Operation & Maintenance Alimak Raise Climber STH-5
This manual is only applicable if the manufacturing number indicated below corresponds to the manufacturing number stamped on the identification sign of the equipment. Where there is a conflict contact Your ALIMAK representative.
YOUR CLIMBER HAS: Manufacturing No.:
Year:
If the bottom right corner of this book is cut, the book is only valid for illustrative use!
Part No. No. 9056 093 - 1 04 2001 - 05 - 07
FOREWORD This product is designed and manufactured to meet stri ct quality and safety standards. This manual is intended to provide advice and instructions to the operator and qualified service personnel so that he can safely control the situations which can occur when the product is used, and can carry out the required service and maintenance on the product. This manual shall always be available in the box intended for this purpose on the machine. Potential risk for user or equipment are indicated in the following way, in this book: WARNING! Information with these symbols and headings indicates the possibility of personal injury. IMPORT IMPORTANT: ANT: Information Information with with these these headings headings indicate indicate the possibility of damage damage to the equipment.
WARNING! Misuse of this equipment could result in personal injury or property damage.
The equipment should not be operated if operators Manual is missing.
Photographs and drawings are illustrative only and do not necessarily show the design of the products on the market at any given point in time. The products must be used in conformity with applicable practice and safety regulations. Specifications of the products and equipment presented herein are subject to change without notice.
FOREWORD This product is designed and manufactured to meet stri ct quality and safety standards. This manual is intended to provide advice and instructions to the operator and qualified service personnel so that he can safely control the situations which can occur when the product is used, and can carry out the required service and maintenance on the product. This manual shall always be available in the box intended for this purpose on the machine. Potential risk for user or equipment are indicated in the following way, in this book: WARNING! Information with these symbols and headings indicates the possibility of personal injury. IMPORT IMPORTANT: ANT: Information Information with with these these headings headings indicate indicate the possibility of damage damage to the equipment.
WARNING! Misuse of this equipment could result in personal injury or property damage.
The equipment should not be operated if operators Manual is missing.
Photographs and drawings are illustrative only and do not necessarily show the design of the products on the market at any given point in time. The products must be used in conformity with applicable practice and safety regulations. Specifications of the products and equipment presented herein are subject to change without notice.
CONTENTS TECHNICAL DESCRIPTION
A TECHNICAL TECHNICAL DAT DATA
B INSTRUCTIONS INSTRUCTIONS FOR USE
C OPERATING OPERATING INSTRUCTIONS INSTRUCTIONS
D SERVICE SERVICE AND MAINTEN MAINTENANC ANCE E
E TROUBLESHOOTING
F EXCAVATION FOR RAISE RAISE CLIMBER CLIMBER
G GUID GUIDE E RAIL RAIL AND AND GUID GUIDE E RAIL RAIL CUR CURVES VES
H PREPARA PREPARATIONS TIONS BEFORE INSTALLA INSTALLATION TION
I INSTALLATION
K DRIVING
L TROUBLE TROUBLESHO SHOOTIN OTING G AND REPAIR REPAIR
M Section Section I: Section II: Section III: Section IV: IV:
Technical echnical Descriptio Description: n: chapter chapter A, B, G H and I Operation & Maintenance: chapter C, D, E and F Installation & Driving: chapter K and L Troubleshooting & Repair: chapter M
ALIMAK AB IS ISO 9001 CERTIFIED This Certificate is valid for the following product or service ranges: design, development, manufacture, rental and service of construction hoists, mast climbing work platforms, permanently installed lifts and equipment for shaft raising and enlarging
INSTRUCTIONS FOR THE USE
Instructions for the use of Alimak Raise Climbers .............................. C 1
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Instructions for the use of Alimak Raise Climbers The regulations below are drawn up only to advise and remind the climber operator/keeper of the necessary control and precautionary measures and must in no way be interpreted as – or preclude – national/local safety regulations and recommendations. 1. The climber climber operato operator, r, i.e. i.e. the person person allowed allowed to operat operatee the raise climber, must have the necessary knowledge of the design, condition and action of the climber. 2. He must must be very very familiar familiar with with operating operating the climber climber both in normal conditions and in emergencies, and with the instructions applying to the climber and its equipment. 3. He must must be very familiar familiar with the use use of of the signal signal devices and the safety climber. If the climber is normally operated by more than one person, the statements under 1 – 3 above apply to at least two of these. 4. The climbe climberr must not be used with a higher higher load or speed than the maximum established at the greatest driving length. Nor must it be used, contrary to prohibitions laid down, for transporting personnel. The same applies to safety climbers. 5. Transp Transport ort of materials materials must must be done in such such way way that the materials cannot injure the passengers, fall down, or get stuck in the climber path. Where required the materials should be securely bundled up and attached to the cage or work platform. 6. In driving driving of raises with with a raise climber climber,, the method of ignition should be such that it allows igniting from a protected location. If electric
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detonators are used with an electrically powered raise climber, these shall have a higher safety factor, See the Swedish Industrial Safety Board rec. No. 14 ”Gruvhissanvisningar”, the 1973 issue recommended detonators type VA, ignition current min. 1.3 Amp. Transporting explosives by raise climbers, as well as storing and handling such goods in the cage and on the platform must be done in such way that no risk for explosion arises through mechanical damage, fire or inadvertent initiation of electric detonators. Detonators must be stored separate from explosives in boxes intended for this purpose. Electric detonators must not be remowed from their storage box if there is any risk of ignition, e.g. during electric operation before the current has been switched off. During charging work on the platform storage boxes are not required, if only the equipment necessary for the charging is present on the platform and the explosives are kept there only during the actual charging work and then in their factoty packaging. 7. If electric ignition is used used together with with electric raise climber, the current must be switched off before the charging work commences. 8. Stepping in and out out of the cage must only be done at a protected location. During running, the passengers must stay in the cage and the door to the t he work platform must be kept closed. The hinged platform section should be raised. 9. During ascent after blasting, but at least once once every working day, the guide rail with its attachment, especially expansion bolts, must be inspected and any damage rectified immediately. tely. If there is any severe damage to the guide tube, proceed with caution with regard to poor ventilation in the upper part of the raise. 10. Setting up the guide rail and scaling must must be done only under the safety roof, if the raise is vertical or inclines 60° (67 gon) or or more. If the raise inclines less than 60° 60° and a safety roof is not used, used, scaling of walls and roof must be done gradually during ascent, and the work must all the time be carried out under the protection of a previously scaled hanging wall. When setting up a guide rail the workers must be under a safe hanging wall or safety roof. 11. During all work on the platform, a safety safety belt with a wire attached to the platform or safety roof must be used. The hinged platform section should be let down only after the scaling is completed.
12. On the bottom level the climber path should be fenced fenced off so that nobody can be hit by falling rocks or other objects or injured by a moving cage. Such fencing can be constructed of loose trestles etc. A warning sign saying ”Work in progress” or similar, should be placed on or adjacent to the fence. Loading rock waste on the bottom level must be done from a protected location, if work is in progress in the raise or if it has not been scaled. 13. During each shift the attachments attachments and resetting of the safety device must be checked, as well as the function of the signal devices.
Theese regulations are in accordance with the regulations of the Swedish Industrial Industrial Safety Board No. 14, 1973, §292, §293. Use of the equipment contrary the manufacturer’s instruc tions is done at the user’s user’s own risk. PIRATTILL PIRA TTILLVERKADE VERKADE delar har medfört olyckstillbud med stigortshissen – i vissa fall med svåra personskad personskador or.. Orsakerna har oftast varit felaktigt materialval. Material med ytterst specifika egenskaper med avseende på bl.a elastisitet och nötningsbeständigh nötningsbeständighet et har använts i stigortshissen. Tänk på det och välj därför alltid Alimak Genuina Reservdelar.. Reservdelar
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OPERATING INSTRUCTIONS
Operating instructions ................................... D 1 Safety check before start ................................ D 1 Measures before start ..................................... D 1 Air driven climbers ........................................ D 2 Electric driven climbers ................................. D 4 Diesel-hydraulic driven climbers ................. D 11 Brakes .............................................................. D 14 Safety device.................................................... D 14 Air and water central ..................................... D 16 Air operated safety roof ................................. D 17 Lubricator ....................................................... D 19 High pressure water pump ............................ D 21 Alimak Dupline system .................................. D 25
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Operating instructions
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Prior to any use of this climber perform safety procedures below, as well as any required maintenance and lubrication specified in this manual.
