

3.6 5.3 6.2

4.1 6.0 7.0

4.5 6.6 7.8

M5

8.8 10.9 12.9

7.6 7.4 7.2 11.1 10.8 10.6 13.0 12.7 12.4

7.0 10.3 12.0

6.8 10.0 11.7

6.4 9.4 11.0

6.0 8.8 10.3

4.4 6.5 7.6

5.2 7.6 8.9

5.9 8.6 10.0

6.5 9.5 11.2

7.1 10.4 12.2

8.1 11.9 14.0

9.0 13.2 15.5

M6

8.8 10.9 12.9

10.7 10.4 10.2 15.7 15.3 14.9 18.4 17.9 17.5

9.9 14.5 17.0

9.6 14.1 16.5

9.0 13.2 15.5

8.4 12.4 14.5

7.7 11.3 13.2

9.0 13.2 15.4

10.1 14.9 17.4

11.3 16.5 19.3

12.3 18.0 21.1

14.1 20.7 24.2

15.6 22.9 26.8

M7

8.8 10.9 12.9

15.5 15.1 14.8 22.7 22.5 21.7 26.6 26.0 25.4

14.4 21.1 24.7

14.0 20.5 24.0

13.1 19.3 22.6

12.3 18.1 21.2

12.6 18.5 21.6

14.8 21.7 25.4

16.8 24.7 28.9

18.7 27.5 32.2

20.5 30.1 35.2

23.6 34.7 40.6

26.2 38.5 45.1

M8

8.8 10.9 12.9

19.5 19.1 18.6 28.7 28.0 27.3 33.6 32.8 32.0

18.1 26.6 31.1

17.6 25.8 30.2

16.5 24.3 28.4

15.5 22.7 26.6

18.5 27.2 31.8

21.6 31.8 37.2

24.6 36.1 42.2

27.3 40.1 46.9

29.8 43.8 51.2

34.3 50.3 58.9

38.0 55.8 65.3

M10

8.8 10.9 12.9

31.0 30.3 29.6 45.6 44.5 43.4 53.3 52.1 50.8

28.8 42.2 49.4

27.9 41.0 48.0

26.3 38.6 45.2

24.7 36.2 42.4

36 53 62

43 63 73

48 71 83

54 79 93

59 87 101

68 100 116

75 110 129

M12

8.8 10.9 12.9

45.2 44.1 43.0 66.3 64.8 63.2 77.6 75.9 74.0

41.9 61.5 72.0

40.7 59.8 70.0

38.3 56.3 65.8

35.9 52.8 61.8

63 92 108

73 108 126

84 123 144

93 137 160

102 149 175

117 172 201

130 191 223

M14

8.8 10.9 12.9

62.0 60.6 59.1 57.5 91.0 88.9 86.7 84.4 106.5 104.1 101.5 98.8

55.9 82.1 96.0

52.6 77.2 90.4

49.3 72.5 84.8

100 146 171

117 172 201

133 195 229

148 218 255

162 238 279

187 274 321

207 304 356

14 (20) | Chapter 5

4.5 6.7 7.8

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

Assembly preloaded FM Tab in kN vor μG

Strength Size Grade

0.08 0.10 0.12

0.14

0.16

0.20

Tightening torque MA in Nm für μK = μG 0.24

0.08

0.10

0.12

0.14

0.16

0.20

0.24

M16

8.8 10.9 12.9

84.7 82.9 80.9 78.8 76.6 72.2 67.8 153 124.4 121.7 118.8 115.7 112.6 106.1 99.6 224 145.5 142.4 139.0 135.4 131.7 124.1 116.6 262

180 264 309

206 302 354

230 338 395

252 370 433

291 428 501

325 477 558

M18

8.8 10.9 12.9

107 152 178

104 149 174

102 145 170

99 141 165

96 137 160

91 129 151

85 121 142

220 314 367

259 369 432

295 421 492

329 469 549

360 513 601

415 592 692

462 657 769

M20

8.8 10.9 12.9

136 194 227

134 190 223

130 186 217

127 181 212

123 176 206

116 166 194

109 156 182

308 438 513

363 517 605

415 592 692

464 661 773

509 725 848

588 838 980

655 933 1092

M22

8.8 10.9 12.9

170 242 283

166 237 277

162 231 271

158 225 264

154 219 257

145 207 242

137 194 228

417 595 696

495 704 824

567 807 945

634 697 808 901 904 993 1151 1284 1057 1162 1347 1502

M24

8.8 10.9 12.9

196 280 327

192 274 320

188 267 313

183 260 305

178 253 296

168 239 279

157 224 262

529 754 882

625 714 798 875 1011 1126 890 1017 1136 1246 1440 1604 1041 1190 1329 1458 1685 1877