Safety check before driving – Before driving, check the counter roller and attachment of the safety device. If the roller is not parallel to the guide rail, it must be replaced. Make sure that the safety device is reset – the white line straight in front of the opening in the red field of the sight glass. Make sure that the four bolts which hold the brake drum are tightened. The pinion must be properly aligned and roll in the centre line of the pin rack. – Check pinions, rollers, U-frame, brakes, bolt joints, telephone equipment and its connection to the cable drum, tools, damages (repair if necessary) – Make sure that the ventilation of the raise is satisfactory.
Measures before start – Pull out the plug from the outlet on the drum for the signal wire and straighten out possible twists on the cable. Then reinsert the plug.
Note: The electrically driven raise climbers have signal conductors included within the power supply cable. It therefore does not have this equipment. – Disconnect and move the plug (A) for battery charging to the outlet under the control panel in the cage – resp. under the diesel-hydraulic power pack for climbers type STH-5D or DD. Note that this connection is necessary for the function of the air and water central.
A A
– Release the locking device on the air and water central. Valid for air and water central type AW-2 for non electric – NONEL – blasting system only!
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Air driven raise climber STH-5L & STH-5LL – Load the climber with necessary equipment. Make sure that the climber is not overloaded. – Open the cook on the air and water central manifold to sup-
C A
ply air to the hose reel and cock (B).
B
– Start the climber by pulling the lever on the control valve. When the lever is released the climber will stop. – Check the guide rail during ascent and make sure that the climber does not catch on the rock wall. Up
Make sure also during ascent that the air motors are receiving oil – oil should emerge from the outlets of the motors! Refill oil is best done up in the raise. Refill by turn off cock (B), evacuate the control valve by driving the climber and remove the refilling plug (C). After refilling, put back the refilling plug and open the cock.
– When descending, push the lever towards the control valve. In inclined raises where hose holders are used, a strict watch must be kept over the hoses. If the hoses has fallen off a hose holder, the climber must be stopped and the hose put back in its holder before the descent is continued. The hose will otherwise be damaged when the climber passes.
Descending after hose rupture etc.
To enable descent after interruption of air supply or other breakdowns, disengage the air motors by turning the disengaging levers (D) through 180° so they point away from the motors. Release control brake (E) by hand and turn the flywheel (F) clockwise so that the climber starts moving. The speed will then be automatically limited by the centrifugal brake. If the climber is to be stopped during descent, apply the control brake.
D3 When engaging the air motors again, turn the disengaging levers (D) in either direction until the levers point towards the motors or stop after turning them through 90°. To be able to fit the coupling in the later case, turn the flywheel slowly with the hand lever while turning the disengaging lever quickly backwards and forwards until it can be turned to point towards the motor.
D
Note! If the disengaging lever is turned to stop without the
E
back-wards and forwards movement, the relative positions of the coupling halves will not change and they will not engage. IMPORTANT: Do not drive the air motors or lower the climber by gravity when adjusting the coupling. Lowering the STH-5LL by gravity
A man with life line climbs down the ladder to the lower drive unit. Disengage the air motors, release the control brake while turning the flywheels.
F
If only one man is to lower the climber, do as follows: 1. Find a 3/4” nut, or alternatively 2 U-washers or suchlike. 2. Put on a life line and climb down the ladder to the lower drive unit. 3. Disengage the air motor. 4. Release the control brake. Put the nut, or washers, between brake lever and brake housing to keep the brake released. 5. Turn the flywheel so that the drive unit moves downwards until it stops. 6. Climb up into the cage. 7. Disengage the air motor. 8. Release the control brake and turn the flywheel quickly. The upper drive unit will then ”hit” the lower one and the climber will start moving. To stop the climber during descent, release the upper control brake lever.
Note! After descending, remove the nut or the washers between brake lever and brake housing. WARNING! Life line must always be used outside the cage.
Air driven service and safety climbers See operating instructions for raise climber
IMPORTANT: The staff on the raise climber must be informed of the ascent with the safety climber.
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Electric driven raise climber STH-5E & STH-5EE – Load the climber with necessary equipment. Make sure that the climber is not overloaded. Operation Instruction STH5-E/EE, with contactor control and DUPLINE control system
Please use this instruction together with circuit diagram No. 9080 459-001 page 1 – 6. Check that all cables are connected in accordance with wiring diagram 9080460-001 page 1. Check that the motors are connected for the right voltage. NOTE! The water pump motor shall always be connected for 400V/50Hz or 460V/60Hz. Please read the following before start of operation. This is how the equipment shall be used: General
If you turn off the switch Q64, in the climber, i.e. no supply motors, all functions can be tested without driving the climber up or down. You then have a complete view of what is happening, and you can follow the starting sequence without driving the climber up and down. The equipment in the STH-5 climber can only be started by means of a key switch pos S48, and in accordance with the instruction sign on the cabin trap door in the base equipment.
The man going up with the climber shall start the equipment. First of all he shall test all functions (also the earth fault relay). Then, when going up with the climber, he shall bring the key for the switch S48. After scraping/drilling, the man in the climber shall make the climber out of current before commencing charging work. This is made by setting the switch ”power” in ”Off” position. The current circuits that are active (the signal system) are current limited to 45 mA, which is a safe level for electric blasting caps.
Charging for blasting must be done in accordance with valid instructions and Authority Safety Regulations. Noone but the operator in the climber should be able to energize the climber, since the key is with the operator in the climber. In order to get down, after having finished the charging work, the climber is slid down. The above is for the STH-5 climber. Trolley and Alicab, the life-saving climbers on the other hand,
may be run without any conditions.
The fundamental thing about the alarm function is that there is a signal from the climber to the base all the time. Each break, activated alarm button, empty battery or cable failure, starts the alarm equipment at the base. The telephones shall always work, provided the cable is
complete. However, the sound/light signals are dependent on voltage. These are started by pressing the ”Call” buttons in the base and the climber respectively. Continue the commissioning. Start instructions and safety test before operation
Four batteries are included with the equipment. The purpose is to change the batteries in the climber at every shift to a fully charged. To achieve a continuous charging of the exchange batteries, the main switch shall be in position ”Power On” and there shall be power to the base station – also when the equipment is not in operation. a) Connect fully charged batteries to the climberequipment. Then check that the green LED lamp, on the I/O cards U59 and U60, in the climber, is lit up. This shows that there is voltage for the cards. Switch the selector switches ”Power” and ”Air/Water” in the climber, to ”Off” position. Switch the selector switch S46, in the base equipment to ”Off” position.
NOTE! For the signal transfer batteries always have to be used, even if telephone equipment has not been installed. Connect the base equipment to the net, and switch on the main switch. Relay K41 shall be activated. The intention is that the main switch shall always be ”On” when the equipment is installed. This is to ensure that the spare batteries are always fully charged when available for exchange as a new shift starts. b) Check that the green LED-lamp on the signal generator U52, is lit up, and that the green LED-lamps on the I/O-cards U31 and U32 are lit up. This shows that there is voltage to the generator and the cards. The yellow LED-lamp on generator and cards (the climber cards as well) shall now be lit up. The yellow LED-lamps show that the cards communicate with each other. c) Check the voltage on terminals 115-116, it should be 230 VAC. Check the output voltage to the climber (terminals 104-106), should be 690 VAC. Check the output voltage from the net unit U26. Adjust with the potentiometer so that the output voltage is as close to 30 VDC as possible.
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d Check the DIP switches and the pot-settings on the earth fault relay K10, so that they are correct. See instruction on circuit diagram, page 1. Test the ground fault equipment with the test/reset button on the electrical panel on the base station. The switch Q13 for STH-5E/EE shall then trip out. The re-setting of the ground fault relay takes place automatically when the test button is released. In the event of a real ground fault, the relay remains in tripped-out position. The indication lamp remains lit until the test/reset button is pressed.
Opportunities are now provided for starting up the the equipment. The alarm relay K34 should now be ”ON”. Switch the selector switch S46 to ”On” position. If the alarm signal is then activated, switch off by S47 ”Reset”.
e) Connect the spare batteries for charging in the base equipment. f) Energize climber by switching on the maximal switch Q13. Then follow the sign instruction on the cabin.
NOTE! the selector switch ”Power” in the climber has to be switched to ”On” position. Make a test of the ”Alarm button” in the climber. This should start the alarm equipment. Check that relay K58 (external alarm) is activated while the alarm button is pressed. Switch off the signal by ”Reset”.
g) Check the telephone communication in both directions. At call from the cage, use the ”Call Base” button. The audible/light signal at the base station is then activated. Before answering the telephone switch off the audible alarm by means of the ”Reset”-button on the electrical panel at base. h) Switch the selector switch in the climber to ”Off” position. Q13 in the base should then trip out. i) Energize climber again. Make a test from the climber that air/water ON/OFF is working. Check that contactor K40 works and that there is voltage for terminals 119 – 120 (115 VAC) at the same time as K40 is ”On”. This should work, only when ”Power” (-Q13) is ”On”.
NOTE! The ”Remote controller” (-S50), has priority compared to the climber controller, and consequently, it must be ”Off” during the air/water test from the climber. k) The remote controller (-S50), is normally used to activate the electric blasting caps. This is made by means of the air/water central, which then lets off compressed air which starts the charging. When that happens the water supply has been cut off manually. This control unit can, however, be used to control air/water at the base.The maximal switch Q13 may then be in ”Off” position. Make a test of this control unit to see if it works, i.e. contactor K40 goes On/Off when you are operating the remote controller. l) Relay K33, is a safety relay, which is normally never activated. DUPLINE possesses a quality which makes a disturbance activate all outputs, and in order to minimize dangerous situations, we have this safety relay which will stop all f unctions, in case it is activated.
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m) Test run up/down, with the Joystick. Check that the contactors change phase sequence. –
Put the switch Q64 in the cage to position ”On”.
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Turn the brake lever so that the control brake is released.
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Start the climber by moving the lever for desired direction of travel.
When the lever is released the climber will stop. Immediately apply the control brake. –
Check the guide rail during ascent and make sure that the climber does not catch on the rock wall.
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When the drilling work is finished and the preparation for the blasting with el. ignition is to be started, the power supply of the climber shall be switched off, i e the rotary switch in the climber is turned in position ”Power Off”. The main circuit breaker at the base station is then tripped-out to Off-position. After the blasting preparation is finalized, the climber is to be slided downward to the base station by means of gravity. As the key for the travelling is kept by the person in the climber, noone can reenergize the electric system, until this person has returned back to the base station.
All functions of the STH5-E/EE have now been tested.
Start-up of Trolley/Alicab, with contactor control.
General: If you switch off the switch Q77, in TROLLEY, resp. Q92 in ALICAB, i.e. no supply for the motor, you can easily control all functions without running the climberup and down. You then have a full survey of what is happening, and you can follow the start-up without driving the climber. Switch the maximal-switch Q12 to ”On” position. The climber is now energized.
When testing the ALICAB: Check that the transformer in the climber -T96 – is connected so that the brake gets correct voltage (230 VDC). Test run up/down, with the joystick. Check that the contactors change phase sequence. IMPORTANT: The vibrations when detonating the round might cause relays and thermal relays to release. Reset the equipment by pushing all resetting buttons (also thermal relay for the high pressure pump)
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Lowering the STH-5E & STH-5EE by gravity
The STH-5E/EE must be lowered by gravity since the power has been switched off (see above). STH-5E
Turn the brake lever to release the control brake. Turn the flywheel by hand to move the climber. The speed will then be automatically limited. To stop the climber during descent, turn the brake lever until the control brake is applied. STH-5EE
A man with life line climbs down the ladder to the lower drive unit. Release the control brake and turn the flywheels. If only one man is to lower the climber, do as follows: WARNING! Life line must always be used outside the cage.
1. Put on a life line and climb down the ladder to the lower drive unit. 2. Release the control brake (on the lower drive unit). 3. Turn the flywheel so that the drive unit moves downwards until it stops. 4. Climb up into the cage. 5. Release the control brake and turn the flywheel quickly. The upper drive unit will then ”hit” the lower one and the climber will start moving. The speed is then automatically limited. To stop the climber during descent, turn the brake lever to apply the control brakes.
If the climber is not to used, set the ALARM-SYSTEM and the STH-5E/EE-switch in position ”Off” IMPORTANT: If the safety climber is to be driven upwards, and the main power cannot be switched on, turn the main switch ”Climber STH-5E/EE” to off-position. The main switch ”Trolley/Cab” is turned to position on. WARNING! Never leave the cage without having applied the control brake.
D 10 In inclined raises where cable holders are used, a strict watch must be kept over the cables. If the cable has fallen off a cableholder, the climber must be stopped and the cable put back in its holder before the descent is continued. The cable will otherwise be damaged when the climber passes.
Electric driven service and safety climbers – Turn the switch ”Trolley/Cab” in the main electric box to position ”On”. If the main current cannot be turned on, turn the switch marked STH-5E/EE to position ”Off”.
IMPORTANT: While charging is going on, the current to the safety climber should not be turned on. Naturally, if an accident occurs during the charging operation, the current may be turned on to the safety climber. If possible, the charge should be disconnected before the ascent. The staff on the raise climber must be informed of the ascent with the safety climber. – The climber ascends by quickly turning the control lever to the position for ascent. When the lever is released, the climber stops. During operation, keep a strict watch at all times over the cables and guide rail. – For descent, the control lever is turned to the position for descent. When the lever is released, the climber stops. Lowering the Alitrolley 5E service climber by gravity
See operating instructions for the raise clinber. Lowering the Alicab 5E safety climber by gravity
If the climber must descend under gravity, depress the pedal at the bottom of the electric motor. Do not depress it to hard! At the same time turn the flywheel until the climber starts to descend. The speed is then automatically restricted by the centrifugal brake. Release the brake pedal to stop the climber.
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Diesel-hydraulic driven raise climber STH-5D & DD – Fill up with fuel according to Deutz´recommendations, Avoid driving the climber so that the tank is emptied – if so, the fuel system has to be ventilated. Check the hydraulic oil level (if it is to low, the diesel engine will stop). Check the oil level in the diesel engine. – Load the climber with necessary equipment. Make sure that the climber is not overloaded.
Start and stop of diesel engine
– Check that the stop button is drawn out, The indication lamp for the magnet is lit. – Press the button for glowing and keep it pressed during – 30 seconds if the engine is cold (warm engine shorter time). – Then press the start button and keep it pressed until the indication lamp for the generator lights up (the diesel engine has started). – To stop the engine – press the stop button.
IMPORTANT: The stop button shall always be in the lower ”pressed” position when the diesel engine is not in operation. If the stop button is drawn out the stop magnet is actuated, which discharges the battery. Driving of climber
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Start the diesel engine (see instruction above). Turn the brake lever to release the control brake. Turn the operating lever towards opsition ”Up”. The further the lever is turned, the faster the speed.
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Stop the climber by resetting the lever. Apply the control brake. Stop the diesel engine. IMPORTANT: Never leave the cage without having applied the control brake.
Lowering the STH-5D & STH-5DD by gravity STH-5D
Disengage the hydraulic motor by turning the disengaging lever through 180° (the lever should point away from the motor). Turn the brake lever to release the control brake. Turn the flywheel by hand until the climber starts moving. The speed will then be automatically limited. To stop the climber turn the brake lever to apply the control brake.
STH-5DD
A man with a life line climbs down the ladder to the lower drive unit. Release the control brakes and turn the flywheels simultaneously. If only one man is to lower the climber, procede as follows: IMPORTANT! Life line must always be used outside the cage.
1. Put on a life line. 2. Climb down to the lower drive unit. 3. Disengage the hydraulic motor. 4. Release the control brake (on the lower drive unit). 5. Turn the flywheel so that the drive unit moves downwards until it stops. 6. Climb up into the cage. 7. Disengage the hydraulic motor. 8. Release the control brake (on the upper drive unit). 9. Turn the flywheel quickly. The upper drive unit will then ”hit” the lower one and the climber will start moving. The speed is then automatically limited. To stop the climber during descent, turn the brake lever to apply the control brakes. If necessary, the climber can be driven downwards with the diesel engine. When the climber is driven backwards on the horizontal part of the guide rail the speed will be comparatively low. When engaging the hydraulic motor(s), turn the disengaging lever(s) to point towards the respective motors. If engagement is not obtained immediately, bring back the lever a little, turn the flywheel a couple of degrees and turn the lever towards the motor again. Repeat if necessary. If the motor(s) must be engaged up in the raise, the control brake should not be released but the flywheel should be turned with the hand lever.