M27

8.8 10.9 12.9

257 367 429

252 359 420

246 351 410

240 342 400

234 333 389

220 314 367

207 295 345

772 915 1050 1176 1292 1498 1672 1100 1304 1496 1674 1840 2134 2381 1287 1526 1750 1959 2153 2497 2787

M30

8.8 10.9 12.9

313 446 522

307 437 511

300 427 499

292 416 487

284 405 474

268 382 447

252 359 420

1053 1246 1428 1597 1754 2931 2265 1500 1775 2033 2274 2498 2893 3226 1755 2077 2380 2662 2923 3386 3775

M33

8.8 10.9 12.9

389 554 649

381 543 635

373 531 621

363 517 605

354 504 589

334 475 556

314 447 523

1415 1679 1928 2161 2377 2759 3081 2015 2392 2747 3078 3385 3930 4388 2358 2799 3214 3601 3961 4598 5135

M36

8.8 10.9 12.9

458 652 763

448 638 747

438 623 729

427 608 711

415 591 692

392 558 653

368 524 614

1825 2164 2482 2778 3054 3541 3951 2600 3082 3535 3957 4349 5043 5627 3042 3607 4136 4631 5089 5902 6585

M39

8.8 10.9 12.9

548 781 914

537 765 895

525 748 875

512 729 853

498 710 831

470 670 784

443 630 738

2348 2791 3208 3597 3958 4598 5137 3345 3975 4569 5123 5637 6549 7317 3914 4652 5346 5994 6596 7664 8562

Table 5: Assembly preload and tightening torque

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 15 (20)

MAINTENANCE MANUAL

PR200

Table of Figures Figure 1: Slew bearing – Repair/ Replacement location on machine ..................................................................... 7 Figure 2: Slew bearing – Repair/ Replacement location detailed view ................................................................... 7 Figure 3: Jacking points ............................................................................................................................................. 9

16 (20) | Chapter 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

PR200

MAINTENANCE MANUAL

TABLE OF TABLES

Table 1: Document history.......................................................................................................................................... 4 Table 2: Review information ....................................................................................................................................... 4 Table 3: Drawing reference ......................................................................................................................................... 5 Table 4: Masses of equipment .................................................................................................................................... 6 Table 5: Assembly preload and tightening torque ................................................................................................. 15

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 17 (20)

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: SR Original language: EN Revision: 0 - 30.10.2015 Created by: Daniel Hammer Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0 info.mining@sandvik.com

+43 3842 2077 – 201 Lokal Internet Site: www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM05_en-v1_Rev0.doc

Chapter 5 | 19 (20)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

6. Accompanying documents

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 1 (12)

MAINTENANCE MANUAL

2 (12) | Chapter 6

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4 1.1 1.2

Document history ...................................................................................................................................................4 Review information.................................................................................................................................................4

2 REFERENCE TO OEM-M ANUAL ............................................................................................................................. 5 3 OIL AND GREASE LUBRICATION SCHEDULES ........................................................................................................... 7

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 3 (12)

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Michael Stock

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

4 (12) | Chapter 6

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

PR200 2

MAINTENANCE MANUAL

REFERENCE TO OEM-MANUAL

Table 3: Reference to OEM-Manual Code

Title

PR200-OEM01

Long Travel Drive

PR200-OEM02

Rail Clamps

PR200-OEM03

Buffer

PR200-OEM04

Slew drive

PR200-OEM05

Slew Bearing

PR200-OEM06

Conveyor Drive

PR200-OEM07

Conveyor belt

PR200-OEM08

Belt scraper

PR200-OEM09

Pulleys

PR200-OEM10

Idlers/Garlands

Manufacturer/Supplier

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 5 (12)

PR200

MAINTENANCE MANUAL

Code

Title

PR200-OEM11

Take-up hydraulic

PR200-OEM12

Hydraulic System

PR200-OEM13

Luffing cylinder

PR200-OEM14

BW-drive

PR200-OEM15

Lubrication system

PR200-OEM16

Cable reeler

PR200-OEM17

Bearings

PR200-OEM18

Operator cabin

PR200-OEM19

Electrical Equipment

6 (12) | Chapter 6

Manufacturer/Supplier

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

PR200 3

MAINTENANCE MANUAL

OIL AND GREASE LUBRICATION SCHEDULES For detailed information refer to the external Document “Oil and Grease Lubrication Schedules (pr200_C1847-LS_en-v1.pdf)”.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 7 (12)

MAINTENANCE MANUAL TABLE OF FIGURES

No table of figures entries found.

8 (12) | Chapter 6

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF TABLES

Table 1: Document history.......................................................................................................................................... 4 Table 2: Review information ....................................................................................................................................... 4 Table 3: Reference to OEM-Manual ............................................................................................................................ 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 9 (12)

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10.2015 Created by: Michael Stock Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0 info.mining@sandvik.com

+43 3842 2077 – 201 Lokal Internet Site: www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM06_en-v1_Rev0.doc

Chapter 6 | 11 (12)

www.mining.sandvik.com

PR200

MAINTENANCE MANUAL

7. Feedback

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

Chapter 7 | 1 (10)

MAINTENANCE MANUAL

2 (10) | Chapter 7

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF CONTENTS

1 DOCUMENT HISTORY AND REVIEW INFORMATION .................................................................................................... 4 1.1 1.2

Document history ...................................................................................................................................................4 Review information.................................................................................................................................................4

2 DOCUMENTATION CUSTOMER SATISFACTION SURVEY............................................................................................ 5

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

Chapter 7 | 3(10)

PR200

MAINTENANCE MANUAL

1

DOCUMENT HISTORY AND REVIEW INFORMATION

1.1

Document history

This document is subject to internal revision control and tracking of changes. Minor and major modifications shall be noted with respect to section and description. The responsible technical writer and the approver are named.

Table 1: Document history Revision Date 0

1.2

10-2015

Description

Modified by

First issue

Michael Stock

Review information

This document is subject to internal review. The responsible reviewer and the function are named.

Table 2: Review information Review date

4 (10) | Chapter 7

Reviewed

Function

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

PR200 2

MAINTENANCE MANUAL

DOCUMENTATION CUSTOMER SATISFACTION SURVEY For detailed information refer to the external Document “Documentation – Customer Satisfaction Survey ‘(pr200_C1847-MM07.1_en_v1.pdf)”.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

Chapter 7 | 5 (10)

MAINTENANCE MANUAL

TABLE OF FIGURES

No table of figures entries found.

6 (10) | Chapter 7

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

PR200

PR200

MAINTENANCE MANUAL

TABLE OF TABLES

Table 1: Document history.......................................................................................................................................... 4 Table 2: Review information ....................................................................................................................................... 4

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

Chapter 7 | 7 (10)

PR200

MAINTENANCE MANUAL

Company Information Machine: PR200 Order: C1847 Output language: EN Original language: EN Revision: 0 - 10.2015 Created by: Michael Stock Checked by: Markus Adamer Sandvik Mining and Construction Materials Handling GmbH & Co KG Vordernberger Strasse 12 AT-8700 Leoben / Austria +43 3842 2077 – 0

+43 3842 2077 – 201

info.mining@sandvik.com

www.mining.sandvik.com

Sandvik Mining and Construction Materials Handling GmbH & Co KG – All Rights Reserved.

This publication is copyright of Sandvik Mining and Construction Materials Handling GmbH & Co KG © Sandvik Mining and Construction Materials Handling GmbH & Co KG 2015.

It must not be copied, reproduced, or otherwise made available in full or in part to any third party without Sandvik Mining and Construction Materials Handling GmbH & Co KG’s prior written consent.

Copyright © Sandvik Mining and Construction Materials Handling pr200_C1847-MM07.0_en-v1_Rev0.doc

Chapter 7 | 9(10)

www.mining.sandvik.com