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Diesel-hydraulic driven service and safety climbers Service climber Alitrolley 5D
See operating instructions for raise climber IMPORTANT: The staff on the raise climber must be informed of the ascent with the safety climber.
Safety climber Alicab 5D Start and stop of diesel engine
Pull the strap with the black ball so that the large (not coloured) lamp lights up. The preheater plugs are then switched on. After about 30 sec. pull the strap further to engage the starter. When the engine has started, release the strap and the indication lamp will go out. The engine is stopped by pulling the strap with the red ball until the engine stops.
Note! Do not pull the start strap while the engine is running. Operating the climber
Start the diesel engine. Turn the brake lever to release the stop brake. Turn the operating lever to position ”Up”. The more the lever is turned, the greather the speed. Stop the climber by turning back the lever. Apply the brake. Stop the diesel engine. During descent the climber can be driven down or lowered by gravity. Descent under gravity is done in the same way as for STH-5D/DD.
IMPORTANT: There is no automatic device to stop the diesel engine if the oil level is to low in the engine or hydraulic oil reservoir, or if the V-belt of the cooling fan snaps. If the oil pressure indicator lights up the engine must be stopped immediately. The staff on the raise climber must be informed of the ascent with the safety climber.
Brakes If the control brake should be put out of operation, the descending speed of the climber will be automatically limited by the centrifugal brake. If both brakes should be defective, the safety device will automatically stop the climber when the speed has reached approx. 0.9 m/s (54 m/min.) If the power transmission between drive unit and guide rail should fail – for instance in case of worm wheel breakage, shaft breakage, pinion breakage or if the meshing between pinion and pin rack should be broken due to breakdown of counter-rollers in the U-frame and worn out stop cleats – the climber will fall down. The safety device will then stop the climber.
Safety device If the maintenance of the climber is satisfactory, the risk of tripping due to breakdown of the drive unit is almost nonexistant. After tripping, drive unit and guide rail must be checked before the climber is released. To release the climber, turn the flywheel(-s) counter-clockwise and the climber will move upwards one or two centimetres (the air driven climber STH-5L can be driven). If the climber moves up, an unintentional tripping has taken place and the climber can descend after releasing of the safety device. Unintentional tripping is sometimes caused by exceptional vibration due to, for instance, worn down guide rails, badly fitted guide rail joints, incorrect tripping rotation speed etc. After tripping, check the tripping rotation speed (150 rpm tripping speed 0.9 m/s). Unintentional trippings can also be caused by worn out centrifugal brake linings, oil on the brake linings or incorrect adjustment. The descent must then be carried out in steps while limiting the speed with the control brake to prevent another tripping. This is especially important if the safety device is installed on a heavy climber, since repeated tripping without resetting after each tripping can cause deformations.
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Resetting the safety device
After parking the climber on the horizontal bottom level of the guide rail, reset the safety device: – Clean the safety device – especially the surfaces which shall be divided/turned. Be careful so that dirt does not press in between the flange surfaces.
Bolt
– Dismantle the four bolts (A). – Turn the brake drum with the resetting lever in the direction of the arrows – until the white reflecting line is in the centre of the cross in the sight glass. – Turn the drum in either direction until the holes for the bolts are in position.
Sight glass Resetting lever
– Put the bolts back and tighten. Tightening torque approx. 75 Nm. – Dismantle the cover of the safety device. Pull out the brake cone approx. 1 – 2 mm from the drum by means of plate part No. 9064 677-000 and 5 bolts M10 x 30. Tighten the bolts alternately. When the white reflecting line has moved approx. 2 mm the brake cone is loose. – When the cone is pulled out from the drum, dismantle the bolts and take off the plate. Reinstall the cover.
Exchange intervals, see sign on safety device. Plate part No. 9064 677-000
Bolt M 10 x 30
IMPORTANT: From a safety point of view the safety device must never be dismantled more than is necessary to reset it. For this reason the safety device is sealed. WARNING: Resetting of the safety device must take place at the horizontal bottom level of the guide rail.
D 16
Air and water central manifold Type LVL for air driven climber STH-5L & LL
6
10
11
Before ascending, open cock (10) – to enable remote control of the central manifold. When cock (4) of the lubricator LB-2 has been turned off, the central manifold will open after about 1/2 – 2minutes. If cock (4) is opened the central manifold will turn off. If there is a sizeable leakage in the guide rail tube, the pressure cannot be raised inside the rail and the central manifold will not open. Connect a cock and a hose to the control valve – connect the hose to cock (4). Air can now be blown into the rail to raise the pressure enough to open the central manifold.
Open Turned off
When ventilating the raise, turn off cock (10), and push lever (6) completely or partly forwards depending on the required amount of air and water. After the ventilation, open cock (10) and the central manifold will turn off.
Type LVE/D for STH-5E/EE and STH-5D/DD The central manifold is turned off when cock (10) is open, and the switch in the cage and the switch on the remote control are in position ”Off”.
Note: The air and water central manifold cannot be remote controlled if the main current supply is broken. On the floor of the raise the operation of the air and water central manifold is done from the remote control. Before ascending do not forget to reset the switch to position ”Off”. If this is not done the central manifold cannot be turned off from the climber. If only a small amount of air and water is required for the ventilation, turn off cock (10) and put lever (6) in the required position. To turn off the central manifold, open cock (10). There is a cock on the central manifold for emptying the guide rail of water before blasting. If the rail is empty, the risk of Oring damage when falling rock hits the guide rail is limited. This is especially the case when the height of the raise is more than 300 m. IMPORTANT: Never empty the rail of water without making sure that the cock on the lubricator (if mounted) at the top of the guide rail is open. If it is closed, the vacuum will change the positions of the O-rings, which will result in leakage.
Lubricator LB-2 or connection plate with 4 cocks 2
3
1 4
D 17
Air operated safety roof Air driven climber STH-5L If the roof is mounted on a air driven climber it can be operated anywhere in the raise if the air supply to the climber is turned on.
Electric or Diesel-hydraulic climber STH-5E/5D If the roof is mounted on a electric or diesel-hydraulic driven climber, it cannot be operated when the climber is being driven. When the climber is in working position, the air for operating the roof is taken from the guide rail via lubricator or header plate.
Air operated safety roof
WARNING!
This elbow has a restriction for reducing the lowering speed of the roof. The elbows must consequently not be replaced with standard elbows. Not valid for safety roof with welded inlet plug.
Single-acting cylinder in support leg C
C
B A Double-acting cylinder
For STH-5E/EE & STH-5D/DD For STH-5L/LL
Operation
The roof is raised by opening cock (A) (– leave the cock open). The height can be adjusted by changing the lengths of the chains – they should be equally long for both legs. To lower the roof, turn off cock (A). The weight of the roof will then press out the air through the outlet channel of the cock. When driving the climber, make sure that the roof is in its upper position. Adjust of the angle of the roof is done with valve (B). Push or pull the valve lever to press the roof against the guide rail. Put pins (C) in the required holes. Put the valve lever in its other position. The roof then tilts over to the required position and the support legs are pressed against the pins. During ascent or descent, make sure that the roof is in its top position and that the legs are parallel with the centre line of the raise. In many cases the space in the curve does not allow the safety roof to pass without changing its angle. This can be done if a hose with cock and claw couplings is available in the curve and accessible from the cage. Connect the hose of the safety roof to this hose and you will now be able to operate the roof.
D 18
D 19
Lubricator Type LB-2
2
Can be used with all types of raise climbers.
1
The lubricator is mounted with four bolts to the header plate. When it is connected it supplies oil/air mixture to two drills. Four O-rings seal the joint between guide rail and lubricator. Lubricator LB-2 is equipped with four cock connections, two for oil/air mixture, one for water, and one for operating air- and water central manifold LVL.
1
4 3
5 6
Oil reservoir, capacity: Oil quality: Max. operating pressure: Weight:
9
3 litres pneumatic tool oil 1 MPa 23 kg (excl. oil)
7 8 1. 2. 3. 4. 5.
Bleed before topping up. Pipe plug Adjusting screw for oil su. Cock for operating air and water central manifold LVL.
Can be used with electric and diesel-hydraulic raise climbers. 1 1
4 3
5 6 7
8
6. 7. 8. 9.
Type LB-3
1
2
Lubricated air Water cock Pipe plug Cable seal Filler plug
The lubricator is mounted with four bolts to the header plate. When it is connected it supplies oil/air mixture to three drills. Four O-rings seal the joint between guide rail and lubricator. Lubricator LB-3 is equipped with four cock connections, three for oil/air mixture, one for water. The air and water central manifold is operated electrically with electric and diesel-hydraulic powered climbers. Thus there is no cock for this purpose on LB-3. Oil reservoir, capacity: Oil quality: Max. operating pressure: Weight:
4.6 litres pneumatic tool oil 1 MPa 27 kg (excl. oil)
Adjusting the oil supply
Remove pipe plugs (7). The oil flow increases when the adjusting screw is turned counter-clockwise. The oil flow is cut off completely when the adjusting screw is turned fully clockwise. After adjusting, replace pipe plugs (7). Make sure they are tightened securely. Any leakage means that the lubricator cannot work satisfactorily. Where the signal/ignition cable is placed inside the guide tube, remove pipe plug (3) and screw on the cable seal (supplied with the telephone equipment). Maintenance
In the event of failure, remove the filler plug, the gable end plug, the pipe plugs and the adjusting screws. Blow through all passages and the pipe at the filler hole in the tank with compressed air.
D 20
D 21
High pressure water pump Type 50/3 E is powered by a 5.5 kW electric motor and type 50/3 L by an Alimak K-14 air motor. The pump is identical for both types. It has 3 cylinders with enamelled interiors. The pistons have cup-shaped replaceable piston packings. Capacity
type 50/3 E
type 50/3 L
Flow rate Pressure (adjustable)
40 – 60 l/min 500 – 6000 kPa (5 – 60 bar)
40 – 60 l/min. 0 – 6000 kPa (0 – 60 bar)
4
11
10
3 100 mm
9 8
Start-up and operation Electric driven pump type 50/3 E
Before start-up, check that there is oil in the pump crankcase. See ”Lubrication”. To obtain an even pressure (flow), air can be pumped into the reservoir as outlined below. This should be done at the initial start-up and then as required. a) Drain off any water from the air reservoir. b) Start the pump with the suction strainer below the water surface and run it for about 1 minute to prevent the pistons from running dry. c) Drain off the water from the pump (loosen pressure line (6). d) Start the pump with the suction strainer lifted. After about 30 sec. lower the suction strainer into the water. e) If there are air locks because air has been pumped too long, open the plug on the side of the pressure valves.
Required water pressure is set (from low to high pressure) as below: 1. Close valve (20). 2. Turn hexagon nipple (5) in counter-clockwise direction, to lower the pressure, or clockwise, to get a pressure of 2000 – 2500 kPa (20 – 25 bar). Start the pump and check on manometer.
D 22
3. Open valve 20. 4. Pressure can now be set with the adjustment screwon the overflow valve (19) between 500 kPa and the earlier pressure of 2000 – 2500 kPa. 5. To increase the pressure to more than 2000 – 2500 kPa, close the valve (20) and turn the hexagon nipple (5) clockwise to required pressure.
1
18
3
7 2 5 4
19
20
6 4
1. 2. 3. 4. 5. 6. 7.
Oil filler plug with dipstick Pressure regulator Suction hose Return hose Nipple for adjustm. of water pressure Pressure line Manometer
8. Suction strainer 9. Water reservoir 10. Water line 11. Float 12. 13. 14.
15. 16. 17. 18. 19. 20.
Air regulator
Plug Overflow valve Valve
D 23
Air driven pump type 50/3 L
a) Blow through air hoses and lines with compressed air before connecting them to the pump. b) Check before start-up that there is oil in the pump crankcase and in the air motor lubricator. See ”Lubrication”. c) Check that the suction strainer (8) is below the water surface. d) Close cock (17) – handle horizontal! e) Turn hand-wheel (14) counter-clockwise until the air regulator (15) is fully closed. Open cock (16). f) Turn hand-wheel (14) clockwise until the pump starts to rotate and the required pressure is obtained, g) Screw the needle valve while the motor is running until the required oil flow (approx. 1 drop/sec.) is obtained. Check through the observation glass. More oil – screw counterclockwise, less oil – screw clockwise. At intervals check the number of drops through the observation glass – if necessary adjust the setting. h) To obtain an even pressure (flow), air can be pumped into the air tank – see items c), d) and e) under headline ”Electric driven pump type 50/3 E”. Before blasting the pump is stopped by closing cock (16). When the pump is started, by opening cock (16), it should be opened slowly so that the air motor is prevented from racing. Do not rev the air motor, the max. speed is 1500 rpm. Required water pressure is set by changing the air pressure to the motor through air regulator (15). Turning the adjusting hand-wheel (14) clockwise increases the water pressure. The pressure regulator (2) on pump type 50/3 L only functions as a safety valve. It is preset at the factory to open at 6000 kPa (60 bar) and should normally require no alteration. Avoid setting the water pressure so high that the pressure regulator (2) is forced to open, as this results in a pulsating pressure and unnecessary wear of the pressure regulator (2). Valve (17) contains a leak hole which lets through a small water flow from the pressure line to the return line. Even if no water is consumed the pump will thus rotate at low speed. The speed then increases in proportion to the water consumption. IMPORTANT: Check at first start-up that the pump is sucking water. If this is not the case, lift up the suction hose above the pump and fill it with water. The pump must not be allowed to run dry.
D 24
15 14 16
1
13 18
12
3
2 7 4 17
6
1. 2. 3. 4. 5. 6. 7.
Oil filler plug with dipstick Pressure regulator Suction hose Return hose Pressure line Manometer
8. 9. 10. 11. 12. 13. 14.
Suction strainer Water reservoir11. Water line Float Lubricator with oil reservoir Sight glass Adjusting hand-wheel
15. 16. 17. 18.
Air regulator Valve On/Off Valve Plug
D 25
Alimak Dupline system This equipment is used for transmitting signals from raise climber to base station or vice versa. Signals from climber are: Alarm, Power ON/OFF, Air/Water ON/OFF, and Audio call signals. Only Audio call signalling is used in the opposite direction, (from base station). The system is powered by batteries in climber and a DC power unit at the base. Study the fenclosed description and circuit diagrams for more detailed information. Principal Function
Explanation of the 3-wire system (Dupline). Only three wires connected to all the inputs/outputs signals at the various locations in the Base panel and Main panel on top of the cage. These (non-shielded) wires of a standard installation cable handle both, the signal communication and the supply of power to any output load. One Pulse generator is located in the Base panel, witch generates pulse trains and synchronizes the transmission signals for an entire of the I/O-unit (signal transmission units). I/O-units (Signal transmission units) is located in the Base panel and the Main panel on the top of the cage. This I/O-unit uses three wires for the communication with all other I/O-units. Each unit has 4 inputs (NPN/contact) and 4 outputs (PNP). Every input and output is given its individual adress with the programming unit (GAP 1605). The On/Off-signal that is applied to an inputs of any I/O-unit is associated to the adress given to that input. Any output of all I/O-unit that is given the identical adress will now follow that input signal and switch its output signal ON or OFF. This means that a signal that is an input at one location (for examples as an output form the PLC) may be output wherever required and as many times as required. The input pulse is prolonged 0.5s to ensure transfer of fast pushbutton activation. Programming unit GAP1605
The GAP 1605 is a portable-programming unit used for reading or programming channel code(s) in the ASIC-based series of Dupline products. Once the battery is installed, the GAP 1605 is ready for use. Connect the cable between the programming unit and I/O-unit (signal transmission unit). 5 keys provide the means of operating the GAP 1605: two keys are used for reading and programming, two keys for changing Groups and channels and one key for selecting the desired Input / Output.
D 27
4 x 8 LED’s display the current coding. The top row of the LED’s displays the selected input or output. The two middle rows display the current channel groups, while the bottom row display the current channel code. << In/Out >> - key
This key is used to scroll though the I/O’s of a module. If a new module is connected off consecutive channel codes are allocated to the I/O’s pressing the << In/Out >> key has no effect since all Dupline modules are programmed to their physical number of inputs/outputs. This key is also used to switch between consecutive and individual coding of the mode; keep << In/Out >> pressed for more than 2 seconds. << Group >> - key
Used to select the Group adress within the range A to P. the Group LED will shift one position right for each key activation. << Channel >> - key
Used to select the channel(s) within the group. LED will shift right one, two or four positions, the number of inputs/outputs. If consecutive selected then pressing the << Channel >> key effect.
The Channel depending on channels are will have no
<< Read / On >> - key
Used to turn on the GAP 1605 and to read the channels codes of the connected module. When the reading is completed, the display will show the channel code of the module: either 1, 2, 3 or 8 inputs/outputs. 2, 4 or 8 In/Out LED’s being ON indicates that consecutive channel codes are allocated to the I/O’s e.g. input 1 coded to P1, input 2 to P2 … input 8 to P8. If only one In/Out LED is ON, and then the I/O’s are coded individually, e.g. input 1 to C5 input 2 to D4 etc. A group LED and channel LED indicate the code for each I/O. If the GAP 1605 is not connected to a dupline system, it will turn off within two seconds. << Prog >> - key
when the displayed I/O-coding corresponds to the desired channel configuration, the codes will be downloaded to the Dupline module when pressing the << Prog >> key. After programming is executed, verification takes place. If this verification fails, all activated LED’s in the display will flash two times, and programming unit will switch off. If such behavious occurs repeatedly on the same module, the module may be faulty. If several modules fail to download, the GAP 1605 may be faulty.
Individual In/Out channel programming
The GAP 1605 features an additional mode of single channel editing. Pressing << In/Out >> key for more than 2 seconds will change the operating mode to single point programming. The << In/Out >> - key is now used to select one of the eight possible inputs/output, thus making individual channel coding possible. The In/Out-LED’s assigned the display channel code to the corresponding physical input/output of the module. In single mode the << Channel >> key also has the ability to disable an In/Out-position. << Channel >> must simply be pressed past channel 8, whereby both the channel LED and the Group LED will turn off. To reenable, just press << Channel >> again. It is possible to change all eight Inputs/outputs, even though some Dupline modules are built for only 1, 2, or 4 Inputs/Outputs. To exit single channel programming, just keep the << In/Out >> pressed for 2 seconds. Output status setting
On receivers it is possible to configure the status of the outputs during Dupline Failure. Normally, any output of a receiver will go off during Dupline Failure. In some cases the inverted function is desirable (e.g. light applications – turn on light if the Dupline is down) To change output status, the GAP 1605 must be put into configuration mode. This is done as follows: – Remove any connected Dupline system. – Keep both << In/Out >> and << Group >> pressed, while pressing << Read/On >>. The first In/Out LED now turns on. Connect the Dupline System, and Press << Read/On >>. If output status is set, then channel LED 1 will illuminate. Pressing << Channel >> will toggle the output status On/OFF. Press << Prog >> to store. If << Read/On >> is pressed when no Dupline system is connection, the LED’s will flash to indicate a false condition. Only a successful reading will reset this condition.
D 28
D 29
Other Features
To code a Dupline module off-line, neither Dupline normal power to supply the module is required. Simply connect the module to the programmer and start coding If On-line coding (module connected to an operation dupline system) is performed, the module automatically disconnect if self form the Dupline and returns to normal operation after the programmer cable is disconnected. The GAP 1605 automatically turns off when no key has been pressed within the last 30 seconds. If the connection cable is removed from the Dupline module, the GAP 1605 will switch off within 2 seconds. Low battery indication
When battery is low, the In/Out row of LED’s will roll centerwards in an eye-catching manner. Warning
When using the GAP 1605 you must connect the cable to the GAP 1605 before connecting the cable to any Dupline module that is to be coded. Even so, the cable must first be removed form the Dupline module before disconnecting it form the GAP 1605. Without observing these precautions you may destroy the ASIC inside the Dupline module though static discharges. Caution
To ensure long battery life, always remember to remove the cable form the Dupline modules. The Dupline modules will be kept in an inactive state as long as the GAP 1605 in connected.
D 30
SERVICE AND MAINTENANCE
Service and maintenance ............................... E 1 Adjustment and wear limits .......................... E 4 Brake torque ................................................... E 4 Worm gear....................................................... E 5 Pinion ............................................................... E 6 U-frame............................................................ E 6 Guide roller ..................................................... E 7 Guide rail......................................................... E 7 Pin rack ........................................................... E 7 Lubrication diagram ...................................... E 10 Hydraulic system ............................................ E 13
E0
Service and maintenance
E1
In order to avoid unnecessary breakdowns, those responsible for the service and maintenance of this equipment must regularly ensure that all scheduled maintenance work according to the maintenance programme below is carried out at the recommended intervals. Adjustments and replacement as a result of checks, must be carried out by trained/authorized servicepersonnel. Only ALIMAK Genuine Spare Parts must be used. WARNING! Care, lubrication, repair etc. must only be carried out on a protected site. When carrying out work service, the main switch must be switched off, locked and provided with a warning sign.
Service intervals Intervals based on operating time shall be followed in the first instance. If the climber is used only periodically, the first applicable interval to be reached shall be followed.
Checklist Checklist, with room for notes on maintenance executed, will be found at the end of this manual. Use them!
Service and maintenance schedule See the appendix at the end of this manual for tightening torques.
Interval
8 operating hours or at least once a day
Part
Instructions
1.
Cleaning
Flush away sludge, cuttings etc. from the climber and guide rail curve.
2.
Safety device
Check that the mounting and counter-roller of the safety device are without. defects.
3.
Rollers in the U- Check that the rollers in the U-frame and in the roller assembly are free from frame and rollers defects. Don´t forget the rolles inside the U-frame! in roller assy.
4.
Telephone equip- Check the telephone equipment. For air- and diesel-hydraulic climbers a test ment cable must be connected between the climber and the main electric box.
5.
Control brake
Check function of the control brake. See also the special instructions for checking brake torque with a spring balance.
6.
Diesel fuel
Refill fuel – valid for diesel-hydraulic climbers only!
7.
Lubricating
See the instructions in the ”Lubricating diagram”.
E2 Interval
40 operating hours or at least once a week
Part
Instructions
10. Sign plates/ instruction manuals
Check that all signs are in position and that they are legible. parts manual, that they are legible. Check also that the documentation according to the documentation box is available.
11. Attachments
Check all attachments: bolts, nuts, pins etc.
12. Guide rollers
Check the guide rollers for wear, bearing play and operation acc. to instructions later in this chapter No rollers must be missing.
13. U-frame
Check U-frame according to instructions later in this chapter.
14. Pinions
Check the wear of the pinions (incl. the safety device) later in this chapter.
15. Control brake
Check brake torque acc. to instructions later in this chapter. Replace the lining when it is worn down to 3 mm.
16. Centrifugal brake Check the centrifugal brakes. The upper brake should be turned so that the cooling air intakes are turned downwards when the climber is on the horizontal part of the guide rail. Repalce the linings when they are worn down to 3 mm. 17. Lubricating
See the instructions in the ”Lubricating diagram”.
18. Function test
– air driven climber:
Check that the air motors receive oil. Disengage the motors and run them. Oil should then emerge from the motor outlets. – electric driven climber:
See headline ”Start instructions”. – diesel-hydraulic climber:
See instruction manual for diesel engine. Also check that there are no fuel or oil leaks. 19. Operating control Check that the operating control moves freely and that no bolts and nuts have – valid for diesel- worked loose. Also check that the mounting of the control arm on the hydraulic hydraulic climber pump and that the ball joints moves freely. only 20. Electric wiring. Check all wires/hoses, sealing glands and connections. Especially the diesel incl. air- and power pack to see that the insulation is not chafed off anywhere. hydr. hoses where applicable
125 operating hours or at least once a month
21. Diesel-hydr. power pack
Check that there are no fuel or oil leaks. Valid for diesel-hydraulic driven climbers only.
22. High pressure water pump
Check crankcase oil with the dipstick on the filler plug. Clean the magnet on the dipstick.
25. Safety device
Check the operation of the safety device.
26. Guide rail
The guide rail should be checked and all nuts tightened. No pins must be mis sing from the rack. The guide rail must be repaired or scrapped when the pins of the rack are worn down to 16 mm, or when the rack flats are worn down to 2 mm above pins.
27. Worm gears
Check worm gears according to instructions later in this chapter.
28. Insulator in guide rail end
Detach the high pressure hose from the guide rail bottom insulator and clean the hole through the insulator.
29. Lubricating
See the instructions in the ”Lubricating diagram”.
30. Signal equipment Check the function of the control device, alarm signal, lighting, and, where and lighting applicable, voice communication system. ALIMAK 30956 - 1/02
E3 Interval
Part
Instructions
31. Control valve for Clean air filter inside the valve with white spirit or suchlike and compressed air motor – valid air. for air driven climber only 32. Diesel engine – valid for dieselhydr. driven climber only
Routine maintenance according to munufacturer´s handbook.
250 operating hours or at least every 3rd month
35. Diesel engine
Routine maintenance according to munufacturer´s handbook.
36. High pressure pump
Check belt tension and adjust if necessary.
500 operating hours or at least twice a year
40. Contactors – Check the condition of the contact points in the contactors. valid for el. driven climber only 41. Shaft couplings
Check.
42. Motor overload Check that the motor overload ptotector is set with the rated current on the protection – data plate for the electric motor.protection valid for el. driven climber only 43. Corrosion, damage and wear
Inspect the equipment in its entirety for corrosion and wear on loadbearing and force-absorbing components with the aid of an ultrasonic thickness mea suring instrument. This inspection any actions which may need to be taken after the inspection must be performed by trained/authorized service personnel. A method for internal corossion protection of the guide rail tubes is available, please contact your ALIMAK representative.
44. Lubricating
See the instructions in the ”Lubricating diagram”.
45. Diesel engine
Routine maintenance according to munufacturer´s handbook.
1000 operating hours or at least once a year
50. Diesel engine
Routine maintenance according to munufacturer´s handbook.
Annually
55. Complete hoist
Have the complete hoist checked by a qualified technician.
Every 3.rd year 60. Safety device or acc. to sign on the safety device
Replace the complete safety device.
E4
Adjustment and wear limits Brake torque Measuring the brake torque is done with the climber in the horizontal drift or the drive unit on the floor. Disengage the motors on air- and diesel-hydraulic climbers 1. Apply the brake. 2. Fit the hand lever in one of the holes in the flywheel. Hook the spring balance onto the outer end of the lever.
Brake curve
3. Turn the flywheel by pulling the spring balance. Read max. force on the balance while turning the flywheel. Note: the angle between balance and lever – 90°.
Cleat
4. Measure distance L. 5. F x L = the braking torque. Example: F = 180 N
L = 0.4 m
Braking torque = 180 x 0.4 = 72.0 Nm (or 7.2 kpm) Minimum allowed braking torque = 40 Nm (or 4 kpm).
At workshop overhauling, it is recommendable to adjust the torque to min. 60 Nm (or 6 kpm).
Brake drum
Cup spring
Disengaged motor Brake shoe L
Flywheel
90°
F
ALIMAK 30958 - 1/01
E5 Worm gear
Check if the worm gears are worn. This is done on the service guide rail with the rack section remowed.
One flat iron bar 60 x 6 length 450 mm is bolted onto the pinion. 450 ± 5 mm
Hole dia. 21 mm < 3.9 mm
Measure the distance between the flat end and the rack. Turn the bar upwards and measure the distance to the rack again. The difference between the dimensions must not exceed 3.9 mm.
When the worm wheel is replaced, the worm screw should also be replaced. IMPORTANT: If the climber is exposed to abnormal load, e.g. a heavy rock fall, or there are other reasons to suspect that the worm gears have been overloaded, e.g. running against a mechanical stop which results in a sudden stop, the gears must be dismantled and checked.
E6
Pinion Check wear on pinion with gauge Part. No. 9046 516-000
Min. 15 mm Nom. 17.5 mm
U-frame Check wear and deformation on U-frame with gauge Part. No. 9046 516-000 according to the figure.
Roller Max. 170 mm Nom. 168 mm
A
A U-frame
Stop cleats A
Check the stop cleats (4 pcs.) inside the U-frame. If the climber is driven with big breakdown rollers inside the U-frame, hardfacing deposit must be added up to the height of the original surface.
ALIMAK 30962 - 1/01
E7
Guide roller
Measure with sliding caliper. Dimensions
D D
New roller (mm)
Worn-out roller (mm)
Ø 72 Ø 124
min. Ø 71 min. Ø 123 D
Note that the ”wearing” on the roller face must be equal – all around.
Guide rail Check wear on guide rail with gauge Part No. 9046 516-000 according to the figures. use the gauge (thickness 2 mm) m m 2 . n i M
Min. 33.5 mm Nom. 38 mm
Min. 43.5 mm Nom. 48 mm
Guide rail
Min. 165 mm Nom. 167 mm
Pin rack
Check wear on pins with gauge Part. No. 9046 516-000
Min. 16 mm Nom. 19 mm
E8
Directions for the safety check and repair of a used raise climber guide rail Check and repair in accordance with the list below, are recommended as minimum measures and do not limit or eliminate the further responsibility of the end user. The repairs and check of the guide rail shall be made by persons, well aware of the actual norms. Cleaning
Each guide rail must be cleaned, so that welds and material can be used for reliable tests. Preferrably, sand blasting should be used. After cleaning
After cleaning, the guide rails shall be sorted out by a qualified and well informed person. A guide rail must not be used if any of the following faults can be found. a) The thickness of the end plate with O-ring positions is less than 12.5 mm. b) The thickness of the opposite end plate is less than 9.5 mm. c) Big damages like compressions and bendings of the pipe which is farthest away from the rack, in combination with other damages and general wear. d) If the same pipe has been damaged by corrosion, which will jeopardize the strength of the pipe. The pipe must not at any point have a wall thickness of less than 3.5 mm. This is checked by means of ultra-sonic sounding part No. 3001 991-301 e) If the guide rail is otherwise deformed and worn out. f) If crackings in welded joints and material can be regarded as serious and cannot be measured safely enough. g) If the guide rail section has been worn more than the limits prescribed.
Greasing control brake for the air motor The coupling half inside the upper coupling housing is equipped with a grease nipple. For lubrication, remove the plug on the upper brake housing. Turn the flywheel by means of the hand lever until the grease nipple can be seen through the hole. Disengage the motor and grease sparingly.
Note! If you use too much grease it might come into contact with the brake linings.
Plug
Grease nipple
E9
E 10
Lubrication diagram
The oil in the worm gears shall be changed after the first 25 operating hours. At the same time, change the hydraulic oil filter if the hoist is a model with diesel-hydraulic machinery. Also change crankcase oil in the diesel engine, at same time. INTERVAL
ITEM LUBRICATING POINT
8 operating hours or at least once a day
40 operating hours at least once a week
LUBRICANT
VOLUME
INSTRUCTIONS
1
Control valve for air driven climber.
Shell Torcula Oil 32
1,1 lit.
Refill oil.
–
Control valve for hose / cable reel.
Shell Torcula Oil 32
1,1 lit.
Refill oil.
–
High pressure water pump
Oil
The regulators liftingspindle should be lubricated with oil once a day. Also inject a little oil into the large hole on th side of the regulator.
–
Air driven high pressure water pump only.
Shell Torcula Oil 32
Refill oil in lubricator.
2
Safety device with frame.
Grease
Grease nipples. 8 pcs. or (12 pcs. for extra roller assy. where applicable.
3
Upper coupling half and shaft for release lever. Valid for air driven climbers only!
Grease
Grease nipples.2 pcs. Dismantle the pipe plug on the brake housing and turn the flywheel until the grease nipple can be seen through the hole. Disengage the motor. Grease sparingly!
4
Rollers on U-frame with climbing machinery.
Grease
Grease nipples. 6 pcs. (12 pcs. for climber with two machineries).
5
Worm gears.
Alioil HD
Check level and refill – if necessary.
6
Lower coupling half and shaft for release lever. Valid for air and dieselhydraulic climbers only!
Grease
Grease nipple. 2 pce. (4 pcs. for climber with two machineries). Turn the flywheel until the grease nipple can be seen through the hole (air driven climbers only!) Disengage the motor.
7
Rollers on suspension frame Grease for diesel-hydraulic power pack. Valid for dieselhydraulic climbers only!
Grease nipples. 6 pcs.
8
Control brake. Valid for Grease electric and diesel-hydraulic climbers. Also grease links and guides for syncronising rod for climber with two machineries.
Grease nipple. (1 pce. for climber with two machineries). Also grease brake lever curve/-s.
–
Cable -/Hose reel
Oil
Oil rollers, chains and links.
–
Cable reel spooling device
Grease
Grease nipple. 1 pce.
–
Air and water central
Oil
Oil links and moving parts.
E 11 INTERVAL
ITEM LUBRICATING POINT
LUBRICANT
VOLUME
INSTRUCTIONS
125 operating hours 12 or at least four times a year
Diesel engine
See manufacturers 9.5 lit. handbook
Change crankcase oil.
250 operating hours or at least four times a year
Diesel engine
See manufacturers 9.5 lit. handbook
Change crankcase oil
High pressure pump
Shell Omala 68
6.0 lit.
Change crankcase oil
400 operating hours 15 or at least twice a year
Worm gears
Alioil HD
3.0 lit.
Change oil
800 operating hours 16 or at least once a year
Hydraulic oil
Shell Tellus Oil TX 46
40 lit.
Change oil
13 –
The lubricating oil grades indicated above have been used when the equipment is delivered from the factory. Only oil recommended by ALIMAK shall be used. If for some reason this is not possible, please contact ALIMAK or ALIMAK Representative for advice.
1 2 8
1
2
3
8 3
4 5/15
4 5/15
6
6
7 12 13 16
8 4 5/15 6 7 12 13 16
E 12
Hydraulic system General information on service work A particle as small as 10 µm (1/100 mm or .000394”) can, cause a pump or motor breakdown in the hydraulic system. Consider the fact that the smallest particle which can be detected by the naked eye is about 40 µm and you can imagine the requirements for cleanliness which apply when working in a hydraulic system. – Always give top priority to cleanliness requirements. Have plastic bags at hand for spare parts and plastic plugs for plugging hoses and pipelines. – Never use cotton waste or other fluffy rags – always use a special drying cloth. – Never use teflon tape to seal threads. – Always make sure that hoses and other spare parts are carefully cleaned. – Remember, a coupling or connection which begins to leak cannot, as a rule, be tightened by force. – Always change the insert in the hydraulic oil filter and the hydraulic oil, and flush the system thoroughly, when replacing the hydraulic pump or motor if a breakdown occurs. IMPORTANT! Due to high oil pressure only ALIMAK Genuine Spare Parts may be used.
Diesel-hydraulic power unit
WARNING: Never use your hand or any other part of your body to locate a leak in a pressurized hydraulic oil system.
E
13
E
14 CONDENSATE
HYDRAULIC OIL
Hydraulic oil tank The tank is equipped with a sensor which indicates “insufficient oil level” in the hydraulic tank. The tank is also equipped with a level glass. The level of the hydraulic oil must always be visible in the glass. Discharge condensate from the hydraulic oil tank regularly, once a month or so, by removing the drain hose plug and permitting a few centilitres of fluid to run out, before tightening the plug. This must always be done after a lengthy period of down time – before the climber is put into operation. The tank is filled with Shell Tellus TX 46 on delivery from the factory. Be sure to use oil with the same specification since oil always remains in the system, when changing oil.
Hydraulic oil filter The hydraulic oil is filtered by a filter on the pressure side of the servo system. The filter is of intermediate pressure type and has a filtration degree of nominal 10 µm.
Replacing oil in the hydraulic system 1. Warm up the system to 20 – 30°C, (68 – 86°F). 2. Empty the tank into a suitable container, (approx. 40 litres ) 3. Remove the spin on filter and mount a new one. 4. Fill up with new hydraulic oil. Use thoroughly cleaned containers. 5. Start the motor and let it idle for about 10 minutes. 6. Check the oil level and refill if necessary.
ALIMAK 30970 - 1/01
Inspection of hydraulic hoses Inspect hoses for leakage and signs of deterioration. Leakage
This refers to leakage in the hose itself or leakage between the hose and the hose coupling. If such leakage is detected, the hose must be replaced. Incipient leakage can be characterised by: – oil in the transition between the coupling and hose. – a swelling at the rubber cover adjacent to the coupling or, in rare cases, along the hose. Signs of hose deterioration
The first signs of hose deterioration are cracks in the rubber cover. Check hoses by bending them and looking for cracks. Hoses with such symptoms should be replaced at the next suitable occasion. There is no immediate danger of rupture. Other damage
Hoses should also be replaced when mechanical damage takes place, such as puncturing of the rubber, kinking or crushing.
Operating temperature A temperature of up to 80°C (176°F) can be regarded as normal for the hydraulic oil. A higher temperature will result as the hydraulic oil oxidizes forming products which impair the viscosity of the oil, which is a measure of its flow characteristics. Furthermore, water will be bound in the oil by condensate which always occurs when the temperature fluctuates alternatively upwards and downwards. The larger the temperature difference, the greater the condensate. One reliable sign that the oil contains too much water is, that it becomes grey and cloudy. The water can be drained off after a lengthy period of down time. See previous pages. If no such down time period is available within the near future, the oil has to be changed.
E
15
TROUBLESHOOTING
Electric troubleshooting ................................. F 1
F0
Electric troubleshooting Advice concerning procedures for troubleshooting All forms of troubleshooting require adapting the procedure to the function and structure of the equipment in question and to other conditions which may be local in nature. For example, the mine, maintenance, previous operational disturbances, etc. The main principles for all forms of troubleshooting in electric systems are presented below. Troubleshooting is carried out with the aid of a test lamp or voltmeter. We recommend a voltmeter – preferably a universal instrument – for rapid and reliable troubleshooting. WARNING: Danger! High voltage. Work on the electric equipment in the machinery may only be carried out by an authorized electrician or authorized service personnel.
1. Use the circuit diagram. This shows how the electric equipment should function, and how it is built and connected. 1a. Check that the stopping circuit is not broken, in other words that thermal relays and phase failure relays have not been actuated and that the control switches in the stopping circuit etc. have their contacts closed. Make sure that stop bottons, are not in the depressed position. When the stopping circuit is unbroken, the main contactor, if any, shall be in the ”On” position. 2. Connect the voltmeter/test lamp between the zero terminal and the terminal as indicated on the circuit diagram, and check that power is supplied where it should be supplied. Go through each terminal, one by one, and work methodically so that the circuits which function correctly can be eliminated and the fault can be localized. 3. Begin at the base station by checking that power is supplied on all three phases of the incoming main voltage. 4. Check that the outgoing power cable receives power when the main switch is switched on. 5. Now begin troubleshooting in the climber by checking that the power reaches the climber. 6. Check in the equipment cabinet to ensure that power occurs on all three phases of the incoming cable from the base station.
Mechanical, hydraulic- and pneumatic truouble shooting – See Repair Manual.
F1
F2 8. Make a trial run and check that the coil on the contactor receives power and that it is actuated. 9. If the fault does not occur in the climber operating system but in its lighting or signal system, carry out fault-tracing in a manner similar to that described above, in other words check the circuits methodically one by one until you have narrowed down the fault and localized it. Experience shows that certain fault causes have symptoms which, in turn, may indicate the cause and the probable location of the fault:
Example: Symptom
Probable cause
Probable fault location
a) Control fuses blow immediately.
Short-circuit, equipment grounded.
Damaged control cable, damaged pushbutton,etc. located ”outside”,
b) Fuse blows after a short time.
Equipment partially grounded, overload.
Damp or water in switch, connection box, etc due to damage delectric installation. Improperly connected new equipment.
c) Hoist stops or cannot be started.
Switch in stopping circuit has tripped/been actuated, blown fuse.
Stop pushbutton depressed, thermal relay actuated due to overload or careless operation, power failure from supplying network. See also a) and b) above.
